SECTION 5 - HANDOVER PROCEDURES

PT. GLOBAL POWER SERVICES

SECTION 5

HANDOVER PROCEDURES

Rev. Date/Checked Date/Approved Date/Issued Notes

Orig.
Rev.A
Rev.B
Rev.C
Rev.D

PT. GLOBAL POWER SERVICES ©DOC2010 Page 1 of 21

SECTION 5 - HANDOVER PROCEDURES

PT. GLOBAL POWER SERVICES

SECTION. 5 HANDOVER PROCEDURES

Index Page

5. HANDOVER PROCEDURES
5.1 INTRODUCTION
5.2 ROLE OF OPERATIONS DOCUMENTATION CENTER
5.3 CHECK OUT DOCUMENTS
5.4 HANDOVER DOCUMENTS
5.5 STATUS REPORTING
5.6 FLOW SHEETS FOR HANDLING CHECK OUT AND HANDOVER
FORMS
5.7 FLOW SHEET FOR CHECK OUT AND COMMISSIONING
PROCEDURES
5.8 EQUIPMENT PROCEDURES
5.9 PREPARATION WORK FOR PIPING TESTS

PT. GLOBAL POWER SERVICES ©DOC2010 Page 2 of 21

SECTION 5 - HANDOVER PROCEDURES

HANDLING OF CHECK OUT AND HANDOVER DOCUMENTS

5.1. Introduction:

In compiling the procedure for the handling of check out and handover documents,
the principle has been adopted to minimize the extent of document handling,
duplication and distribution while ensuring that all relevant parties are informed of
the status of documentation. Attention has been given to avoiding the creation of
an unmanageable burden of paper work for any one party.

The narrative procedure describes the main principles adopted for the handling
and routing of check out and handover documents. The more detailed sequence for
handling the documents is shown in flow sheet format which also indicates
responsibilities.

5.2. Role of Commissioning Documentation center :

To facilitate document availability and handling, the Commissioning

Documentation Center will play a central role in the handling of check out
handover documents. The responsibilities of the Commissioning Documentation
Center include:

- holding a stock of all check out forms, check lists and related documents;

- providing documents on request of Operation and Project personnel;

- receiving and filing original signed-off check out forms;

- receiving and filing original signed - off handover packages, i.e. " Mechanical
Completion "and Ready for Commissioning " package

- copying and distributing handover certificates as required. (The flow sheet shows the
absolute minimum distribution which may be broadened on request) and

- coordinating with Projects personnel and Operations personnel where necessary on all
matters relating to check out and handover documents.

The Commissioning Documentation Center must ensure that it is sufficiently staffed

to execute its responsibilities and that it has adequate facilities to provide an effective
service.

5.3. Check out Documents :

For equipment check out, Operations has a direct interface with Construction, with
Projects maintaining a coordinating function. On receiving advice from the
Contractor that an equipment item (mechanical, piping, control systems or electrical)

PT. GLOBAL POWER SERVICES ©DOC2010 Page 3 of 21

SECTION 5 - HANDOVER PROCEDURES

is ready for check out, Operations raises the relevant check out form and check list as
well as standard punch list forms. Operations is responsible for obtaining the necessary
signatures on the check out form from the participants in the check out and for copying
and distributing the completed form before submitting the original form to the
Commissioning Documentation Center for filing.

The completed original punch lists arising from the check out are submitted to the
Project Manager. The Project Manager ensures that the necessary punch list items
are worked off by the appropriate milestones, retaining the original punch list for
appending to the RFC package.

Operations also raises box-up certificates for vessels, towers, etc., once advised by the
Project Manager that all required punch work has been completed. Once the box-up
certificate has been signed off, the original is submitted by Operations to the
Commissioning Documentation Center.

5.4. Handover Documents:

The Project Manager is the principle responsible party for all documents which relate to
handover of plant and equipment from Construction to Operations. The Project
Manager initiates the handover certificate ( " Mechanical Completion " certificate
for systems and " Ready for Commissioning " certificate for areas/ system's and for
electrical substations ), compiles the required packages and ensures that the necessary
signatures are obtained. Each respective department is, however, responsible for
obtaining the signatures of appropriate personnel within their department.

Once a handover package has been compiled and signed-off by Operations, the
Project Manager submits the complete original package to the Commissioning
Documentation Center, ensuring that Construction receives a copy of the handover
certificate. All other distribution of handover documents is undertaken by the
Commissioning Division.

The Certificate of Completion of Control Systems facilities and the Certificate of

Completion of Electrical Facilities will also be processed by the Project Manager.
Although not strictly handover documents, they are treated as such with respect to
responsibility for handling as they must be included in the respective RFC package by
the Project Manager.

5.5. Status Reporting :

Project Planning ensures that each handover certificate includes the correct
area/system/sub-system number so that the progress of completion of the certificates
can be tracked by this unique number. A register of all issued handover certificates
is to be kept updated by Project Planning and The Commissioning Department.
Project Planning and the Commissioning Department will also keep a record of the

PT. GLOBAL POWER SERVICES ©DOC2010 Page 4 of 21

SECTION 5 - HANDOVER PROCEDURES

issue and sign-off of all checked out forms.

Handover meetings are used as the main forum for Projects to report the status of check
out and handover documents.

5.6 FLOW SHEET FOR HANDLING CHECK OUT AND HANDOVER FORMS

(4) Copies: Plant Manager, EC/Vendor, as applicable; Area Coordinator (Sign-off Certificate)
(5) Copies: Plant Manager, EC/Vendor, as applicable (Completion Certificate)
(6) Copies: Plant Manager, EC/Vendor, as applicable (Completion Certificate)

PT. GLOBAL POWER SERVICES ©DOC2010 Page 5 of 21

SECTION 5 - HANDOVER PROCEDURES

FLOWSHEETFORHANDLINGCHECKOUTANDHANDOVERFORMS

1. Copies: Plant Manager, E/C.Vewlof, u ipplictbfe; Project Mintger (Checkout Form)

2. Copies: Plant Manager; E/C Vendor, u ipplicible; Project Muugcr
3. Copies: Plant Manager (package): EC/Vendor, u ipplicible (MC Certificate)

PT. GLOBAL POWER SERVICES ©DOC2010 Page 6 of 21

SECTION 5 - HANDOVER PROCEDURES

PT. GLOBAL POWER SERVICES ©DOC2010 Page 7 of 21

SECTION 5 - HANDOVER PROCEDURES

PT. GLOBAL POWER SERVICES

CHECK OUT AND COMMISSIONING PROCEDURES
= ACTION
= DOC

PT. GLOBAL POWER SERVICES ©DOC2010 Page 8 of 21

SECTION 5 - HANDOVER PROCEDURES

PT. GLOBAL POWER SERVICES ©DOC2010 Page 9 of 21

SECTION 5 - HANDOVER PROCEDURES

PT. GLOBAL POWER SERVICES ©DOC2010 Page 10 of 21

SECTION 5 - HANDOVER PROCEDURES

5.8. Equipment Procedures

A. Equipment Check out

Al As construction work progresses, Area Project Coordinators will establish completion

dates for departmental systems to meet or better the Commissioning schedule.

A2 Regular meetings will be held between the Area Coordinators, Contractors check out
representatives and company department Superintendents to ensure efficient teamwork.

A3 Punch lists prepared by the Operations will provide additional information on

outstanding work and will assist in day-to-day planning.

A4 Preceding the check out activities, each item of equipment, as identified in the list of
systems, will be tagged with an inspection card. Check points on the card will specifically
pertain to one of the following:

A.4.1 Driven equipment.

A.4.2Drive motors (Card located on M.C.C)
A.4.3Field mounted instruments
A.4.4Process controls
A.4.5Tanks and towers

All equipment and systems are to be checked for compliance with established Plant-
standard specifications and installation specifications contained in the Contractors
arrangements.

A5 Electrical Test

Due to the number of checks to be made on the large number of motors, the contractors
shall be permitted to proceed with megger and electrical check-out tests as indicated on
the Electrical Inspection card, provided such tests are carried out under the
supervision of the Contractor's Electrical Superintendent or Foreman. Megger and
electrical check-out tests shall not commence until the relevant section of the Inspection card
has been completed. Megger and electrical check out readings are to be recorded on the
electrical card.

The Electrical Inspection cards, when signed in the appropriate location, will indicate
that all the electrical tests required have been performed. Prior to energizing each
Motor Control Center, all starters shall be locked in the "off position, to prevent
unauthorized personnel from starting the equipment.

Starters shall again be locked in the "off position following the test after fuses have
been removed. All motors shall be megger tested immediately prior to energizing.
(See section 7 for Electrical Commissioning Procedures)

PT. GLOBAL POWER SERVICES ©DOC2010 Page 11 of 21

SECTION 5 - HANDOVER PROCEDURES

The contractors should maintain their own internal system of the tagging and
checking out of Motor Control Centers, relays, interlocks, etc., with the final check
to be made with the Project Electrical Area Engineer present. This work shall proceed
at such a rate as to prevent delays in the scheduled check out. (See section 7 Electrical
Installation)

A6 Hydrostatic Tests

Field erected vessels shall be tested as isolated units and big unpiled tanks shall be
additionally preloaded to a certain settlement before final pipe connections. All site
vessel tests shall be witnessed by the Project Engineer and Area coordinator and
Department Supervisor.

The Contractor and/or Operations shall ensure that all major vessels have been
hydrostatically tested prior to connecting piping to the vessel in order to prevent
induced stresses from being placed on pumps due to settlement of the vessel. (See
Section 18 for additional information pertaining to preloading tests).

A7 Mechanical Test

All work described on the Project Engineer's Completion Lists shall be completed,
piping thoroughly cleaned, flushed or blown, and Equipment Inspection Cards shall
be completed' for both mechanical and electrical work before any "wet tests" are
performed.

"Flushing" shall include the thorough cleaning of all tanks, tops of tanks, chests, pipe
lines and area adjacent to the system to be tested. In all cases, control valves and other
instrumentation liable to damage shall be removed prior to flushing. This
instrumentation will be identified by the Instrument Supervisor for each area.

"Blowing" shall include the thorough steam blowing to atmosphere of all steam lines
serving the turbine and other items of equipment where deemed necessary. Blowing
of lines shall be repeated approximately four times and shall be considered complete
when a test plate placed across the discharge pipe is completely free from pitting.

A8. Instrumentation

Following installation, process controls shall be given a visual inspection by the

contractor to ensure that mill standards for installation have been met.

All field instruments shall be tagged with an Instrument Inspection Card. Check out
and testing shall be performed by the Contractor and witnessed by the Project
Engineer. Final loop testing will be carried out by Plant Owner. All instrument air
lines shall be blown and tested for leaks before making final connections to instruments.

The check out shall include continuity testing, control valve stroking, the
inspection of piping and electrical connections, the inspection of control circuit

PT. GLOBAL POWER SERVICES ©DOC2010 Page 12 of 21

SECTION 5 - HANDOVER PROCEDURES

interconnections and live loop tests. The instrument check out sheet is included in
this manual. (Section 6)

A9 The Area Coordinator will sign both sides of the equipment card after witnessing
the check-out of each item by the Contractor. The card has to be completed and signed
prior to doing wet tests.

B. Wet Test

For the purpose of coordination, the wet tests shall be conducted by ….. "Wet tests"
shall not be run without representatives of the Area Coordinator and the Contractor
being present (and the Vendor, if applicable).

Equipment shall be energized for testing at the request of …., and immediately
following the test, the equipment started shall once again be locked in the "off position
by the Contractor (See Section 7 For Electrical Lock-Out Procedures).

In the cases where equipment vendors are on site and are available for the testing out
of equipment supplied by their firms, tests shall be run under their direction by the
department superintendent and his process personnel in the presence of the area project
coordinator and the erection contractor's representative.

Performance of the wet test shall include the water test of all pumps, agitators, tanks,
piping, etc. Pumps shall not be run without water in the system, nor until a fine screen
has been installed in the pump suction flanged connection. Where the insertion of a
screen and an extra gasket in the suction lines from some chest and tanks to pumps
is not practical, the chest or tank and the suction pipe through the suction valve to
pump casing shall be thoroughly cleaned out by the Contractor and inspected by the
Process Engineer just prior to water filling. During this test, motor loads, heads, and
where possible, the proper functioning of instruments, shall be witnessed, recorded
and compared with the theoretical values.

The Area Coordinator will obtain the services of the vendor's representative and
company instrumentation personnel for checking instrumentation during wet tests. Those
services will probably be on a continuous basis for the duration of the wet tests.

A detailed list of all repairs, additions and/or deletions will be prepared by the Area
Coordinator as a result of observations made during the "wet test". This " Punch List
" will be issued to the contractor showing a mutually agreed upon date for the
completion of the work.
C. Acceptance

When work noted on the Punch Lists for each system has been completed, it will
be inspected by the Area Coordinator and, following inspection and hanging the
certificates of:

PT. GLOBAL POWER SERVICES ©DOC2010 Page 13 of 21

SECTION 5 - HANDOVER PROCEDURES

1. Mechanical Completion
2. Electrical Completion
3. Control System Completion

A certificate of "Completion of MEI Erection" will be issued to the Commissioning

Manager from the Project Manager. The system will then be turned over to …. after
the certificate has been signed by the Commissioning Manager and the General
Plant Manager. At this time, after putting safety locks on the starters, the Equipment
Inspection Card will be rem6ved by the Area Coordinator, who will replace it with a
Red Card, signifying that the equipment has been handed over to …. for operation.
The Equipment Inspection Cards and appropriate forms will be filed by the
Commissioning coordinator for record purposes.

Acceptance of the equipment from the contractor will be subject to the guarantee
clauses in the contract documents. In addition, the contractor's responsibility for
correcting installation defects, which may become apparent during the initial stages
of operation, shall remain, even though it may be mutually advantageous that, with the
Contractor's approval, …. carries out the work. In cases where major modifications
are required, it may be necessary that the Contractor carries out the work even though
jurisdiction for the work rests with the mill maintenance crew. In such cases, the work
division will be clearly defined and agreed with all parties before commencement of
the work. No work shall be performed by the contractor on completed systems
except on written instructions from the Project Manager.

D. Equipment Cleaning

Following the equipment acceptance, mill personnel will proceed with the clean
out of tanks, vessels and lines. Procedures will be drawn up for specific areas and
would be similar to the following:

Dl. Have lock-out procedures and boards ready for pre start-up cleaning of tanks
and vessels.

D2. Check out list to be used and initialed by the shift team leader as each area is
completed.
D3. Obtain clearance from construction and maintenance before attempting
clean-out procedure.

D4. Assemble necessary equipment for entry and clean-out (extension lights,
ladders, water hoses, shovels, brooms, wheelbarrows, flashlights and
protective clothing).

D5. With vessel drain open, use water hose to flush all lines to and from the
vessel wherever possible.

D6. Lock-out the vessel as prescribed under “The Established Lock Out

PT. GLOBAL POWER SERVICES ©DOC2010 Page 14 of 21

SECTION 5 - HANDOVER PROCEDURES

Procedures ".

D7. Remove man-hole covers and make visual inspection from outside to determine
type and amount of clean-out required.

D8. Using the prescribed vessel entry procedure of locking out, testing and
stationing one man outside the man-hole, have the required number of men
"dry-clean" the vessel using brooms and shovels to remove all tramp metal,
concrete, wire, rope, etc.

D9. Follow the dry-cleaning with a thorough wash-out using water hoses of flush
the vessel from top to bottom and out the drain.

D10 Inspection by department head, or delegate, to accept or reject the vessel as

being ready for operation.

Dl1. Following acceptance, all clearing and inspection equipment to be removed and
accounted for and vessel entry locks to be removed from equipment as per the
established lock out procedure.

D12. Swing covers back over the man-holes, but leave unbolted for last minute
inspection prior to water tests. Leave vessel drains open.

D13. Chemical solution lines to be disconnected at the points of application and

flushed with water from their respective pumps.

D14. The chlorine line is to be disconnected at the C12 mixer and steamed out and
air-dried. Liquid C12 traps are to be carefully opened and dried.

E. Water Trials

Once each item of equipment in each system has been checked out systematically by
operating personnel, it becomes possible to operate equipment on water in one or more
systems simultaneously. The water trial prior to start-up enables crews to simulate
actual operating conditions and to practice techniques they have learned during the
training programs. Such trials also provide an opportunity for additional equipment tests,
instrument calibration and capacity checks prior to actual start-up of the mill. Operating
crews, as part of their training, have the responsibility for preparing detailed procedures for
these trials.

The purpose of this section is to help testing personnel prepare and do system checks. The
section is not complete and shall not be used as a specification. Common sense should
always be used in execution of the testing activities.

The final instructions will be given based on the testing and commissioning system
planning.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 15 of 21

SECTION 5 - HANDOVER PROCEDURES

Identification of all lines.

1. Test Loops

The test-loops are to be defined so that as many pipes as possible can be tested at one
time to speed-up the testing activities. However, special attention should be paid to see
that the loops shall not be too large to make the testing hard or impossible to execute
(filling time etc.).

Appendix I gives important information about flow substances which may be

connected to the same loop of each test type. (Flow substance: Lrapp-m8; an extract in
Appendix I).
Test type:
- Hydro Service
- Air
- Flush
- Clean blowing (air/steam)

One loop may be defined to consist of all pipes with the same flow substance (e.g.
APM, Mill Compressed Air). In some cases, from the execution point of view, they
may have to be reduced to smaller sub-systems. Also loops that consist of pipes with
two or more substances can be formed, but the lines have to have the same testing
specifications.

The Loop list has to include all necessary information such as :

- Lines included
- Lines ready for testing
- Type of test
- Test pressure
- Additional information regarding the testing Lines tested
- Etc.

In the pipeline list, all lines should be marked to show which loop they belong to so
that, when a line is to be tested, it may easily be checked to show if the whole loop is
ready for testing or if the loop must be broken down to smaller systems.

The test loops should be identified as follows:

- W-TL- for hydro test
- A-TL- for air test
- S-TL- for service test
- S-CB- for steam-clean blowing
- A-CB- for air clean blowing

PT. GLOBAL POWER SERVICES ©DOC2010 Page 16 of 21

SECTION 5 - HANDOVER PROCEDURES

2. Schematics

A schematic isometric drawing consisting of all lines in each test-loop should be done
prior to the testing, if not otherwise available.

The purpose of the schematic is to help the testing personnel to plan the test, locate
high / low-points etc. A rough sketch will be acceptable.

The schematics should show the following:

- Loop number
- Area / Line identification / Drawing numbers
- Pipes
- Test limits
- All instruments
- Continuation
- Vents, drain and other testing equipment
- Test type (hydro / air / service / flush / blow as described in "test Loops")

3. Planning

A testing plan and schedule has to be prepared, which identifies the priorities and to
ensure that all persons involved are aware of these time tables and plans.

4. Equipment

All the testing equipment has to available and ready.

- Pumps
- Hoses and Connections
- Valves, vents and drains
- Plugs and caps etc.
- Clips
- Manometers
- Tools
* Combination spanners
* Adjustable spanners (shifters, crescent wrenches)
* Flogging spanners (daggers, slug wrenches)
* Torque multiplier wrenches
* Hammers
* Pliers
* Screw drivers (heavy duty)
* Stilsons (pipe wrenches)
* Toolbox with lock

PT. GLOBAL POWER SERVICES ©DOC2010 Page 17 of 21

SECTION 5 - HANDOVER PROCEDURES

- PTFE (Teflon) tape

- Gaskets
- Spare parts
- Blind plates
- Safety devices
- Test manifolds
- Etc.

5. Test Procedure
- Identify the loop for the line to be tested.
- Check if the whole loop can be tested or if you must break down the loop.
- Have the loop schematic available
- Have all the isometric drawings involved available.
- Walk the line.
- Check if the line is ready for testing.
* Welding
* Surface
* Material
* Supports
* All documents
* Punch list work completed
* Clearance (NDT-etc.).
* High / low-point pockets (if necessary).
* Etc.

- Check that nobody is working on the lines to be tested

* Welding
* Surface
* Material
* Supports
* All documents
* Punch list work completed
* Clearance (NDT-etc.).
* High / low-point pockets (if necessary).
* Etc.

- Check that nobody is working on the lines to be tested.

* Civil works are finished
* Commissioning has not started
* Insulation work has not started

- Check that lines to be tested are not “live"

- Check that testing does not interfere with any other activity.
- Check that there is no danger in execution of the testing activities.
- Check the test method.
- Drains and vents are closed.
- Isolate the system with blind plates.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 18 of 21

SECTION 5 - HANDOVER PROCEDURES

- Open all valves and remove if necessary.

- Remove orifice plates and other instruments if necessary (Instrument dept.and/or
Contractor)
- Remove equipment that cannot tolerate the pressure test (Instrument and/or
Contractor)
- Check how to drain the line after the test
- Connect test-manifold
- Close the drains '
- Open the vents
- Fill the line so that it is full to the highest point (closes lower high-point vents and
continue filling until you reach the top)
- Close the vents
- Connect manometers (one to the top and one to the bottom)
- Walk the line with inspectors responsible for the testing
- Pressurize the line
- Check the manometer readings
- Walk the line
- Wait one hour, the pressure should not decrease (note the effect of temperature on
the pressure)
- Walk the line
- Wait one hour, the pressure should not decrease. (Note the effect of temperature on
the pressure)
- Connect the drain hoses
- Remove the pressure
- Open the vents
- Open the drains and empty the line Disconnect the test-manifold and pump
- Disconnect the manometers clean possible-pockets when the lines are empty,
close the vents and drains
- Remove blind plates and other testing equipment Change the gaskets if necessary
- Re-fix the spring hangers (steam lines)
- Re-install all instruments and equipment that were removed for testing according
to the instructions of respective departments Weld or screw all plugs, caps etc. - --
- Required
- Record all actions
- Have the documents signed

5.1 Service Test

- Isolate the line with blind plates, if necessary
- Open all valves
- Close the drains and vents
- Set a date and time for the test
- Have the line put "live" (commissioning)
- Walk the line with inspectors responsible for the testing
- Check for leaks and other faults
- Remove blind plates (if necessary / possible)
- Record all actions
- Have the documents signed

PT. GLOBAL POWER SERVICES ©DOC2010 Page 19 of 21

SECTION 5 - HANDOVER PROCEDURES

5.2 Only if hydrostatic test cannot be applied

- Check the test pressure
- Isolate the line with blind plates, if necessary
- Open all valves
- Set a date and time for the test Connect the test manifold Close the drains and vents
- Connect manometers
- Walk the line with inspectors responsible for the testing
- "Flag on" (warning signs indicating test is underway)
- Pressurize the line carefully to no more than 0.5 bars
- Check the manometers. The pressure should not decrease
- Check the welds, valves etc. with soap water (externally) for leaks
- Raise the pressure to the test pressure
- Wait one hour. The pressure should not decrease (note the effect of temperature on
the pressure)
- "Flag off”
- Remove the blind plates and other testing equipment
- Record all actions
- Have the documents signed

5.3 Flushing

As in sub clause 5.0 except:

 No manometers
 No pressure (only hydrostatic)

Fill the lines to the top and let it drain freely so that all dirt shall be removed from
the lines.

As in sub clause 5.2 except :

Do not fill and drain, but let the water flow freely through the system for some
time.

5.4 Clean Blowing

Only some aspects are mentioned. This section does not describe these activities
thoroughly. The final instructions will be specified in a separate document.

5.5 Air Blowing

As in sub clause 5.3 but use air instead of water.

5.6 Steam Blowing

This will be specified in a separate document.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 20 of 21

SECTION 5 - HANDOVER PROCEDURES

Other Methods

- Gas detector
- Spark tester
- Test with gas other than air

DOCUMENTATION

• The testing personnel shall keep records of all testing activities

• A test certificate must be released

• Also a list of all executed tests must be released to enable progress follow-up

PT. GLOBAL POWER SERVICES ©DOC2010 Page 21 of 21