MATERIAL HANDLING AND PRESERVATION FOR OIL AND GAS EQUIPMENT
TABLE OF CONTENTS
1 PURPOSE ........................................................................................................................................ 4
2 SCOPE ............................................................................................................................................. 4
3 REFERENCES ................................................................................................................................... 5
4 DEFINITIONS AND ABBREVIATIONS .......................................................................................... 6
4.1 Definitions ............................................................................................................................................................. 6
4.2 Abbreviations ........................................................................................................................................................ 7
5 PROJECT DESCRIPTION ................................................................................................................. 8
6 PRESERVATION PLAN ................................................................................................................... 11
7 ROLES AND REPONSIBILITIES ..................................................................................................... 11
7.1 Organization Chart ............................................................................................................................................... 11
7.2 Roles and Responsibilities ..................................................................................................................................... 12
7.2.1 Preservation Coordinator ......................................................................................................................... 12
7.2.2 Warehouse Team .................................................................................................................................... 12
7.2.3 QA/QC Team .......................................................................................................................................... 13
7.2.4 Construction Team/ Precom Team ............................................................................................................ 13
7.2.5 Commissioning Team .............................................................................................................................. 13
8 PRESERVATION EXECUTION ........................................................................................................ 14
8.1 Responsibility Matrix............................................................................................................................................. 14
8.2 Preservation flowchart .......................................................................................................................................... 15
9 ONSHORE PRESERVATION ........................................................................................................... 16
9.1 Preservation at Contractor’s yard ........................................................................................................................... 16
9.1.1 Inspection Of Equipment(s) on Receipt ..................................................................................................... 16
9.1.2 Storage .................................................................................................................................................. 16
9.1.3 Special Care for Instrument and Telecom .................................................................................................. 17
9.1.4 Special Care for Electrical......................................................................................................................... 18
9.1.5 Special Care for Mechanical, Safety & Special tools .................................................................................... 19
9.1.6 Special Care for Piping and Valves ............................................................................................................ 22
9.1.7 Preservation during Construction Phase .................................................................................................... 23
9.1.8 Preservation during Onshore Commissioning Phase .................................................................................... 23
9.2 Preservation Before and during Sail away ............................................................................................................... 25
10 OFFSHORE PRESERVATION .......................................................................................................... 25
10.1 Preservation During Hook-Up and Commissioning Offshore ...................................................................................... 25
11 PRESERVATION MAINTENANCE PHASE ....................................................................................... 25
12 PERIODIC INSPECTIONS AND RECORDING ................................................................................. 26
13 PRESERVATION LABELS/TAGS ..................................................................................................... 26
14 CONSUMABLE MATERIALS USED FOR PRESERVATION ................................................................ 26
15 APPENDIX ..................................................................................................................................... 27
15.1 Appendix 1 – Storage classification: ....................................................................................................................... 27
15.2 Appendix 2 – Equipment Preservation Tag/Label ..................................................................................................... 30
15.3 Appendix 3 – Equipment Preservation Log Sheet .................................................................................................... 31
15.4 Appendix 4 – Preservation Form List And Schedule ................................................................................................. 32
15.5 Appendix 5 – ICAPS Preservation Form .................................................................................................................. 40
15.6 Appendix 6 – Preservation Material and Consumables…………………………………………………………………………………………….66
1 PURPOSE
The purpose of this procedure is to provide general guidelines on the preservation requirements on all equipment, all piping, all spare parts, special tools and consumables provided for XXXX Project. It shall be used as the basis for equipment and material protection and preservation which shall continue during all onshore and Offshore Project phases: vendors shipment, Worksite Storage, construction, transportation, handling, Pre-Commissioning, Commissioning, prior to handover.
In order to safeguard the integrity and functionality of equipment, it is necessary:
To ensure the full equipment or materials are not damaged during transportation.
To ensure package equipment shall be protected against the effects of climatic conditions such as rain, moisture, humidity, sunlight, dust, marine environment and ship's movement during transportation.
To ensure that the equipment is handled and stored properly before being installed either Onshore or Offshore and before/after commissioning.
To ensure no Mechanical deformation when not running, seizing, external chocks,
To ensure duration as long term v/s short term preservation requirement, expiry date of consumables,
This procedure covers the requirements for the preservation of mechanical equipment, piping system, electrical & instrument items, skid equipment and spare part/special tools. Preservation ICAPS forms and Log preservation sheet will be used to follow the Preservation activities. Refer to Appendix 3,4 and 5.
Note: Initial preservation at vendor shop is required. Factory / workshop are also the place where the first
preservation activity starts.
2 SCOPE
This document is applicable for all Construction, pre-commissioning , commissioning and HUC activities to be carried out for XXXX Project, as per the requirements of the EPCIC4 CONTRACT.
Preservation and maintenance procedures will be implemented with routine inspection log sheets.
During Commissioning, equipment may be required to run on a permanent basis, while some others shall be preserved until the time arrives to put them in normal operation. ICAPS check list will be used to ensure that the preservation is done correctly, recorded and reported. ICAPS Preservation data base will be prefilled in excel file by Item before import in ICAPS Sofware.
The offshore preservation after Handover to FOPs and prior to first oil will be detailed in following procedure:
“X & XX WHP - Offshore Pre- First Oil Preservation Procedure” XXXX
Block 5 - AXXX FIELD Development
Document Title: X & XX WHP – Preservation Procedure and Schedule
Project: XXXX Document Number: XXXX Date: 17-Jul-2020 Rev.: 02
Doc Type: PRC System: GENE Phase DE Status: AFC Class: 1
INTERIM CERTIFICATE(S)
Means any certificate(s) issued by COMPANY before the PROVISIONAL ACCEPTANCE CERTIFICATE pursuant to sub-Article 19.1.
OPERCOM®
Trademark, property of COMPANY, designating the methodology of the Pre-Commissioning and Commissioning activities described through a set of four Standards XXX
EXHIBITS
Means Exhibits A through L together with the documents attached and referred to therein, all as attached to the AGREEMENT.
MANUFACTURER/ VENDOR
The party that manufactures or supplies equipment and services to perform the duties specified by the CONTRACTOR
TRANSFER AND CARE OF CUSTODY
When the plant is built in a yard and is moved to the final site location. Once at the final site, and at predefined stage, the management of the PTW is then switched from the Contractor to the Company. This is called Transfer of Care and Custody.
TRANSFER OF OPERATION AND MAINTENANCE
Means when Operation, Maintenance and Preservation are transferred from CONTRACTOR to COMPANY. This is defined in OPERCOM® and there can be one or several TRANSFER OF OPERATIONS AND MAINTENANCE (TOM).
SIMOPS
stands for SIMultaneous OPerationS, meaning any WORK performed while drilling or production activities are ongoing.
WORKSITE(S)
Means the SITE and/or all and any construction location(s), as listed in EXHIBIT F, where any major parts of the PLANT (such as decks, bridges, equipment skids and major sub-assemblies) shall be fabricated and assembled, excluding all other offices, premises and workshops of CONTRACTOR and SUBCONTRACTORS.
WORKSHOP(S)
Means any location(s), other than WORKSITES, including offices, premises and workshops, where any equipment, materials or manufactured items including CONTRACTOR ITEMS shall be engineered, manufactured and assembled. WORKSHOPS include offices, premises and workshops of SUBCONTRACTORS.
Block 5 -XXXX FIELD Development
Document Title: X & XX WHP – Preservation Procedure and Schedule
Doc Type: PRC System: GENE Phase DE Status: AFC Class: 1
Page 7 of 74
WORK
Means all and any part of the works and services required to be performed by CONTRACTOR under the CONTRACT for the full and complete realisation of the PLANT, as outlined in ARTICLE 1 and described in detail in EXHIBIT A and as may be modified by CHANGE ORDERS.
SITE
Means the offshore location where the PLANT is to be constructed and the vicinity thereof.
LOCATION(S)
Means any locations where the WORK is performed by CONTRACTOR or SUBCONTRACTORS. COMPANY’s LOCATION(S) means any LOCATION under the custody of COMPANY and CONTRACTOR’s LOCATION(S) means any LOCATION under the custody of CONTRACTOR or SUBCONTRACTORS. For the avoidance of doubt, a LOCATION may be under the custody of a PARTY despite the fact that some equipment or facilities within such LOCATION are under the care and custody of the other PARTY.
SUPPLIER(S)
Means supplier(s) of any COMPANY ITEM(S).
VENDOR(S)
Means any CONTRACTOR’s and/or SUBCONTRACTORS’ supplier(s) of CONTRACTOR ITEM(S). VENDORS’ presence on WORKSITE may be required to assist CONTRACTOR and/or COMPANY for the installation, commissioning and start-up of such CONTRACTOR ITEMS and during the performance of PERFORMANCE TESTS.
SUBCONTRACTOR
Means any company or person, to whom CONTRACTOR has subcontracted directly or indirectly at any level the performance of any part of the WORK. SUBCONTRACTORS include VENDORS and contractors of ASSIGNED CONTRACTS.
SUB-VENDOR
The party or parties entering into a contract with VENDOR, for the performance work
Shall
The word ‘shall’ indicates a requirement.
Should
The word ‘should’ indicates recommendation.
4.2 Abbreviations
Abbreviations Description
AFC
Approved For Construction
AOC
Achievement of Commissioning
AOCC
Achievement of Commissioning Certificate
CA
Certifying Authority
CAF
Contractor Authorized Fluid
COF
Company Only Fluid
CM
Commissioning Manager
CSL
Commissioning Site Leader
FAT
Factory Acceptance Test
FTS
Functional Tests Sheet
HSE-SA
Health Safety Environment Site Authority
HSE-SA-D
Health Safety Environment Site Authority Delegate
HSE
Health, Safety and Environment
OT
Operational Tests
OTP
Operational Tests Procedure
P&ID
Process and Instrumentation Diagram
PRC
PReliminary Checks
PTW
Permit To Work
PVP
Piping & Vessels Preparation
PSSR
Pre-Start Up Safety Review
RFC
Ready for Commissioning
Page 8 of 74
Abbreviations Description
RLMU
Red Line Mark Up
RSES
Responsible for Safety and Environment on Site
SEA
Site Electrical Authority
SAT
Site Acceptance Tests
SIMOPS
SIMultaneous OPerationS
SLD
Single Line Diagram
SOW
Scope of WORK
TOM
Transfer of Operation and Maintenance
TOMC
Transfer of Operation and Maintenance Certificate
TOCC
Transfer of Care and Custody
VMR
VENDOR(S) / SUPPLIER(S) Mobilization Request
WHCP
Wellhead Control Panel
5 PROJECT DESCRIPTION
The XXXXfield is QATAR’s largest oil field. It is a conventional oil field (of approximately 60 m water depth) situated offshore the State of Qatar approximately 70 km north-north-east of Ras Laffan. The field overlays the giant pre-Khuff gas field known as North Field.
Thirty-three platforms, including five production hubs, are installed in XXX field. These are spread over nine different areas across the field - Locations A to I. Crude is exported by tanker via tandem offloading from two FSOs which are permanently moored in the field to two (of three) SPMs. Gas is gathered in a gas grid pipeline system and exported via North Field Alpha.
The field has been developed through several phases and further development phases are envisaged by COMPANY as operator of the AXX concession.
Page 9 of 74
Figure 5-1: XXXField Block 5 Location
In order to improve the field production capacity COMPANY has initiated AXX project. XXX project consists in installing 7 new WHPs and 1 process platform to existing Al-Shaheen field platforms. The project is planned to be developed in 3 batches:
The first batch (Batch 1) consists of three (3) new wellhead platforms (DC, EG and FC) bridge-linked to existing platforms (DA, ED and FA).
The second batch (Batch 2) consists of 2 new wellhead platforms (CE and EH) bridge-linked to existing platforms (CD and EG).
The third batch (Batch 3) consists of 2 new remote wellhead platforms and one new process platform bridge-linked to existing platform GD.
Figure 5-2: Field Layout for Gallaf Project
Batch 2 main facilities include the following, for each location:
Jacket and piles.
Topsides.
Bridge.
Integration works (process tie-ins, electrical, ICSS, Telecom, interfaces).
The new facilities shall make use of the full design envelope of the existing facilities; best possible use will be made of existing installations to maintain the production plateau.
As a base case, platforms shall be designed for full 24 well-slot access and operation using 60-foot drilling jack-ups on one defined footprint.
6 PRESERVATION PLAN
Equipment are after being dispatched from factory/workshop after initial preservation at vendor shop and until the equipment are in normal operation on site, all of them might spend some time in transportation, storage, on stand-by, etc... During this time, equipment can be exposed to a number of aggressive environments or situations and could be deteriorated/ damaged. Ensuring integrity and functionality of an equipment is critical in keeping its availability through that time and at the time where it will be required for service.
In order to safeguard the integrity and functionality of equipment, it is necessary to preserve it, taking in consideration the following criteria’s as a minimum:
Weather conditions: condensation, sun radiation, frost, water ingress, dust, etc.
Local conditions: corrosive atmosphere, presence of sand, etc.
Duration: long term v/s short term preservation requirement, expiry date of consumables, etc.
Functionality: Mechanical deformation when not running, seizing, external chocks, etc.
Project phases: Storage, construction, transportation, handling, Pre-Commissioning, Commissioning, stand-by time etc.
A log sheet (Appendix 3) shall be completed for each equipment item or package requiring preservation and used to record preservation activities as they occur.
All the individual preservation activities with each equipment item number, the type of preservation performed (PRSV form), date of each activity was performed shall be recorded. The original documentation will be maintained by CONTRACTOR and ultimately turned over to COMPANY with the project quality records.
The Preservation related activities shall be prepared and tracked using ICAPS from commissioning phase until the equipment is formally transferred to Company.
The Preservation history and records shall be made available at any time until the equipment is formally transferred.
7 ROLES AND REPONSIBILITIES
7.1 Organization Chart
Procurement Team ( PE& QA/QC *Buyer )Vendor LocationTo shippingYard Reception to ConstructionUNTIL RFCWAREHOUSE TEAMCONSTRUCTION TEAMCOMMISSIONING TEAMHUC TEAMFROM RFC TO SAIL AWAYFROM OFFSHOREINSTALLATION TO HANDOVERPRESERVATION COORDINATORNOC DISCIPLINES LEAD CST & COM & HUC
7.2 Roles and Responsibilities
7.2.1 Preservation Coordinator
A Preservation Coordinator will be responsible for ensuring that preservation requirements are fully identified, performed and documented. The Preservation Coordinator will use the database for preservation to control and record preservation activities throughout the various phases of the project including at the Vendors works.
The Preservation Coordinator will provide leadership in the development and population of the Preservation Database and Preservation Planning. This is to ensure that equipment and materials are cared and maintained in accordance with Manufacturers Preservation Procedure, Specification and this Procedure from the suppliers works through to final hand- over to Company’s Operations.
If any preservation issues arise at any time in the lifespan of the Project, the Preservation Coordinator and his team have the authority to stop the works and ensure this is addressed and corrected immediately.
The Preservation Coordinator can stop the works and report to PMT for any personnel who destroys equipment or carry out the work without equipment protection and preservation activities.
The Preservation Coordinators responsibilities shall include but not be limited to the following:
Provide guidance and expertise on all matters related to Equipment Protection and Preservation of the equipment and materials related to the project.
Maintain data collected from the Preservation Team and Vendors to track and verify that the equipment is preserved as per Manufacturer Specification, Project Specification and this Procedure.
Provide single point of contact for information and guidance when conflict arises pertaining to the overall care of the equipment between interface owners.
Coordinate preservation activities at all locations.
Identify preservation resources needs at key project phases develop mobilization plan for the preservation team.
Develop the preservation plan for all phase of the project.
Be the focal point for onshore and offshore preservation execution including technical interface with Company.
Develop plan and procedure to ensure an effective completion phase.
Provide guidance to develop Preservation Management Procedure Preservation Activities Tracking and Reporting
Management and supervision of Vendors / Suppliers
Note: Preservation Coordinator and his team of discipline MC/field engineers will monitor Equipment prior to and during Construction to identify the need for additional temporary protection or preservation, to prevent equipment or material being damaged by climate or construction activities. Where required, temporary structures will be installed.
7.2.2 Warehouse Team
Warehouse team including Warehouse keeper / controllers responsibilities shall include but not be limited to the following:
Receiving and handling all items at all intermediate and final destinations
All sensitive electronic devices and equipment(s) shall be stored in a Climate Controlled Warehouse as per Manufactures instructions.
Inform to PE, QC and preservation team for Visual inspection any material come to warehouse.
Interface with the Preservation team.
Responsibilities to protect & preserve all materials in warehouse.
Cleanliness of the working areas
Timely check and record of preservation activities.
7.2.3 QA/QC Team
QA/QC’s responsibilities shall include but not be limited to the following:
Ensure all materials/equipment meet required specification with full certification as required.
Inspection of all incoming materials/ equipment.
Control of all material/ equipment certificates.
Perform material traceability.
Raise OS&D during receiving inspection when material/equipment was damaged, shortage or not meet required specification & control OS&D Report.
Notify and send to the QA/QC manager, Package Engineer, Company, Procurement Manager any OS&D report on material receipts and follow up corrective actions.
Control of all issues of job site materials/ equipment & ensure all materials/ equipment are maintained in good condition.
7.2.4 Construction Team/ Precom Team
Construction Team/Precom Team’s responsibilities shall include but not be limited to the following:
Timely notification and replacement of all damaged items during construction phase
Security of the components and equipment during construction phase
Identify potential hazards to installed equipment’s and provide control to protect from damage caused by construction.
Preserving (in accordance with supplier’s procedures and Project overall Equipment Protection and Preservation program) all items during the fabrication and construction phases to ensure all items are ready for commissioning in accordance with the project schedule.
Preserving and protecting all items prior to transportation from storage areas to installation site.
Bringing equipment, components, and systems out of preservation after transportation to bring
to “ready for commissioning” status.
Cleanliness of the working areas
Timely check and record of preservation activities.
7.2.5 Commissioning Team
Commissioning Teams responsibilities shall include but not be limited to the following:
Responsibility to protect and preserve all equipment during the Commissioning phase.
Cleanliness of the working areas.
Participate in Preservation Audits during the Storage and Construction Phases.
Management of the Preservation team to handle all preservation activities during performance of the work.
Where required, Commissioning team shall ensure Nitrogen blankets on key equipment are maintained for preservation purposes.
Timely check and record of preservation activities.
Manage ICAPS preservation forms.
8 PRESERVATION EXECUTION
8.1 Responsibility Matrix
ITEM Sequence From To Description Responsibility
1st Step
Supplier
Receipt and Storage
Inspection
QA/QC
Storage and
Preservation at SMOP Warehouse
Warehouse Keeper
2nd Step
Issue for Construction
Mechanical Completion &
Pre- commissioning
Protection & Preservation
Construction Team
3rd Step
From RFC
To Sail Away
Protection &
Preservation
Commissioning Team
4th Step
From Offshore Installation
To Handover
Protection & Preservation
HUC Team
5th Step
Handover to
Company Operations
First Oil
Preservation Prior to first Oil & Maintenance
Company Operation Team
8.2 Preservation flowchart
Set up system , Preservation data base & documentIssue Preservation Schedule & Record Review/Approved by COMPANYIssue Notification WeeklyPerformed Equipment PreservationActivitiesReview/Approved by COMPANYICAPS Update Issue the Preservation Report
9 ONSHORE PRESERVATION
9.1 Preservation at Contractor’s yard
CONTRACTOR shall have the sole responsibility and not limited of the following, refer to following preservation organization chart
9.1.1 Inspection Of Equipment(s) on Receipt
Upon arrival of equipment(s) CONTRACTOR shall immediately conduct a thorough inspection to ensure equipment(s) integrity and the condition of the preservation and identify any anomalies (defects, outstanding works, missing items etc...) shall be rectified accordingly.
CONTRACTORS’ “Preservation team” shall be activated and mobilized to perform/execute the preservation activities as required and the preservation activities shall extend until the formal TRANSFER of the PLANT(s) to CPY.
9.1.2 Storage
CONTRACTOR shall be solely responsible for the care and cleanliness of the equipment during equipment handling, storage and construction period and shall ensure a standard of care and cleanliness appropriate to the type and duty of the equipment(s).
Indoor ventilated storage shall be used for almost equipment. Outdoor storage is only acceptable for equipment as recommended by the VENDORS/SUPPLIERS. For special or sensitive equipment(s), designated store rooms shall be equipped with air conditioners, vented, clean and dry.
The Storage environment has to fulfill the VENDORS/SUPPLIERS’ requirements. See in appendix 1 storage classification example.
9.1.3 Special Care for Instrument and Telecom
ICAPS Preservation Forms (appendix 4) used are:
PRSV08 - Instrumentation & Telecom Panels
PRSV09 – Fire & Gas Devices and PA Speakers
PRSV10 – Junction Boxes
PRSV11 - Gauges, Transmitters etc
See below principal preservation activities for Instruments & Telecom:
I1- Miscellaneous Items/ Bulk items:
All sensitive electronic devices and equipment(s) shall be stored in a humidity/temperature controlled storage room(s)
All openings in hydraulic/pneumatic tubing shall be provided with steel caps or solid shank steel plugs of metallurgy equal to the metallurgy of the component being capped or plugged. Non-metallic plugs shall not be used.
Gaskets/O-rings on instrument equipment shall be greased with acid-free wax or equivalent.
All non-terminated cable ends shall to be fitted with shrinking shroud.
I2- Control valves:
Check all openings are closed and sealed. Keep the original protection.
Ensure all exposed parts are protected with appropriate preservation fluid.
The actuated control valves/ on-off valves need to be inspected on arrival at site and shall be kept in their original packing positions.
Actuator of valves are provided a tarpaulin covering or something similar to protect the actuator and valve stem during the construction phase of the job
Ensure all exposed parts are protected with appropriate preservation fluid
I3- Wellhead control panel:
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water.
All Control panels, Starter boxes, junction boxes, etc… shall have silica gel bags inside.
For manually operated valves, open and close valve. Ensure it operates smoothly.
Ensure that plywood/ bubble wrap covering for instrument glass surfaces for protection of field devices.
Check thal all nozzles are connected or covered/ sealed.
Ensure all exposed parts are protected with appropriate preservation fluid.
All spare cable entries in panels and boxes shall be plugged. The plugs to be same certification as enclosure if permanents.
Ensure that equipment and surrounding areas are clean and free from debris, rust.
Check equipment is free from mechanical damage.
Ensure that equipment is fully covered with canvas sheet.
Preservation Tag is endorsed and displayed after completion of activity.
T1- Telecom and Fire & Gas
Telecom equipment containing electronics shall be protected with desiccant or vapor corrosion Inhibitor.
All sensitive electronic devices and equipment(s) shall be stored in a humidity/temperature controlled storage room(s). During pre-com/construction phase, all sensitive electronic devices shall be covered by bubble wrap and canvas sheet. During commissioning phase, all sensitive electronic devices shall be removed all covering for inspection and testing, and re-covered for transportation.
Gaskets/O-rings on instrument equipment shall be greased with acid-free wax or equivalent.
All non-terminated cable ends shall to be fitted with shrinking shroud.
All spare cable entries in panels and boxes shall be plugged. The plugs to be same certification as enclosure if permanents.
9.1.4 Special Care for Electrical
ICAPS Preservation Forms (Appendix 4) used are:
PRSV01 - Switchgear, Switchboards, DBs & Control Panels
PRSV02 – Batteries & UPS Systems
PRSV03 – Generators & Motors
PRSV04 - Junction boxes
PRSV05 - Navaids Systems
PRSV06 - Transformers
PRSV07 - Heaters
See below principal preservation activities for Electrical:
E1- Miscellaneous Items/ Bulk items:
All electrical and electronic equipment exposed to humidity shall be protected with desiccant or vapour corrosion inhibitor.
All threaded entries to be plugged and threads recoated with rust preventatives where necessary.
All gland plates to be checked and reinstated where required.
All non-terminated cable ends shall be fitted with heat shrink shrouds or electrical insulation tape.
E2- Switchgear, Switchboards, DBs & Control Panels:
Check equipment is free from physical damage.
Electrical equipment to be stored in clean and covered area, especially to battery, to be stored in air conditioned
room as per manufacturer’s recommendation
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water.
Ensure that silica gel bags shall have been installed.
Ensure that Space Heaters are energized as Vendor's recommendation. Mark as "LIVE" danger.
Confirm Switchgear, Switchboards, DBs & Control Panels are stored in air conditioning if required.
Check air purging connections. Report any abnormalities.
Ensure that equipment and surrounding areas are clean and free from debris, rust.
All spare cable entries in panels and boxes shall be plugged. The plugs to be same certification as enclosure if permanents.
Preservation Tag is endorsed and displayed after completion of activity.
E3- Batteries/ UPS:
Check equipment is free from physical damage
Remove any salt deposits and clean external fittings
Ensure that terminal connections are tight and coated in preservation product
Measure battery charge of individual cells & record voltage
Check battery & electrical compartment are stored properly (stored in cool, dry & ventilated).
Ensure that if Battery needs a recharge the periodical basis will need to be determined.
Battery banks to be marked as being " LIVE-DANGER".
Preservation Tag is endorsed and displayed after completion of activity.
E4- Transformers:
Check equipment is free from physical damage.
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water.
Ensure that silica gel bags shall have been installed.
Ensure that Space Heaters are energized as Vendor's recommendation. Mark as "LIVE" danger.
Check air cooling/ ventilation aired inlet/ outlets are clear.
If transformers are oil filled check level indicator shows correct level.
Apply grease at grease point (if required).
Apply insulation resistance measurement requirement as per vendor recommendation
Ensure that equipment and surrounding areas are clean and free from debris, rust.
Preservation Tag is endorsed and displayed after completion of activity.
E5- Motors:
Check equipment is free from mechanical damage.
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water.
All Control panels, Starter boxes, junction boxes, motor terminal boxes, etc… shall have silica gel bags inside and shall be wrapped by canvas.
Shafts on Electrical Motor and Mechanical seal shall be protected with Vendor / Manufacture approved grease, silicon-based lubricant or equal.
Ensure that Motor Pump > 22 KW, then Heaters are energized as Vendor's recommendation. Mark as "LIVE" danger.
Check insulation resistance, record (Mohms):Mohms @ 1000v
Shafts to be hand turned periodically as per Manufacturer's recommendation. Record and report any noises, roughness, stiction etc.:
Ensure that equipment is fully covered with canvas sheet.
Preservation Tag is endorsed and displayed after completion of activity.
E6- Navigation aid system
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water
Ensure that silica gel bags shall have been installed inside panels.
Confirm Control Panels are stored in air conditioning if required
Check air purging connections. Report any abnormalities.
Check battery and electrical components are clean & dry.
Measure battery charge of individual cells & record voltage.
Ensure that if Battery need a recharge the periodical basis will need to be determined.
Check that all lighting fixtures and lanterns in exposed areas are dry and all holes are sealed off
Equipment will be covered properly
9.1.5 Special Care for Mechanical, Safety & Special tools
ICAPS Preservation Forms (Appendix 4) used are:
PRSV12 - Compressors
PRSV13 – Pumps
PRSV14 – HVAC Equipment
PRSV15 - Cranes
PRSV16 - Package, Skid Mounted & Misc Equipment
PRSV17 - Pressure Vessels, Coolers & Exchangers
PRSV18 - Safety Equipment
PRSV19 - Special Tools, Accommodation & Lab Equipment
PRSV20 - Filters & Strainers
PRSV21 - Trolleys, Pulleys, Hoists & Chain Blocks
PRSV22 - Tanks
PRSV23 - Fans & Blowers
PRSV24 – Winch
PRSV25 - Diesel Engines
PRSV26 -Weather Protection
See below principal preservation activities for Mechanical:
M1- Miscellaneous Equipment Items:
Check that all open ends are connected or covered/ sealed.
Ensure all exposed parts are protected with appropriate preservation fluid.
Ensure that equipment and surrounding areas are clean and free from debris, rust.
Ensure that equipment is fully covered with canvas sheet.
M2- Pumps:
Confirm Isolation power prior to task.
Check equipment is free from mechanical damage.
Check lube oil piping and level. Report any abnormalities.
Ensure all exposed parts are protected with appropriate preservation fluid.
Apply grease at grease points (if required).
Shafts to be hand turned periodically as per Manufacturer's recommendation. Record and report any noises, roughness, stiction, etc…
Ensure that Pump skid is clean and clear of debris, rust.
Ensure that equipment is fully covered with canvas sheet.
Preservation Tag is endorsed and displayed after completion of activity.
M3- HVAC:
Ensure all exposed parts are protected with appropriate preservation fluid.
Dry N2 to be used for necessary items
Major equipment (ACU, ACCU,FAN ) shall maintain as per vendor recommendation
Apply grease at grease points (if required).
Visually inspect all the ducting. Report any obstructions or abnormalities.
Duct spool shall be protected by plastic cover.
For manually operated valves, open and close valve. Ensure it operates smoothly.
All Control panels, Starter boxes, junction boxes, etc…shall have silica gel bags inside.
Copper pipes shall be covered each extremity by plastic.
Ensure that Heaters are energized as Vendor's recommendation. Mark as "LIVE" danger.
Check insulation resistance, record:(Mohms) @ 1000v
Shafts to be hand turned periodically as per Manufacturer's recommendation. Record and report any noises, roughness, stiction, etc…
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water.
Check all instruments are properly installed and protected. Report any abnormalities.
Ensure any spindles are lubricated. If required clean and reapply lubricant.
Check that all guards are fitted correctly.
Ensure all equipment and associated areas are clean and free from debris, rust.
Louvers should be visual checked and then left closed.
Check equipment is free from mechanical damage.
Ensure that equipment is fully covered with canvas sheet.
Preservation Tag is endorsed and displayed after completion of activity.
M4- Pedestal Cranes:
Ensure crane motor is properly protected as per vendor recommendation.
Ensure all caps from day tank are plugged.
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water.
Seal all breathers to brakes and gearboxes with strong tape.
Check all oil levels. Report any abnormalities.
Ensure all exposed parts are protected with appropriate preservation fluid.
Apply grease at door hinges, grease nipples and fastener (if required).
Check all exposed connecting pins are lubricated correctly. Add lubrication if required.
Check that all ropes are lubricated.
Check all instruments are properly installed and protected. Report any abnormalities.
Check all control panels. Check silica gel bags have been installed. Replace if necessary.
Check all guards are fitted correctly.
All loose items should be removed from the crane.
Check that all Vents & Drains are clear and not holding water.
Ensure that Crane and surrounding areas are clean and free from debris, rust.
Visual check and report for any areas of corrosion, discolorations on structural members, etc…
Check equipment is free from mechanical damage.
Preservation Tag is endorsed and displayed after completion of activity.
M5- Packages/ Skids:
Check all instruments are properly installed and protected. Report any abnormalities.
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water.
All Control panels, Starter boxes, junction boxes, etc… shall have silica gel bags inside.
For manually operated valves, open and close valve. Ensure it operates smoothly.
If applicable, check nitrogen pressure charge (pressure: 1 bar(g).
Ensure that plywood/ bubble wrap covering for instrument glass surfaces for protection of field devices.
Check that all nozzles are connected or covered/ sealed.
Ensure all exposed parts are protected with appropriate preservation fluid.
Ensure that equipment and surrounding areas are clean and free from debris, rust.
Check equipment is free from mechanical damage.
Ensure that equipment is fully covered with canvas sheet.
Preservation Tag is endorsed and displayed after completion of activity.
Packages (Chemical, etc…) to be drained and dry water after OTP (operation test procedure).
M6 - Filters/ Tanks:
Check the open points/ nozzles shall be sealed and closed properly.
Ensure manhole handling davit arm is lubricated. If required, clean & reapply lubricant.
Ensure that all surrounding areas are clean and free from debris, rust.
Check equipment is free from mechanical damage.
Ensure that equipment is fully covered with canvas sheet.
Preservation Tag is endorsed and displayed after completion of activity.
M7- Generators:
Check all instruments are properly installed and protected. Report any abnormalities.
Check plug and tapes on unused holes and cable entries to stop the ingress of dust and water.
All Control panels, Starter boxes, junction boxes, etc… shall have silica gel bags inside.
To use plywood/ bubble wrap covering for instrument glass surfaces for protection of field devices.
Check that all nozzles are connected or covered/ sealed.
Check all oil levels. Report any abnormalities.
Ensure engine exhaust has been capped.
Check equipment is free from mechanical damage.
Ensure that Heaters are energized as Vendor's recommendation. Mark as "LIVE" danger.
Check insulation resistance, record (Mohms) @ 1000v
Check that all Vents & Drains are clear and not holding water.
Ensure all exposed parts are protected with appropriate preservation fluid.
Ensure that equipment and surrounding areas are clean and free from debris, rust.
Preservation Tag is endorsed and displayed after completion of activity.
9.1.6 Special Care for Piping and Valves
For protection against rust contamination on stainless steel surfaces, CRA piping, equipment as well, then cleaning & protection for these materials shall be applied as per Pickling & Passivation for Stainless Steel & Duplex Stainless Steel of Piping & Welding Joint Procedure (doc. No.: XXX
Coat all metal surfaces of machine/ equipment, etc: with rust preventive wax, where painting is not required.
ICAPS Preservation Forms (Appendix 4) used are:
PRSV27 - Valves
PRSV28 - Piping & Vessel
See below principal preservation activities for Piping:
P1- Piping:
Check all materials for any physical damage.
Open end piping shall be blind off by blind flange/ plastic cap or suitable covering.
Drain out ensuring that no water is trapped in system.
Stainless steels are allocated separately to carbon steel to avoid carbon contamination.
Gate valves/ globe valve/ check valve need be stored in close position.
All manual ball valves shall be locked in open position prior to transportation.
All piping shall be internally drained out ensuring that no water is trapped in system prior to purge N2.
All Hydrocarbon system including Vessels shall be inerted with nitrogen gas at 1 barg (15 psig) before the Topside sailing. A pressure indicator (0-2 bar(g) range) shall be placed to monitor the pressure maintenance. The utilities systems shall be sealed to prevent ingress of water/dust.
All items surrounding the Wellhead area shall be protected by suitable protection material to avoid damage during drilling operation.
P2- Bulk/ Miscellaneous/ Fittings Items:
All exposed flanges shall be protected with permanent corrosion protection & mechanical damages.
Open flexible hose connections shall be plugged.
All threaded openings shall be provided with steel caps or solid-shank steel plugs of metallurgy equal to the metallurgy of the component being capped or plugged.
Insulated units, where insulation is exposed to damage during storage installation shall be protected with 10 mm plywood plates.
All spools/lines shall be protected with min. 10mm water resistant plywood plate with 4 off galvanized bolts and a form of rubber gasket sufficient to provide mechanical protection and water/dust tight sealing.
All ends that have been beveled for welding shall be provided with closure designed to prevent of foreign material and damage to the bevel.
P3- Pressure Vessels:
Check all instruments are properly protected. Report any abnormalities.
Equipment shall be carefully cleaned of dust and dried before preservation works carried out.
Check that all nozzles are connected or covered.
Where charge with nitrogen, check inerted pressure is maintained pressure: 1 bar (g)).
Notes: If vessel is Nitrogen filled check and note internal pressure.
If vessel is nitrogen filled DO NOT operate any valves.
Ensure mainhole handling davit arm is lubricated. If required, clean & reapply lubricant.
Ensure that all surrounding areas are clean and free from debris.
Check equipment is free from mechanical damage.
Ensure that equipment is fully covered with canvas sheet.
Preservation Tag is endorsed and displayed after completion of activity
9.1.7 Preservation during Construction Phase
CONTRACTOR shall be responsible to provide preservation of equipment during fabrication, construction and installation, a temporary slanting roof with sidings shall be erected around the skids special equipment, etc...to protect them from accidental damaged during construction works. Normal equipment (vessels & tanks,..) will be covered by canvas sheet. Control valves/ motor valves are provided a tarpaulin covering or something similar to protect the actuator and valve stem during the construction phase.
Contractor shall use plywood/ bubble wrap covering for instrument glass surfaces for protection of field devices against blasting activity, painting, welding grits, falling debris, accidental damage, water/rain etc... Carton paper can use instead of plywood in case of equipment/ devices installed inside or well protected areas.
The enclosure/ canvas sheet must be provided with access (Velcro-type opening) for lifting, hook up of piping, hook up of electrical/instrument cables and access for periodic maintenance of preservation without removal of the entire enclosure.
Before Welding activities on Platform, Welders make sure that the equipment close the welding area are not damaged by hot works.
Blasting & painting Team needs to check and cover more a temporary canvas sheet before grit blasting. After grit blasting make sure that to check & clean all girts inside packages. Document to refer : “ X & XX WHP - Painting and blasting procedure “, XXXX. Preservation team need to check after painting and blasting, to maintain preservation works in good status.
Apply a coating of exterior preservative to all shafts, couplings, and exposed-machined surfaces. Clean shaft couplings and exposed machined surfaces and coat them with exterior preservative. Exposed external machined surfaces shall be coated with a rust preventive wax.
9.1.8 Preservation during Onshore Commissioning Phase
CONTRACTOR shall undertake the responsibilities of preserving all subsystems and equipment(s) that have completed commissioning testing to provide protection from damage and ensure the integrity and operability of the equipment(s) until the TRANSFER to CPY.
The preservation of subsystems and equipment(s) during the commissioning period shall also extend to process piping, vessels and valves.
Mechanical Preservation
Equipment coating should be checked regularly
Equipment with mechanical seal - manufacturer preservation procedure should be followed.
Bearing housing shall be inspected, cleaned, etc...
Piping preservation
Check all long term stored spools have all open ends capped or plugged.
Drain out ensuring that no water is trapped in system.
Open end piping shall be blind off by blind flange/ plastic cap or suitable covering.
All manual ball valves shall be locked in open position prior to transportation.
All piping shall be internally drained out ensuring that no water is trapped in system prior to purge N2.
All Hydrocarbon system including Vessels shall be inerted with nitrogen gas at 1 barg (15 psig) before the Topside sailing. A pressure indicator (0-2 bar(g) range) shall be placed to monitor the pressure maintenance. The utilities systems shall be sealed to prevent ingress of water/dust.
Electrical Preservation
UCP panels, JBs, and DBs shall be preserved by placing silica gels inside to absorb moisture. For outside panels, JBs, etc, are covered by plastic sheet/ canvas sheet.
Instrument Preservation
All instruments expose to damage shall be wrapped and sealed, etc... by plastic sheet/ canvas sheet.
Instrument panels, JBs, and housings / enclosures, etc… shall be preserved by placing silica gels inside to absorb moisture. For outside panels, JBs, etc… are covered by plastic sheet/ canvas sheet.
Telecom Preservation
All telecom equipment expose to damage shall be wrapped and sealed, etc... by plastic sheet/ canvas sheet.
Telecom panels, JBs, and housings /enclosures, etc… shall be preserved by placing silica gels inside to absorb moisture. For outside panels, JBs, etc… are covered by plastic sheet/ canvas sheet.
Painting
Equipment shall be examined for damage of painted coating. If damage has occurred, touch up paint shall be done using a procedure consistent with the requirements of the Manufacturer's coating system supplied on the equipment. etc:
Material Safety Data Sheets (MSDS)
All MSDS required for every lube oil or chemical shall be made available at the storage location.
Storage and Handling
Manufacturer Instruction noted on the packing crates shall be regarded as mandatory during handling and storage, etc. CONTRACTOR makes sure that actual preservation on crates is incorporated on preservation procedure.
The manufacturer’s recommendations regarding handling and storage shall be incorporated into preservation preservation procedure and the manufacturer's recommendations shall be performed preservation before handover.
Humidity / temperature controlled storage rooms that are normally unmanned and locked shall be inspected on a weekly basis to ensure that the equipment is stored securely and the temporary air conditioner systems are working, etc....
Bulk Storage items: non-ferrous material must be segregated from ferrous material. Special attention for storage of stainless steel/high nickel pipe fitting, flange, etc. must be taken into consideration. Segregation of these materials from other carbon steel and no contact with raw unseasoned wood or
iron stiles shall take place.
9.2 Preservation Before and during Sail away
CONTRACTOR shall perform the minimum preservation activity covered one (1) platform for equipment(s) before the platforms sail-away.
SubSystem number to be updated In Preservation ICAPS data base according last subsystem list
CONTRACTOR will develop the list of status equipment that been verified and agreed by CONTRACTOR, COMPANY and T&I CONTRACTOR, there are any damages or defects during topside transportation will be recorded when the Topsides are put in place.
All field devices that will be affected and may get damage during the marine activities ex: during (heavy Lifting, sea fastening, mooring etc...) shall be removed and to be re-installed during the offshore scope of work activities.
A list of the removed item(s) shall be prepared and submit to CPY for approval.
For the offshore installed equipment, steps as specified in Responsibility matrix. Preservation schedule and records to be applied by disciplinary preservation record as well.
All items surrounding the Wellhead area shall be protected by suitable protection material to avoid damage during drilling operation.
All manual ball valves shall be locked in open position prior to transportation. Fail-close On/off ball valves shall be kept in closed position.
10 OFFSHORE PRESERVATION
10.1 Preservation During Hook-Up and Commissioning Offshore
TOPSIDEs will be delivered offshore and put in place, equipment and items will be unpreserved for construction activities and continuous testing purposes, the below activities will be carried by CONTRACTOR to protect equipment from accidental damaged:
Check all long term stored spools have all open ends capped or plugged
A temporary slanting roof with sidings shall be erected around the skids special equipment, etc...
Instruments fragile devices shall be covered with bubble wrap & canvas sheet for protection.
Contractor shall use carton paper & bubble wrap covering for item glass surfaces for protection of field devices against blasting activity, painting, welding grits, falling debris, accidental damage, water/rain etc...
The enclosure must be provided with access (Velcro-type opening) for lifting, hook up of piping, hook up of electrical/instrument cables and access for periodic maintenance of preservation without removal of the entire enclosure.
Once offshore construction is completed, Construction will do preservation & hand over to Commissioning team. All preservation will be reporting in ICAPS and follow by the preservation Log sheet.
11 PRESERVATION MAINTENANCE PHASE
The preservation maintenance activities shall extend until formal TRANSFER of the PLANT. CONTRACTOR is responsible for the continual preservation activities and not limited to the following:
Filling out preservation labels and fix it to the equipment.
Performance of preservation activities.
Timely issue of requisite preservation record sheets and labels to the equipment.
Reinstating preservation in accordance with requirements.
Preparation of MSDS in the preservation dossier of all preservation products being used.
Recording and updating of the preservation activities including any defects or abnormalities found during performing preservation, on preservation records and input to ICAPS as PL before Topside sailing/ handover.
Updating of the ICAPS preservation data base.
Updating of the preservation dossier.
12 PERIODIC INSPECTIONS AND RECORDING
CONTRACTOR shall carry-out the following activities:
Periodic/routine inspection of equipment shall be scheduled into monthly interval or as per Vendor's recommendation at Vendor preservation procedure, which frequency/ interval shorter shall be applied for routine inspection.
Placement of preservation tags/labels (appendix 1) on the equipment's body showing the type of preservation application, preservation material used, the name who performs preservation activity, date(s) when the preservation performed.
The performance of inspection/preservation activities shall be logged/recorded in the preservation schedule & record (appendix 4) and shall be input to ICAPS for tracking and monitoring.
Frequencies of preservation activities will be indicate later after receiving vendors recommendations.
The historical preservation records of the subsystem equipment shall be included in Preservation Dossier which will be required during the formal TRANSFER of the PLANT to COMPANY.
The preservation application, inspection & monitoring shall also cover piping, vessels, etc… that has been successfully competed commissioning.
The tracking and monitoring of the equipment's preservation activity shall be submitted to COMPANY on weekly basis.
13 PRESERVATION LABELS/TAGS
- Stand-alone tags/labels, one preservation tag shall be fixed to each equipment. Refer to Appendix 2.
- For package or equipment skid, one label will be affixed for each package or skid.
- Preservation labels are NOT applicable for bulk items or miscellaneous items.
14 CONSUMABLE MATERIALS USED FOR PRESERVATION
Consumable required for preservation activities shall be provided and supplied by CONTRACTOR until the formal TRANSFER of the PLANT to COMPANY.
Onshore material list for preservation is indicated in Appendix 6
See below examples of preservation consumable which can be used :
Lube compatible preservative (gear)
Preservative oil level (motors)
Grease (bearings)
Nitrogen Blanket (vessel, Pump and compressor)
Watertight plugs. (Terminal box)
Robust protective caps (Flanges)
Protective slanting roof with sidings (skid, valves)
Aluminium sheeted glass fiber cloth (instrument)
Silica gel (Cabinet)
Tarpaulin (General equipment)
Preservation oil for rotating equipment ( pump, engine, fan, compressor, etc: )
15 APPENDIX
15.1 Appendix 1 Storage classification:
The following classifications shall be applied for material storage place.
Class 1: Materials or equipment shall be stored in air-conditioned room inside warehouse.
Class 2: Materials or equipment shall be stored in warehouse or shipping dry container.
Class 3: Materials or equipment shall be stored at covered area or in shed.
Class 4: Materials or equipment shall be stored at open area, with proper protection.
Material Storage Classification:
CATEGORY DESCRIPTION CLASS REMARKS
Common
Anchor bolts/nuts
4
Bolts & Nuts
3
Gas Cylinders
3
Caution for flammable
Scaffolding materials
4
Painting material
2
Waterproof box
Insulation material
2
Waterproof box
Civil
Reinforcing bars
4
Structural Steel
4
Forming materials
4
Wrapping materials
3
Waterproof box
Bulk Cement
3
Waterproof box
Sacked Cement
3
Waterproof box
Equipment & machinery
Heat exchanger
4
Vessels, towers, tanks and drums
4
Internals/Trays
4
Compressors and Turbines
4
N2 Dry seal Gas unit
2
Furnace
4
Pumps
4
Except for indoor
Tank material
4
Packing equipment
4
Construction spares
2
Waterproof box
Special Tools
2
Waterproof box
Spare rotors
2
Waterproof box
Miscellaneous
Wooden items
2
Shipping box
Chemicals
2 or 3
By vendor’s
Lube oil
2 or 3
By vendor’s
Catalyst packing
4 or 3
By vendor’s
Electrical
Transformers
4
Indoor and clean covered area as per vendor recommendation
Switchgear/panels
2
Indoor and clean covered area as per vendor recommendation
Batteries
2
To be stored inside the air conditioned room as per vendor recommendation
Lighting materials
3
Waterproof box
Lighting poles
4
Cable drums
4
Cable ends to be protected
Cable tray
4
Other bulk materials
2
Waterproof box
Instrument
Computer
1
All sensitive telecoms equipment
1
Instrument panels outdoor
4
Instrument panels indoor
2
Analyzer house
4
Field Analyzer
2
All flow, level, pressure and temperature instrument
3
Shipping box
Cable drums
4
Cable ends protection
Fittings
2
Other bulk material
4
Piping
Prefabricated piping
4
Pipes/Tube
4
Fittings and Flange of 2” and above
4
Fittings and Flange of 1-1/2” and below
2
Shipping box
Valves of 2” and above
4
Valves of 1-1/2” and below
2
Shipping box
Bolts & Nuts
2
Shipping box
Gaskets
2
Shipping box
Piping miscellaneous of small sizes
2
Shipping box
Piping miscellaneous of big sizes
4
Spring-hangers ,supports
4
Cold supports
3
Shipping box
Other piping supports
