Pre Commissioning Check List Yasref Refinery

Yanbu Export Refinery Project PRE-COMMISSIONING CHECKLIST Document No.: 111-EP3-CG-CG8-0003 Revision No.: 0 Issue Date : 26 November 2012

TABLE OF CONTENTS 1.0

INTRODUCTION .................................................................................................. 3

2.0

DEFINITIONS AND ACRONYM........................................................................... 3

3.0

REFERENCE ....................................................................................................... 4

3.0

RESPONSIBILITIES ............................................................................................ 4

3.1

CONTRACTOR .................................................................................................... 4

3.2

COMPANY PMT .................................................................................................. 5

3.3

YERP OPERATIONS ........................................................................................... 5

4.0

PRE-COMMISSIONING ACTIVITIES................................................................... 5

5.0

CONTRACTOR – YERP PMT COORDINATION ................................................. 6

6.0

PRECOMMISSIONING RECORDS ..................................................................... 6

7.0

LIST OF YERP PRECOMMISSIONING FORMS ................................................. 6

8.0

PRE-COMMISSIONING CHECK LIST ................................................................. 9

General Confidential Page 2 of 222

Yanbu Export Refinery Project PRE-COMMISSIONING CHECKLIST Document No.: 111-EP3-CG-CG8-0003 Revision No.: 0 Issue Date : 26 November 2012

1.0

INTRODUCTION This checklist is intended to define the Completion of Pre-commissioning activities prior to the Commissioning of Plant..

2.0

DEFINITIONS AND ACRONYM COMPANY

:

SAUDI ARAMCO

CONTRACTOR

:

Daelim Saudi Arabia

YERP PMT

: :

YANBU EXPORT REFINERY PROJECT Project Management Team

Commissioning

:

Placement of a facility in service, after the scope of work defined in the Project Proposal / Construction documentation, drawings, specifications, and Precommissioning is complete and Mechanical Completion has been achieved. For a process Facility, commissioning includes the testing of a plant’s system with test medium in the line. After Commissioning, the plant is ready for Start-Up, during which feedstock and other normal operating liquids and gases are introduced in the lines.

Facility

:

The product of a Saudi Aramco project (capital or noncapital) consisting of structures, equipment, materials, fabrication and erection.

MC

:

Mechanical Completion is achieved when the facility in the Approved scope, construction documentation, drawings, specifications and material requisitions has been installed and tested(Pre-commissioned) and is available for commissioning and Start-Up.

Pre-commissioning :

The steps required after construction of the facility, unit, or system necessary to prepare that entity for the introduction of process or utility materials. These steps include cleaning, adjusting, testing, inspection, and documentation. The system components for continuity, Operability and in the case of process plants available for commissioning.

General Confidential Page 3 of 222

Yanbu Export Refinery Project PRE-COMMISSIONING CHECKLIST Document No.: 111-EP3-CG-CG8-0003 Revision No.: 0 Issue Date : 26 November 2012 Mechanical Completion:

3.0

Achieved when the facility defined in the approved scope, construction documentation, drawings, specifications and material requisitions has been installed and tested and is available for commissioning.

REFERENCE YERP-SAEF-122 YERP-SAGI-0002.710 100-YER-PM-PPM-0787 100-YER-PM-PPM-0701

3.0

RESPONSIBILITIES

3.1

CONTRACTOR

Project Records Mechanical Completion and Performance Acceptance of Facility Pre-commissioning Project procedure 487 Mechanical Completion and Performance Acceptance

The Contractor is responsible for:  Creating a Contract Package specific Pre-commissioning and Mechanical Completion Plan.  Having a software system capable of tracking all pre-commissioning activities.  Setting the schedule for pre-commissioning of the various segments of the package and informing the COMPANY PMT of this schedule.  Creating the Pre-commissioning Checklists required for the Contract Package and reviewing these lists with the COMPANY PMT.  Performing required inspections of items in the Contract Package and coordinating with the COMPANY PMT when an inspection is to be witnessed by COMPANY PMT and/or COMPANY Operations.  Performing required tests of items in the Contract Package and coordinating with the COMPANY PMT when a test is to be is to be witnessed by COMPANY PMT and/or COMPANY Operations.  Cleaning items in the Contract Package in preparation for the start of operation.  Preparing project drawings by markup to an as-built condition.  Preparing the dossiers needed for the documentation of systems completion and subsequent turnover to COMPANY Operations.  Certifying the completion of pre-commissioning for items in the Contract Package by completing and signing the appropriate Pre-commissioning Checklists.  Coordinating with and informing COMPANY PMT of the completion of precommissioning of the entire Contract Package.

General Confidential Page 4 of 222

Yanbu Export Refinery Project PRE-COMMISSIONING CHECKLIST Document No.: 111-EP3-CG-CG8-0003 Revision No.: 0 Issue Date : 26 November 2012 3.2

COMPANY PMT The COMPANY PMT is responsible for:  Approving the Pre-commissioning and Mechanical Completion Plan prepared by the Contractor.  Approving the Pre-commissioning Checklists prepared by the Contractor.  Monitoring and witnessing (as required) inspections and testing performed by the Contractor.  Performing inspections and witnessing tests as indicated in the appropriate Inspection and Test Plans, or as required by any other contractual document.  Confirming the completion of pre-commissioning for items in the Contract Package by co-signing the appropriate Pre-commissioning Checklists with the Contractor.  Confirming the completion of pre-commissioning of the entire Contract Package by starting the Mechanical Completion process.

3.3

YERP OPERATIONS The COMPANY OPERATION is responsible for:  Performing the inspections indicated in YERP-SAGI-0002.710, Mechanical Completion and Performance Acceptance of Facilities.  Witnessing the tests indicated in YERP-SAGI-0002.710, Mechanical Completion and Performance Acceptance of Facilities.

4.0

PRE-COMMISSIONING ACTIVITIES Pre-commissioning activities shall be performed in preparation for the certification of mechanical completion per YERP-SAGI-0002.710, Mechanical Completion and Performance Acceptance of Facilities. Pre-commissioning includes making the required inspections or confirming that these inspections have been made. Where documentation of an inspection is required, this documentation will be completed or the existence of the completed documentation will be confirmed. Pre-commissioning includes performing the required tests or confirming that these tests have been made. Where documentation of a test is required, this documentation will be completed or the existence of the completed documentation will be confirmed. Pre-commissioning includes completing the Contractor’s Pre-commissioning Checklists where all of the items on the checklists are addressed, the Contractor indicates General Confidential Page 5 of 222

Yanbu Export Refinery Project PRE-COMMISSIONING CHECKLIST Document No.: 111-EP3-CG-CG8-0003 Revision No.: 0 Issue Date : 26 November 2012 completeness and correctness of the activities by signature, and the COMPANY PMT confirms completeness of the checklist by signature. Pre-commissioning includes cleaning of equipment, piping, and other items in preparation for the start of operations. Pre-commissioning includes the marking of drawings and other documents, which are required to be as-built, to show the as-built condition. Pre-commissioning includes completing the dossiers of documents needed for the completion of the Contractor’s responsibilities.

5.0

CONTRACTOR – YERP PMT COORDINATION Toward the conclusion of construction activities there are inspections to be made by YERP PMT and YERP Operations and tests to be witnessed by YERP PMT and YERP Operations. The inspections to be performed by YERP PMT and tests to be witnessed are identified in the Inspection and Test Plans used for construction. The YERP PMT, at their discretion, may choose to make inspections and/or witness tests that are not listed on any inspection plan. The Contractor is responsible to lead the coordination of these inspections and tests with the Contractor’s inspections and testing, through YERP PMT, in order to maximize the efficiencies of these activities.

6.0

PRECOMMISSIONING RECORDS After the pre-commissioning activity has been performed, the forms completed, and the document dossiers assembled, the documents will be submitted as required by YERPSAEP-122, Project Records.

7.0

LIST OF YERP PRECOMMISSIONING FORMS The list of the YERP Pre-commissioning forms is included in TABLE 1

General Confidential Page 6 of 222

Yanbu Export Refinery Project PRE-COMMISSIONING CHECKLIST Document No.: 111-EP3-CG-CG8-0003 Revision No.: 0 Issue Date : 26 November 2012

FORM NUMBER D-001 D-002 E-001A E-001B E-002 F-001 F-002 G-005 CENTRIFUGAL G-006 PUMPS 04/09 POSITIVDISPLACEM G-007 ENT PUMPS SUBMERSIBLE G-110 (RECIPROCATING) PUMPS 04 04/09 J-001 J-002 J-003 J-004 J-005 J-006 J-007 J-008 J-009 J-010 J-011 J-012 J-013 J-014 J-015 J-016 J-017 J-018 J-019 K-001 K-402 K-403 K-501 K-502 K-511 K-600 L-001 L-002

EQUIPMENT DESCRIPTION PRESSURE VESSEL STORAGE TANKS HEAT EXCHANGERS FIN FAN BLOWERS FURNACES AND HEATERS BOILERS CENTRIFUGAL PUMPS POSITIVE DISPLACEMENT PUMPS (RECIPROCATING) 04/09 SUBMERSIBLE PUMPS GEARS CONVENTIONAL ELECTRONIC AND PNEUMATIC TRANSMITTERS TRANSDUCERS SWITCHES INDICATORS ORIFICE PLATES, VENTURIS AND LO-LOSS TUBES CONTROL VALVE THERMOCOUPLES RESISTANCE TEMPERATURE DETECTORS CONTROLLERS INSTRUMENT AIR LINE PRESSURE TEST TURBINE POSITIVE DISPLACEMENT, AND MAGNETIC FLOW PILOTMETERS TUBES/ANNUBAR FLOW METERS INSTALLATION INSPECTION (INSTRUMENT INSTALLATION) LOOP CHECK COVER SHEET (LOOP CHECK) INSTRUMENT AND CONTROL CABLES VIBRATION TEMPERATURE MONITOR H2S MONITORING SYSTEMS COMBUSTIBLE GAS MONITORING SYSTEM HVAC CENTRIFUGAL COMPRESSOR POSITIVE DISPLACEMENT COMPRESSORS (RECIPROCATING) STEAM TURBINES COMBUSTION GAS TURBINES DIESEL ENGINE MIXERS PIPING, GENERAL PIPING, SPECIAL PURPOSE

TABLE 1 LIST OF PRECOMMISSIONING FORMS (CONT) General Confidential Page 7 of 222

DATE

Yanbu Export Refinery Project PRE-COMMISSIONING CHECKLIST Document No.: 111-EP3-CG-CG8-0003 Revision No.: 0 Issue Date : 26 November 2012

FORM NUMBER L-003 L-004 P-000 P-001 P-002 P-003 P-004 P-006 P-007 P-008 P-009 P-010 P-012 P-013 P-014 P-016 P-017 P-018 P-019 P-020 P-023 P-25 P-027 P-050 P-061 P-062 P-071 P-080 P-082 X-001 X-003 X-004 X-005 X-007 X-010

EQUIPMENT DESCRIPTION VALVES PLUMBING & NON-ELECTRIC UTILITIES TESTING GUIDELINES (ELECTRICAL TESTING) BATTERY SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM LOW VOLTAGE CABLES MEDIUM VOLTAGE CABLES (5KV-15KV-35KV) MOLDED CASE CIRCUIT BREAKERS LOW VOLTAGE POWER CIRCUIT BREAKERS MEDIUM VOLTAGE CIRCUIT BREAKERS DEHYDRATOR-DESALTER TRANSFORMER PROTECTIVE RELAYS METERING LIGHTING METAL ENCLOSED BUS LOW VOLTAGE MOTOR CONTROL CENTERS MEDIUM VOLTAGE MOTOR CONTROL GEAR NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS OUTDOOR BUS MOTORS STRUCTURES SWITCHGEAR - GENERAL AUTOMATIC TRANSFER SWITCHES OIL FILLED POWER TRANSFORMERS VOLTAGE AND CURRENT TRANSFORMERS DRY TYPE POWER TRANSFORMERS OUTDOOR SUBSTATIONS SURGE ARRESTORS VARIABLE FREQUENCY DRIVES FOR NEMA FRAME MOTORS GROUNDING SYSTEMS HEAT TRACING CATHODIC PROTECTION RECTIFIER CATHODIC PROTECTION PLANT POTENTIAL SURVEY CATHODIC PROTECTION EXTERNAL TANK BOTTOM POTENTIAL PROTECTION SURVEY CATHODIC TANK INTERNAL POTENTIAL SURVEY CATHODIC PROTECTION PIPELINE POTENTIAL SURVEY ONSHORE ANODE BED PERFORMANCE EVALUATION

TABLE 1 LIST OF PRECOMMISSIONING FORMS (CONT)

General Confidential Page 8 of 222

DATE

Yanbu Export Refinery Project PRE-COMMISSIONING CHECKLIST Document No.: 111-EP3-CG-CG8-0003 Revision No.: 0 Issue Date : 26 November 2012

8.0

PRE-COMMISSIONING CHECK LIST

General Confidential Page 9 of 222

FORM YERP - D001

SHT 1 of 7

YERP PRE-COMMISSIONING CHECKLIST EQUIPMENT TYPE: PRESSURE VESSELS EQUIP. NO.: BI/JO NO.: REF. DRAWINGS: & DOCUMENTS

USER REFERENCE: DESCRIPTION: PLANT NO.

Columns and Drums NOTE: The items listed below must be supplemented with any specific instructions for commissioning and start-up, that may have been supplied by the manufacturer.

Internal

Yes

-

Check for physical damage that may have been caused during shipment to or installation at the construction site.

-

Review adequacy of restraint rings, or other tower packing hold down devices for upset and reverse flow conditions.

-

Confirm that all internals shown on the design drawings have been correctly installed. Typically this includes baffles, dividers, impingement plates, vortex breakers, nozzles, flow distributors, piping, catalyst supports, and other mechanical equipment.

-

For vessels that are subject to vacuum conditions, ensure that the stiffening rings are installed, and all welding is complete.

-

For vessels with piping, access ladders, or other similar equipment that can experience thermal expansion or contraction, different than the structure it is attached to, should be checked for adequate flexibility. Look for supports or restraints that can cause damage from excessive restraint allow damage due to vibration.

WITNESS

CONTRACTOR

INSPECTION

No

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 10 of 222

NA

REMARKS

FORM YERP - D001

SHT 2 of 7

YERP PRE-COMMISSIONING CHECKLIST EQUIPMENT TYPE: PRESSURE VESSELS EQUIP. NO.: BI/JO NO.: REF. DRAWINGS: & DOCUMENTS

USER REFERENCE: DESCRIPTION: PLANT NO.

Internal (Continued) Yes -

Check support beams and their attachment to the shell, to ensure that one end is free to move during differential thermal expansion

-

For vessels with internals that must be removed, check for adequate access and clearance. -Check that seal welding has been completed under tray down comers, in pans, around draw-off boxes, and for other installations of internals.

-

If the vessel is to have catalyst installed, the type and its condition should be checked before filling.

-

Check that all internal nuts, bolts, and other fasteners are securely constrained, and will not become loose during operation.

-

Spot check adequacy and make-up of bolted joints in internal distribution pipes. Check for proper support to avoid vibration damage without thermal restraint.

-

Spot check the material, size and that the methods of securing demister pads, and other wire screens, over outlet collectors and grids in catalyst beds are adequate. (NOTE: normally the screens will be wired and/or banded in place.)

-

Inspect cladding near seals, welds and structural attachments for defects and provisions for thermal expansion.

WITNESS

CONTRACTOR

INSPECTION

No

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 11 of 222

NA

REMARKS

FORM YERP - D001

SHT 3 of 7

YERP PRE-COMMISSIONING CHECKLIST EQUIPMENT TYPE: PRESSURE VESSELS EQUIP. NO.: BI/JO NO.: REF. DRAWINGS: & DOCUMENTS

USER REFERENCE: DESCRIPTION: PLANT NO.

Internal (Continued) - For vessels with internal linings, ensure that they have been installed and tested per the construction drawings and specifications. Especially note lining details at nozzles, manholes, and flange surfaces for defects or other irregularities. -

Check that any field modifications or repairs to internally lined or clad vessels have been properly completed and inspected.

-

Ensure that clearance for thermal expansion of vertical thermo wells, shrouds, grid beams, grids, etc., has been provided, especially in internally insulated vessels or clad vessels with alloy internals.

-

Confirm that all instruments have been installed in their proper locations and checked-out.

-

If stacked vessels (having a common head) are started at different times, such that one is hot and the other is cold, check that internal insulation is used to protect against differential expansion in the common head.

-

Prior to final close-out, confirm that vessel is free of all loose debris or standing water, and meets the construction requirements for internal cleanliness and dryness.

WITNESS

CONTRACTOR

INSPECTION

Yes

No

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 12 of 222

N.A

REMARKS

FORM YERP - D001

SHT 4 of 7

YERP PRE-COMMISSIONING CHECKLIST EQUIPMENT TYPE: PRESSURE VESSELS EQUIP. NO.: BI/JO NO.: REF. DRAWINGS: & DOCUMENTS

USER REFERENCE: DESCRIPTION: PLANT NO.

Trayed Vessels

Follow the general checklist above, for the inside of vessels, with the items shown below.

- Visually check structural installation, orientation, level, clearance, and materials of trays, grids, and other tray support systems. Compare details with construction drawings and Company Standards.

and supplement

Yes

No

N.A

- Measure weir elevations and confirm that they are all correct. - Confirm that all tray sections are securely restrained. - Confirm that all tray caps are installed and free to move. - For those trayed vessels that utilize special nozzles or flow distributors, confirm that their location and orientation are correct. - Ensure that draw-off trays have been leak tested, and that the leakage rate is within specification limits.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 13 of 222

REMARKS

FORM YERP - D001

SHT 5 of 7

YERP PRE-COMMISSIONING CHECKLIST EQUIPMENT TYPE: PRESSURE VESSELS EQUIP. NO.: BI/JO NO.: REF. DRAWINGS: & DOCUMENTS

USER REFERENCE: DESCRIPTION: PLANT NO.

External Yes

No

N.A

- Check for physical damage that may have been caused during shipment to or installation at the construction site. - Check that vessel orientation agrees with construction drawings and axial centerline is either plumb (vertical) or level (horizontal). - Check that vessel is properly installed on its foundation, anchor bolts secured and grouting properly placed. - For horizontal vessels that incorporate one, or more, sliding supports, ensure that they have been installed as detailed on the construction drawings. - Check that vent holes are provided at the top of vessel support skirts, as shown on the construction drawings. - Confirm that vessel grounding straps have been properly installed. - Check suitability of flanges, facings, and gaskets for service conditions. - Visually check adequacy of nozzle reinforcement for obvious omissions.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 14 of 222

REMARKS

FORM YERP - D001

SHT 6 of 7

YERP PRE-COMMISSIONING CHECKLIST EQUIPMENT TYPE: PRESSURE VESSELS EQUIP. NO.: BI/JO NO.: REF. DRAWINGS: & DOCUMENTS

USER REFERENCE: DESCRIPTION: PLANT NO.

External (Continued) Yes

No

N.A

- Check that all support brackets and clips for piping, ladders, platforms, etc., have been properly installed, especially for stress relieved vessels. - Confirm that access ladders are properly fitted and securely fastened to the support clips provided. Check provisions for differential expansion between towers and ladders. - Check that platforms have been installed to allow safe access to all valves and instrumentation that's located on the vessel, and that they have been fitted with guard rails. - Confirm that all connecting piping and valves have been Installed on the vessel, including isolation, control, instrumentation, and relief. Also confirm that all instruments (local and those with transmitters) are properly installed. - Check that all lifting davits have been installed where required and are working correctly

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 15 of 222

REMARKS

FORM YERP - D001

SHT 7 of 7

YERP PRE-COMMISSIONING CHECKLIST EQUIPMENT TYPE: PRESSURE VESSELS EQUIP. NO.: BI/JO NO.: REF. DRAWINGS: & DOCUMENTS

USER REFERENCE: DESCRIPTION: PLANT NO.

External (Continued) Yes

No

N.A

- Check special designs, including refractory brick, metal and Rubber linings, expansion joints, flexible hose and support grids for adherence to construction drawings and Company standards. Determine if previous inspections were adequate. - Check all equipment for damage that could be caused by unusual conditions. ( For example, leaving equipment "blocked in" after steam-out and causing a vacuum.) - Check that the vessel nameplate has been installed. - Confirm that the Manufacturer's Test Certificate is available, and the information on the vessel nameplate agrees with the certificate and is legible. - Confirm that the final external paint coating has been applied. - Confirm that the color coding agrees with Company standards, and the vessel identification numbers are clearly visible and correct.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 16 of 222

REMARKS

FORM YERP - D0002

SHT 1 of 3

YERP PRE-COMMISSIONING FORM EQUIPMENT TYPE: STORAGE TANK EQUIP. NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS:

USER REFERENCE: DESCRIPTION: PLANT NO:

STORAGE TANKS Yes

No

N.A

- Check that the name plate is installed correctly and that the information on it is correct and legible. - Note any modifications or alterations during construction and erection and ensure that they are according to specifications. If they are not according to specifications, record all deviations. - Check the tank shell for any bulges or distortions and record them. - Make sure that non-destructive examination has been conducted and the results are recorded on field welds. - Make sure that welding procedures are documented and heat treatment and stress relieving if required is conducted and recorded. - Inspect the shell wall thicknesses using ultra sonic examinations and record them on a map to determine corrosion rate for future monitoring. - Check that welds in the tank bottom has been tested for leaks, a vacuum box could be used, before hydro test is conducted and coating is applied. - Check that the coating has been applied according to specification.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 17 of 222

REMARKS

FORM YERP - D0002

SHT 2 of 3

YERP PRE-COMMISSIONING FORM EQUIPMENT TYPE: STORAGE TANK EQUIP. NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS:

USER REFERENCE: DESCRIPTION: PLANT NO:

STORAGE TANKS (Continued)

Yes

No

N.A

- Check that the color coding complies with specifications. - Check that the insulation, if required, has been applied in accordance with the specifications. - Check the roof drainage system is functioning properly. - Check that the level of the floating roof while filling the tank at different points. This can be done by measuring the distance between the roof rim and a horizontal weld seam. - Check that stable material has been provided under the tank bottom and contour and that compacting has been done properly. - Check that cathodic protection has been provided if required. - Check for any leak around the mixers and heaters after the tank has been filled. - Check that the sealing of the floating roof is functioning properly. - Check that stiffeners are provided, if required, on floating head, - Check that the vacuum breaker, if required, is installed, tagged and test certificate checked. - Check the wind girder, if required, has been installed per drawings.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 18 of 222

REMARKS

FORM YERP - D0002

SHT 3 of 3

YERP PRE-COMMISSIONING FORM EQUIPMENT TYPE: STORAGE TANK EQUIP. NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS:

USER REFERENCE: DESCRIPTION: PLANT NO:

STORAGE TANKS (Continued) Yes

No

N.A

- Check that the ladders, platforms and stairways are installed per drawings. - Check that fireproofing, if required, has been provided and applied in accordance with specifications. - Check that all instruments have been installed in their proper locations per drawings. - Check that tank is internally cleaned and free of all debris before final close out. - Check that rain water is drained away from the tank bottom. - Insure that temporary supports have been removed when spring support are used. - Check that safe access has been provided to all valves and

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 19 of 222

REMARKS

FORM YERP- E-001A

SHT 1 of 4

YERP PRE-COMMISSIONING FORM HEAT EXCHANGERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

HEAT EXCHANGERS NOTE: The items listed below must be supplemented with any specific instructions for commissioning and start-up, that may have been supplied by the equipment manufacturer.

SHELL & TUBE

Yes

No

N.A

1. Check for physical damage that may have been caused during shipment or installation at the construction site. 2. Check that the nameplate has been installed and ASME stamped for OOK exchangers. Confirm that the Manufacturer's Test Certificate is available, the information on the nameplate is legible and agrees with the certificate. Check the data for correctness and proper reference to process fluids and operating conditions. 3. Check that the exchanger and the nozzles' orientation agrees with the construction drawings, and that the exchanger centerline is level and at the correct elevation. 4. Check that the supports are grouted and foundation bolts properly tightened. 5. For exchangers that incorporate one, or more, sliding supports, ensure that they have been installed as detailed on the construction drawings, lubricated, and are free to move as the exchanger is subjected to its various operating conditions.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 20 of 222

REMARKS

FORM YERP- E-001A

SHT 2 of

YERP PRE-COMMISSIONING FORM HEAT EXCHANGERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SHELL & TUBE (Continued) Yes

No

N.A

6. For exchangers with internal linings, ensure that they have been installed and tested per the construction drawings and specifications. 7. Check that any field modifications or repairs, to internally lined or clad exchangers, have been properly completed and inspected. 8. Check that all support brackets and clips for piping, ladders, plat forms, etc., have been properly installed, especially for stress relieved exchanger. 9. Confirm that lifting lugs and special davits or brackets used to pull tube bundles are installed and properly located. 10. Where required, check anodic protection installation for adequacy, if accessible. 11. Confirm that exchanger grounding connections have been properly installed. 12. Review heat-up and cool-down sequence to ensure that the various combinations of conditions (such as hot fluid or pressure on only one side) will not cause structural damage or differential thermal growth interference of floating head or U-tubes with shell cover. 13. Check suitability of flanges, facings, gaskets, etc. for service conditions. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 21 of 222

REMARKS

FORM YERP- E-001A

SHT 3 of 4

YERP PRE-COMMISSIONING FORM HEAT EXCHANGERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SHELL & TUBE (Continued) Yes

No

N.A

14. Confirm that all connecting piping and valves have been connected to the exchanger, including isolation, control, instrumentation, and relief. Also, confirm that all instruments (local and those with transmitters) are properly installed. 15. Prior to final close-out, confirm that exchanger is free of all loose debris or standing water, and meets the construction requirements for internal cleanliness and dryness. 16. Confirm that the final external paint coating has been applied, where applicable. 17. Confirm that the insulation has been applied, where applicable. 18. Confirm that the color coding agrees with Company standards, and the exchanger identification numbers are clearly visible and correct. 19. After heat-up, check that sliding end has moved and investigate implications if movement has not occurred. 20. Check that restraining bars for shell expansion joints have been removed and visually examine expansion joints for any damage.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 22 of 222

REMARKS

FORM YERP- E-001A

SHT 4 of 4

YERP PRE-COMMISSIONING FORM HEAT EXCHANGERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIN-FAN (AIR-COOLED) Follow the checklist items for SHELL & TUBE exchangers above, plus the following: Yes

No

N.A

1. Check that clips installed for shipment have been removed. 2. Check that the bundle is not welded down and is free to expand. 3. Check that there is provision for bundle movement in the direction of header expansion, when several exchangers are joined by a common header. 4. Check that the louvers operate freely, and that proper settings are attainable. 5. Review long-term mechanical suitability of linkage and louver bushings. 6. Confirm that access ladders are properly fitted and securely fastened to the support clips provided. Check provisions for differential expansion between ladders and equipment.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 23 of 222

REMARKS

FORM YERP - E-001B

SHT 1 of 1

YERP PRE-COMMISSIONING FORM FIN FAN EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes 1

RECEIPT INSPECTION FOR DAMAGES AND SHORTAGES.

2

STORAGE PROTECTION (LUBRICATE FAN AND MOTOR BEARINGS.) LUBRICANT_______________.

3

ROTATE SHAFT WEEKLY.

4

FAN SHAFT SHOULD BE CHECKED DIRECTLY ON THE SHAFT IN TWO PLACES 90 DEG. APART TO SEE THAT IT IS VERTICAL/PLUMB.

5

FAN INSTALLED AND SHAFT TO HUB BOLTING TORQUED CORRECTLY.

6

FAN BLADE TO SHROUD CLEARANCE AND CONCENTRICITY CHECKED.

7

ALL BLADE PITCH ANGLES SET. YES___ NO___

8

THE MAX. DEVIATION OF THE TIP BLADE FOR EACH OF THE BLADES RELATIVE TO EACH OTHER IS 9 mm (3/4").

9

THE TORQUE OF THE FAN BLADE HOLDING SCREWS/BOLTS CHECKED.

No

10 BLADE CONTROL INSTALLED AND FUNCTIONAL. 11 PITCH ANGLE SET (FIXED OR AUTO). 12 LUBE LINES INSTALLED. 13 FAN GUARD INSTALLED. 14 MOTOR AND SHEAVES INSTALLED. 15 SHEAVES ALIGNED.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 24 of 222

REMARKS

FORM YERP-E-002

SHT 1 of 1

YERP PRE-COMMISSIONING FORM FIN FAN EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIN-FAN (Continued)

Yes

No

16 BELTS INSTALLED AND TENSIONED. 17 BELT GUARD INSTALLED. 18 VIBRATION SENSOR SET. 19 GROUNDING STRAP INSTALLED. 20 START-STOP SWITCH AT MOTOR, GRADE, AND CONTROL ROOM CHECKED. 21 DIRECTION OF ROTATION CHECKED. 22 INDICATING LIGHTS FUNCTIONAL 23 MOTOR FOUR HOURS MECHANICAL RUN TEST COMPLETED. 24 VIBRATION LEVEL CHECKED AT DCS. 25 SHAFT AND SHEAVES ALIGNMENT RECHECKED. 26 MOTOR AMPS DURING OPERATION AT MIN, MAX AND NORMAL FAN PITCH CHECKED. 27 EXCHANGER BUNDLETIE RODS ARE LOOSE.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 25 of 222

REMARKS

FORM YERP-E-002

SHT 1 of 2

YERP PRE-COMMISSIONING FORM BLOWERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes 1

BASE PLATE CHECKED FOR LEVELING.

2

BASE PLATE CHECKED FOR GROUTING.

3

PROTECTIVE FLUID DRAINED OUT.

4

BEARING OIL FLUSH COMPLETED.

5

OILERS INSTALLED AND FILLED TO CORRECT LEVEL ( LUBE OIL USED).

6

COUPLING RUNOUT CHECKED ON ALL COUPLINGS. ( SHOULD BE WITHIN 0.001" )

7

COUPLING GAP CHECKED IN FOUR POSITIONS. ( SHOULD BE WITHIN 0.002" )

8

BLOWER AND DRIVER CHECKED FOR FREEDOM OF MOVEMENT.

9

SOFT FOOT CHECKED ON EACH HOLD DOWN BOLT. ( SHOULD BE WITHIN 0.002" )

No

10 COLD ALIGNMENT CHECKED AS PER REQUIRED. 11 JACKSCREWS REMOVED & FOUNDATION BOLTS TIGHTENED 12 THE COLD ALIGNMENT RECHECKED. 13 SUCTION AND DISCHARGE PIPING CHECKED FOR CLEANLINESS. 14 PIPE SUPPORTS, SPECIFICALLY SPRING SUPPORTS, CHECKED TO BE WITHIN THE LOAD RANGE SPECIFIED ON THE PIPING DRAWINGS. 15 SUCTION STRAINER OR FILTER INSTALLED.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 26 of 222

REMARKS

FORM YERP-E-002

SHT 2 of 2

YERP PRE-COMMISSIONING FORM BLOWERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes

No

16 FLANGE BOLT HOLE OFFSETS AND FACE PARALLELISM CHECKED. - VERTICAL BOLT HOLE OFFSET : - HORIZONTAL BOLT HOLE OFFSET : - ROTATIONAL OFFSET : - FLANGE FACE PARALLELISM : - FLANGE FACE SEPARATION : 17 ALL PROCESS PIPING CONNECTED TO THE MACHINE AT THE SAME TIME. ( IT IS NOT ACCEPTABLE TO CONNECT ONE PIPE ONE DAY, ANOTHER THE NEXT DAY, ETC.) 18 THE MAX MOVEMENT AT THE COUPLING DURING PIPING INSTALLATION IS 0.002 19 BLOWER DOWELED TO BASE PLATE. 20 GROUNDING STRAPS INSTALLED. 21 DRIVER DIRECTION OF ROTATION CHECKED. 22 ROTOR FLOATS CHECKED TO BE WITHIN THE MANUFACTURERS TOLERANCES. 23 COUPLING LUBRICATION AS REQUIRED. 24 COUPLING HUB FIT ON THE SHAFTS CHECKED FOR DISTANCE PUSHED ON TO THE SHAFT/ INTERFERENCE AND SQUARENESS TO THE SHAFT. ( FACE RUNOUT ) 25 THE KEYS AND THE KEY WAYS CHECKED FOR THE CORRECT FIT. 26 MECHANICAL & ELECTRICAL RUNOUT CHECKED AT THE VIBRATION PROBE AREAS INCLUDING THE THRUST PROBES IF FITTED. 27 COUPLING GUARD INSTALLED.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 27 of 222

REMARKS

FORM YERP- F-001

SHT 1 of 8

YERP PRE-COMMISSIONING FORM FURNACES AND HEATERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

GENERAL NOTE: The items listed below are generic in nature, and must be supplemented with any specific instructions for commissioning and start-up, that may have been supplied by the manufacturer.

Yes

No

N.A

1 Check that the name plate is installed correctly and that the information on it is correct and legible. 2 Note any modifications or alterations during construction and erection and ensure that they are according to specifications. All deviations should be recorded. 3 Make sure that non-destructive examination has been conducted and the results are recorded on field welds. 4 Make sure that welding procedures are documented and heat treatment and stress relieving are conducted and recorded. 5 Ensure that the safety instruction sheet is completed. 6 Check that hydro test is conducted in accordance with codes and specifications. 7 Ensure that all exposed surfaces, easily accessible by operators, and with a temperature above 660C are insulated for personnel protection. 8 Ensure that safe access is provided to all valves and instruments. 9 Check that all spare parts, if any required, are provided.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 28 of 222

REMARKS

FORM YERP- F-001

SHT 2 of 8

YERP PRE-COMMISSIONING FORM FURNACES AND HEATERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

HEATER CASING

Yes

No

N.A

Yes

No

N.A

1 Check for sources of air infiltration. Entry and exit points for all tubes require sealing devices. Packing should be provided around convection section tubes at the end of the tube sheets. Convection section header boxes should be gasketed. 2 Check that large panels are adequately supported. Additional stiffening may be required to prevent bowing. 3 Check that rain water cannot accumulate in arches, angles, or channels.

ACCESS AND OBSERVATION DOORS 1 Check that adequate radiant section observation doors have been provided for the tubes, supports, walls, arch and burner flames. 2 Make sure that convection section observation doors have been installed to view representative tubes, extended surface, and tube sheets. 3 Make sure that all doors fit properly, to minimize air infiltration. 4 Make sure that any explosion on pressure release doors will not discharge flue gas in a direction where personnel exposure could occur. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 29 of 222

REMARKS

FORM YERP- F-001

SHT 3 of 8

YERP PRE-COMMISSIONING FORM FURNACES AND HEATERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

BURNERS Yes

No

N.A

1 Installed burners should be protected from mechanical damage and all refractory material kept dry. 2 Make sure there is no serious refractory damage and that burner internals are clear of debris. 3 Check for adequate clearance between burner tiles and floor refractory. 4 Check gun size, position, and alignment. 5 Ensure that suitable ignition equipment has been provided. Check that spares have been provided. 6 Make certain that both ignitor guns and burner assembly can be removed while heater is in operation. 7 Check that burner support is adequate to ensure that burner alignment does not change while in service. 8 Ensure that suitable flame scanners have been provided and that spares are available.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 30 of 222

REMARKS

FORM YERP- F-001

SHT 4 of 8

YERP PRE-COMMISSIONING FORM FURNACES AND HEATERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

DAMPERS

Yes

No

N.A

1 Check operability of all dampers. Critical dampers, such as flue gas/combustion air bypass dampers, must be thoroughly checked, both internally and externally. (Tight closure and ease of operation are essential if these dampers are to perform their intended function.) Look for the possibility of thermal growth problems. 2 Check that stack damper indicator corresponds with damper position and that stops have been provided. 3 Make certain that forced draft heaters cannot be over pressured by improper damper operation. 4 Check that mechanical bearings in hot service have been selected for the expected operating conditions. Installing them outboard to reduce their operating temperature is the preferred practice. 5 Check for shaft leakage problems in forced or induced draft systems. 6 Check that individual burner dampers are capable of locking in the "fully open" or "fully closed" position.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 31 of 222

REMARKS

FORM YERP- F-001

SHT 5 of 8

YERP PRE-COMMISSIONING FORM FURNACES AND HEATERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

BURNER PIPING

Yes

No

N.A

1 Review burner fuel valving system to ensure all burner startup, operating and shutdown requirements are met. 2 Review the ignitor fuel and air valving system to ensure all ignitor startup, operating and shutdown requirements are met 3 Ensure that all oil and atomizing steam connections are properly connected (i.e., none are reversed at the burners). 4 Check that the insulation and steam tracing called for on the design drawings has been properly installed. 5 Check that piping flexibility and support is adequate for gun height repositioning, and that only minor thermal growth forces will be imposed at the burner gun to piping junctions. 6 Check that fuel piping has been seal welded.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 32 of 222

REMARKS

FORM YERP- F-001

SHT 6 of 8

YERP PRE-COMMISSIONING FORM FURNACES AND HEATERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

RADIANT AND CONVECTION SECTION COILS

Yes

No

N.A

Yes

No

N.A

1. Review support and guide system for freedom of movement. Check that the inlet and outlet piping does not impose excessive forces on the coil assemblies. 2. Check for adequate clearances for thermal movement inside heater, at tube entry and exit points, and crossover piping. 3. Review the operability of any piping spring or counterweight support systems.

SOOT BLOWERS 1 Check that steam piping is properly sloped and trapped. 2 Ensure that blowers have been properly serviced for start-up, in accordance with the manufacturer's instructions. 3 Conduct blower run-in test, in accordance with the manufacturer's instructions, to ensure that limit switches are positioned properly and that the lance has adequate clearances when in the soot blower cavity. Make sure that all poppet valves are adjusted to provide the required lance steam pressure.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 33 of 222

REMARKS

FORM YERP- F-001

SHT 7 of 8

YERP PRE-COMMISSIONING FORM FURNACES AND HEATERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

AIR PREHEATERS Yes

No

N.A

Yes

No

N.A

1 The items to be checked will depend on the actual type of air preheater used. Follow the instructions of the manufacturer. In all cases, make certain that adequate instrumentation has been installed to study the thermal performance of the air preheater and provide for its safe operation. Also, make sure that adequate cleaning facilities have been provided to maintain thermal performance and that associated air/flue gas dampers will provide for satisfactory operation of the fired heater with the air preheat system bypassed.

FANS 1 Ensure that instrumentation in accordance with the design drawings has been installed. In all cases, the instrumentation must provide for the operability and safety requirements for the forced draft systems. 2 Check bearing lubrication and cooling systems. 3 Check operability of forced draft fan inlet guide vane assembly. 4 Make certain that ductwork does not impose loads on fans. 5 Check operability of automatic back-flow check for forced draft fans operating in parallel. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 34 of 222

REMARKS

FORM YERP- F-001

SHT 8 of 8

YERP PRE-COMMISSIONING FORM FURNACES AND HEATERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

REFRACTORY PLACEMENT & INSULATION

Yes

No

N.A

Yes

No

N.A

1 Ensure that the installation, curing and drying of refractory has been carried out in accordance with the refractory manufacturer procedures and all the work is done by qualified 2 Inspect refractory and insulation for quality of workmanship and overall integrity. 3 Check that all expansion joint packing have been installed, and no other thermal expansion problems are evident. 4 Make sure that convection section setting will not impose forces on the arch nose area. 5 Ensure that all required field testing are carried out, for example production, cold crushing and density tests.

DRYOUT 1 Following the hydrotest, ensure that the test water has been removed from the coils, to the maximum extent practical. 2 Ensure that all fuel lines have been steam blown dry, but not through the burner guns. 4 Check the performance of all burners during the dryout operation. 5 Monitor the thermal movement of tubes, tube support systems and refractory during dryout for evidence of any problems.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 35 of 222

REMARKS

FORM YERP - F-002

SHT 1 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

GENERAL NOTE: The items listed below are generic in nature, and must be supplemented with any specific instructions for commissioning and start-up, that may have been supplied by the manufacturer. Yes

No

N.A

1 Check that the name plate is installed correctly and that the information on it is correct and legible. 2 Note any modifications or alteration during construction and erection and ensure that they are according to specifications. All deviations should be recorded. 3 Make sure that non-destructive examination has been conducted and the results are recorded on field welds. 4 Make sure that welding procedures are documented and heat treatment and stress relieving are conducted and recorded. 5 Ensure that the safety instruction sheets for all pressure containing parts are completed. 6 Ensure that hydrotest is conducted in accordance with codes and specifications. 7 Ensure that cleaning and boiling procedures have been carried out in accordance specifications. Ensure that oil and grease are removed from the internal surfaces.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 36 of 222

REMARKS

FORM YERP - F-002

SHT 2 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

GENERAL (Continued) 8 Record the boiler thermal expansion during boiling procedure. The direction and dimension of all pressure parts should be checked and recorded. Also, monitor the thermal movement of the refractory.

Yes

No

N.A

9 Check the explosion door for free and easy movement. 10 Ensure that all exposed surfaces, easily accessible by operators, and with a temperature above 660C are insulated for personnel protection. 11 Ensure that the boiler is provided with a noise control system in accordance with the project specifications. 12 Ensure that the boiler is provided with flame monitoring and burner management system in accordance with YERP-34SAMSS-619. 13 Ensure that the boiler is provided with package unit instrumentation in accordance with YERP-34-SAMSS-831. 14 Ensure that all connections are provided in accordance with YERP-32-SAMSS-021. 15 Check and adjust if necessary the set pressure and maximum Relief pressure of the safety relief valves after start up. 16 Ensure that safe access is provided to all valves and instruments. 17 Check that all spare parts, if any required, are provided. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 37 of 222

REMARKS

FORM YERP - F-002

SHT 3 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CASING Yes

No

N.A

Yes

No

N.A

1 Check for sources of air infiltration. Entry and exit points for all tubes and pipes require sealing devices. Smoke-bomb test can be applied to check for tightness. 2 Check that large panels are adequately supported. Additional stiffening may be required to prevent bowing. 3 Check that rain water cannot accumulate in arches, angles, or channels.

ACCESS AND OBSERVATION DOORS 1 Check that adequate observation doors have been provided for the tubes, supports, walls, and burner flames. 2 Make sure that all doors fit properly, to minimize air infiltration. 3 Make sure that any explosion on pressure release doors will not discharge flue gas in a direction where personnel exposure could occur.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 38 of 222

REMARKS

FORM YERP - F-002

SHT 4 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

BURNERS Yes

No

N.A

1 Installed burners should be protected from mechanical damage and all refractory material kept dry. 2 Make sure there is no serious refractory damage and that burner internals are clear of debris. 3 Check for adequate clearance between burner tiles and refractory. 4 Check gun size, position, and alignment. 5 Ensure that suitable ignition equipment has been provided. Check that spares have been provided. 6 Make certain that both ignitor guns and burner assembly can be removed while heater is in operation. 7 Check that burner support is adequate to ensure that burner alignment does not change while in service.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 39 of 222

REMARKS

FORM YERP - F-002

SHT 5 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

DAMPERS Yes

No

N.A

1 Check operability of all dampers. Critical dampers, such as flue gas/combustion air bypass dampers, must be thoroughly checked, both internally and externally. (Tight closure and ease of operation are essential if these dampers are to perform their intended function.) Look for the possibility of thermal growth problems. 2 Check that stack damper indicator corresponds with damper position and that stops have been provided. 3 Make certain that forced draft boiler cannot be over pressured by improper damper operation. 4 Check that mechanical bearings in hot service have been selected for the expected operating conditions. Installing them outboard to reduce their operating temperature is the preferred practice. 5 Check for shaft leakage problems in forced or induced draft systems. 6 Check that individual burner dampers are capable of locking in the "fully open" or "fully closed" position.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 40 of 222

REMARKS

FORM YERP - F-002

SHT 6 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

BURNER PIPING

Yes

No

N.A

Yes

No

N.A

1 Review burner and ignitor fuel and air valving system to ensure all burner startup, operating and shutdown requirements are met. 2 Ensure that all oil and atomizing steam connections are properly connected (i.e., none are reversed at the burners). 3 Check that the insulation and steam tracing called for on the design drawings has been properly installed. 4 Check that piping flexibility and support is adequate for gun height repositioning, and that only minor thermal growth forces will be imposed at the burner gun to piping junctions. 5 Check that fuel piping has been seal welded.

Tubes 1 Ensure that the vertical tubes are properly supported or guided to prevent sagging and vibration and to allow for thermal expansion. 2 Ensure that the floor tubes are covered with refractory

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 41 of 222

REMARKS

FORM YERP - F-002

SHT 7 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

DRUMS AND HEADERS

Yes

No

N.A

Yes

No

N.A

1 Ensure that all internals are correctly installed and well fastened in accordance with the design drawings.. 2 Ensure that the internal is clean and free of debris prior to final close out.

SOOT BLOWERS 1 Check that steam piping is properly sloped and trapped. 2 Ensure that blowers have been properly serviced for start-up, in accordance with the manufacturer's instructions. 3 Conduct blower run-in test, in accordance with the manufacturer’s instructions, to ensure that limit switches are positioned properly and that the lance has adequate clearances when in the soot blower cavity. Make sure that all poppet valves are adjusted to provide the required lance steam pressure.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 42 of 222

REMARKS

FORM YERP - F-002

SHT 8 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

AIR PREHEATERS Yes

No

N.A

Yes

No

N.A

1 The items to be checked will depend on the actual type of air Preheater used. Follow the instructions of the manufacturer. In all cases, make certain that adequate instrumentation has been installed to study the thermal performance of the air preheater and provide for its safe operation. Also, make sure that adequate cleaning facilities have been provided to maintain thermal performance and that associated air/flue gas dampers will provide for satisfactory operation of the fired heater with the air preheat system bypassed.

FANS 1 Ensure that instrumentation in accordance with the design drawings has been installed. In all cases, the instrumentation must provide for the operability and safety requirements for the forced draft systems. 2 Check bearing lubrication and cooling systems. 3 Check operability of forced draft fan inlet guide vane assembly. 4 Make certain that ductwork does not impose loads on fans. 5 Check operability of automatic back-flow check for forced draft fans operating in parallel.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 43 of 222

REMARKS

FORM YERP - F-002

SHT 9 of 9

YERP PRE-COMMISSIONING FORM BOILERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

REFRACTORY PLACEMENT & INSULATION Yes

No

N.A

Yes

No

N.A

1 Ensure that the installation, curing and drying of refractory has been carried out in accordance with refractory manufacturer procedures and all the work is done by qualified people. 2 Inspect refractory and insulation for quality of workmanship and overall integrity. 3 Check that all expansion joint packing have been installed, and no other thermal expansion problems are evident. 4 Ensure that all required field testing are carried out, for example production, cold crushing and density tests.

DUCT 1 Ensure that stiffeners are provided to prevent distortion and vibration fans, if required. An analysis of the duct vibration shall be supplied by the vendor and the design of the stiffeners and supports verified. 2 Ensure that adequate provision are made for expansion and contraction throughout the duct work. 3 Ensure that expansion joints are sealed to prevent leakage WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 44 of 222

REMARKS

FORM YERP - G-005

SHT 1 of 1

YERP PRE-COMMISSIONING FORM CENTRIFUGAL PUMPS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes

No

1. BASEPLATE LEVELED AND PROPERLY GROUTED. 2. JACKSCREWS REMOVED AND FOUNDATION BOLTS TIGHTENED. 3. SUCTION SCREEN INSTALLED. 4. PIPING STRAIN CHECKED. 5. FINAL COLD ALIGNMENT TO MANUFACTURER'S TOLERANCE. 6. PUMP AND DRIVER CHECKED FOR FREEDOM OF MOVEMENT. 7. DRIVER CHECKED FOR CORRECT ROTATION (UNCOUPLED) 8. BEARING HOUSING FLUSHED AND RE LUBRICATED. LUBRICATOR FILLED AND OPERABLE. LUBRICANT ___________ 9. MOTOR BEARING LUBRICATION CHECKED 10. MECHANICAL SEAL OR PACKING INSTALLED. TYPE 11. COUPLING INSTALLED. 12. GUARD IN PLACE AND SECURED. 13. PUMP AND DRIVER DOWELED (WHEN SPECIFIED). 14. COOLING WATER PIPING INSTALLED (WHEN SPECIFIED) 15. SEAL FLUSH PIPING INSTALLED.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 45 of 222

REMARKS

FORM YERP - G-006

SHT 1 of 1

YERP PRE-COMMISSIONING FORM POSITIVE DISPLACEMENT PUMPS (RECIPROCATING) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes 1.

BASEPLATE LEVEL AND PROPERLY GROUTED. JACKSCREWS REMOVED AND FOUNDATION BOLTS TIGHTENED.

2.

SUCTION SCREEN INSTALLED.

3.

PIPING STRAIN CHECKED.

4.

FINAL COLD ALIGNMENT TO MANUFACTURER'S TOLERANCE.

5.

PUMP AND DRIVER CHECKED FOR FREEDOM OF MOVEMENT.

6.

DRIVER CHECKED FOR CORRECT ROTATION (UNCOUPLED)

7.

GEAR UNIT CHECKED PER GEAR UNIT CHECK LIST (WHEN APPLICABLE).

8.

BEARING HOUSING FLUSHED AND RE LUBRICATED. LUBRICATOR FILLED AND OPERABLE. LUBRICANT ___________

9.

MOTOR BEARING LUBRICATION CHECKED.

No

10. PACKING INSTALLED. TYPE_________ 11. COUPLING OR BELT INSTALLED. 12. BELT OR COUPLING GUARD IN PLACE AND SECURED. 13. PUMP AND DRIVER DOWELED (WHEN SPECIFIED).

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 46 of 222

REMARKS

FORM YERP - G-007

SHT 1 of 1

YERP PRE-COMMISSIONING FORM SUBMERSIBLE PUMPS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes 1

PUMPS CHECKED PER DATA SHEET

2

NAME PLATE DATA CHECKED.

3

PUMP UNDAMAGED

4

POSITION & MOUNTING CHECKED PER _____

5

CAISSONS INSTALLATION CHECKED PER_____

6

PUMP LEVEL CHECKED

7

SEAL SYSTEM COMPLETED

8

SUCTION STRAINER FITTED

9

MOTOR WINDINGS MEGGER CHECKED

10

CABLE MEGGER CHECKED

11

ACCESS TO DISCHARGE VALVE CHECKED

12

INSTRUMENTATION SYSTEM VERIFIED

13

ELECTRICAL SYSTEM VERIFIED

14

VENDOR'S RECOMMENDATIONS FOLLOWED

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 47 of 222

No

REMARKS

FORM YERP - G-110

SHT 1 of 1

YERP PRE-COMMISSIONING FORM GEARS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes 1

RECEIPT INSPECTION FOR DAMAGES AND SHORTAGES Y

2

SOFT FEET CHECKED.

3

INTERNAL ALIGNMENT CHECKED. ( TOOTH CONTACT CHECK WITH BLUING).

4

COLD ALIGNMENT CHECKED.

5

LUBE OIL SUPPLY PIPING FLUSHED AND CASING CLEANED.

6

ALL BLIND FLANGES REMOVED.

7

DIRECTION OF ROTATION CHECKED.

8

DOWEL PINS INSTALLED.

9

COUPLING HUBS ARE INSTALLED PER DWG.

10

NAME PLATE DATA PER DWG.

11

COUPLING GUARD IN PLACE AND SECURED.

12

SHIMS MOUNTED PER SPEC.(MATERIAL, CONFIGURATION).

13

TEMPERATURE SENSORS INSTALLED.

14

VIBRATION SENSORS INSTALLED.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 48 of 222

No

REMARKS

FORM YERP- J-001

SHT 1 of 1

YERP PRE-COMMISSIONING FORM CONVENTIONAL ELECTRONIC AND PNEUMATIC TRANSMITTERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD CALIBRATION INPUT (%)

OUTPUT SIMULATED PROCESS INPUT

UPSCALE READING

DOWNSCALE ERROR

READING

ERROR

0 25 50 75 100

PROCESS INPUT RANGE:

SIGNAL OUTPUT RANGE:

EXTERNAL SPAN:

ZERO ADJUSTMENT:

ZERO ELEVATION:

ZERO SUPPRESSION:

SPECIFIC GRAVITY (FOR LIQUID INTERFACE LEVEL MEASUREMENT): FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 49 of 222

REMARKS

FORM YERP- J-002

SHT 1 of 1

YERP PRE-COMMISSIONING FORM TRANSDUCERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD CALIBRATION INPUT (%)

OUTPUT SIMULATED UPSCALE

PROCESS INPUT

READING

DOWNSCALE

ERROR

READING

ERROR

0 25 50 75 100

INPUT RANGE:

OUTPUT RANGE:

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 50 of 222

REMARKS

FORM YERP - J-003

SHT 1 of 1

YERP PRE-COMMISSIONING FORM SWITCHES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SWITCH FUNCTION: SWITCH SET POINT: SWITCH ACTION AT SET POINT: SPECIFIC GRAVITY (FOR LIQUID INTERFACE): CHECKS TO BE PERFORMED

RESULT

SWITCH ACTIVATES AT SWITCH ACTION AT SET POINT SWITCH RESETS AT

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER: DATE CALIBRATED: REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 51 of 222

REMARKS

FORM YERP - J-004

SHT 1 of 1

YERP PRE-COMMISSIONING FORM INDICATORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD CALIBRATION INPUT (%)

OUTPUT

INPUT UPSCALE READING

DOWNSCALE

ERROR

READING

ERROR

0 25 50 75 100

INDICATOR RANGE:

SCALE:

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 52 of 222

REMARKS

FORM YERP - J-005

SHT 1 of 1

YERP PRE-COMMISSIONING FORM ORIFICE PLATES, VENTURIES, AND LO-LOSS TUBES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

CHECK UPSTREAM AND DOWN STREAM PIPING FOR STRAIGHT RUN REQUIREMENTS CHECK FLANGE TYPE AND RATING CHECK LOCATION OF TABS CHECK METER MATERIAL CHECK DIRECTION OF FLOW ORIFICE PLATE SIZE BORE DIAMETER PLATE THICKNESS NO. OF WEEP HOLES AND THEIR DIAMETER PLATE HOLDER MATERIAL ORIFICE PLATE STAMP INFORMATION INSTALLATION OF TRANSMITTER AND IMPULSE LINES

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 53 of 222

REMARKS

FORM YERP - J-006

SHT 1 of 2

YERP PRE-COMMISSIONING FORM CONTROL VALVES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

VALVE TYPE AND SIZE: INPUT SIGNAL RANGE: ACTION ON SIGNAL FAILURE: INCREASE AIR ACTION: ACTUATOR TYPE:

ANSI RATING: AIR SUPPLY: ACTION ON SUPPLY FAILURE: POSITIONER ACTION (DIR./REV.): POSITIONER GAUGES RANGE:

FIELD CALIBRATION INPUT (%)

VALVE TRAVEL UPSCALE DOWNSCALE

0 25 50 75 100 CLOSING TIME (SEC): CLOSING OR OPENING TIME DURING AIR SUPPLY FAILURE:

OPENING TIME (SEC): CLOSING OR OPENING TIME DURING SIGNAL FAILURE:

SEAT LEAKAGE TEST (FOR CLASS 5 AND CLASS 6 VALVES ONLY) VALVE LEAKAGE CLASS MAX. ALLOWABLE LEAKAGE RATE TEST MEDIUM TEST PRESSURE LEAKAGE RATE RESULT (PASS/FAIL) NOTE: LEAKAGE TEST SHOULD BE DONE IN ACCORDANCE WITH ANSI/FCI 70.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 54 of 222

REMARKS

FORM YERP - J-006

SHT 2 of 2

YERP PRE-COMMISSIONING FORM CONTROL VALVES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ANCILLARY EQUIPMENT SOLENOID VALVE

LIMIT SWITCHES

MANUFACTURER:

MANUFACTURER

MODEL NO.:

MODEL NO.:

VOLTAGE RATING:

VOLTAGE RATING:

FREQUENCY:

FREQUENCY:

TAG NO.:

TAG No's.:

ZV OPERATION (PASS/FAIL)

XLS OPERATION (PASS/FAIL):

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

WITNESS

CONTRACTOR

DATE CALIBRATED:

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 55 of 222

REMARKS

FORM YERP - J-007

SHT 1 of 2

YERP PRE-COMMISSIONING FORM THERMOCOUPLES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

THERMOCOUPLE TYPE: THERMOCOUPLE RANGE: CHECKS TO BE PERFORMED

RESULT PASS

FAIL

CHECK THERMOCOUPLE MATERIAL IS CORRECT FOR SERVICE RANGE CHECK THERMOCOUPLE TOUCHES BOTTOM OF WELL CHECK WELL LOCATION FOR ACCESSIBILITY CHECK IMMERSION LENGTH CHECK EXTENSION WIRE AND TERMINAL BLOCK MATERIAL CHECK JUNCTIONS FOR CORRECT POLARITY CHECK GROUNDING OF THERMOCOUPLE

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 56 of 222

REMARKS

FORM YERP - J-007

SHT 2 of 2

YERP PRE-COMMISSIONING FORM THERMOCOUPLES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

USE THE FOLLOWING TABLE TO CHECK THE RESPONSE OF THE THERMOCOUPLE

INPUT (%)

INPUT (°C)

VOLTAGE UPSCALE DOWN SCALE

0 25 50 75 100

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 57 of 222

REMARKS

FORM YERP - J-008

SHT 1 of 2

YERP PRE-COMMISSIONING FORM RESISTANCE TEMPERATURE DETECTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

RTD TYPE: RTD RANGE: CALIBRATION TABLE CHECKS TO BE PERFORMED

RESULT PASS

FAIL

CHECK RANGE IS ADEQUATE FOR SERVICE CHECK BULB RESISTANCE AT AMBIENT TEMPERATURE CHECK WELL LOCATION FOR ACCESSIBILITY CHECK THERMOWELL IMMERSION LENGTH USE THE FOLLOWING TABLE TO CHECK THE RESPONSE OF THE RTD

INPUT (%)

INPUT (°C)

RESISTANCE UPSCALE DOWN SCALE

0 25 50 75 100 WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 58 of 222

REMARKS

FORM YERP - J-008

SHT 2 of 2

YERP PRE-COMMISSIONING FORM RESISTANCE TEMPERATURE DETECTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 59 of 222

REMARKS

FORM YERP - J-009

SHT 1 of 1

YERP PRE-COMMISSIONING FORM CONTROLLERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CONTROLLER ACTION (INCREASE/ICREASE OR INCREASE/DECREASE): CONTROLLER TYPE (PID, OVERRIDE, SELECTOR, etc.):

CONTROLLER SETTING TYPE PROPORTIONAL BAND INTEGRAL DERIVATIVE

SETTING

INPUT SIGNAL:

OUTPUT SIGNAL:

OUTPUT MANUAL SIGNAL RANGE: INPUT INDICATION RANGE: VERIFY OPERABILITY OF CHART VERIFY BUMBLESS TRANSFER: CHECK P&ID AND SAMA DIAGRAMS VERIFY/CHECK INTERNAL SCALING, LOGIC, CONFIGURATION:

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS: WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 60 of 222

REMARKS

FORM YERP - J-010

SHT 1 of 1

YERP PRE-COMMISSIONING FORM INSTRUMENT AIR LINE PRESSURE TEST EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE: TEST BOUNDERIES FROM

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CATAGORY

TEST MEDIUM

TEST PRESSURE

TEST RESULT

TO

CATEGORY CODES: A: AIR SUPPLY LINE I: PROCESS IMPULSE P: PNEUMATIC SIGNAL TUBING FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 61 of 222

REMARKS

FORM YERP - J-011

SHT 1 of 1

YERP PRE-COMMISSIONING FORM TURBINE, POSITIVE DISPLACEMENT, AND MAGNETIC FLOW METERS EQUIPMENT TYPE: USER REFERENCE: EQUIPMENT TAG NO.: DESCRIPTION: BI/JO NO.: PLANT NO. / LOCATION: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: SERIAL NO.: COMMISSIONING DATE: METER FACTOR:

REPEATABILITY:

LINEARITY:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

SPIN METER TO CHECK FREEDOM OF MOVEMENT VERIFY THAT MAGNETIC FLOW METER WILL ALWAYS BE LIQUID FULL DURING PROCESS OPERATION CHECK METER RANGE AND SPAN CHECK UPSTREAM AND DOWN STREAM PIPING FOR STRAIGHT RUN REQUIREMENTS CHECK FLANGE TYPE AND RATING CHECK DIRECTION OF FLOW CHECK THAT INSTALLATION IS PER MANUFACTURER'S RECOMMENDATION OBTAIN 5 POINT MANUFACTURER CALIBRATION, LINEARITY AND REPEATABILITY CHECKS CHECK METER MATERIAL CHECK MANIFOLD CONFIGURATION REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 62 of 222

REMARKS

FORM YERP - J-012

SHT 1 of 1

YERP PRE-COMMISSIONING FORM PITOT TUBE/ANNUBAR FLOW METERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

CHECK THE ALIGNMENT OF THE SENSING PORTS, i. e. THE PITOT TUBE IS INSTALLED PERPENDICULAR TO THE AXIS OF THE PIPE OR IT IS WITHIN ACCEPTABLE ALIGNMENT LIMITS CHECK THAT THE LINE DIAMETER AND THICKNESS ARE THE SAME AS THOSE USED IN THE TUBE SIZING CHECK UPSTREAM AND DOWN STREAM PIPING FOR STRAIGHT RUN REQUIREMENTS CHECK THAT THE PORTS ARE CLEAN AND NOT PLUGGED CHECK FLOW DIRECTION CHECK METER MATERIAL CHECK INSERTION LENGTH REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 63 of 222

REMARKS

FORM YERP - J-013

SHT 1 of 2

YERP PRE-COMMISSIONING FORM INSTALLATION INSPECTION EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

RESULT PASS FAIL

CHECKS TO BE PERFORMED

SUPPORT

FABRICATION AS PER STANDARD DRAWING DEBURRED, PRIMED AND PAINTED LOCATION AS PER LAYOUT ACCESS IS NOT OBSTRUCTED GROUNDING CONDUCTOR INSTALLED AREA CLEAR FOR MAINTENANCE FIXING ON STRUCTURAL STEEL SECURE

INSTRUMENT

FIELD CALIBRATION COMPLETE MOUNTING AS PER APPROVED DRAWING

TABLE IS CONTINUED IN NEXT PAGE WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 64 of 222

REMARKS

FORM YERP - J-013

SHT 2 of 2

YERP PRE-COMMISSIONING FORM INSTALLATION INSPECTION EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

INSTRUMENT (CONTINUED FORM PAGE 1)

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

INSTRUMENT SECURED ELEVATION CORRECT WITH RESPECT TO TAPPING POINTS SEAL FITTING INSTALLED AD FILLED (IF REQUIRED) SUNSHADE INSTALLED

IMPULSE TUBING

MATERIAL AS PER SPECIFICATION ISOLATION AND EQUALIZING VALVES INSTALLED VENT AND DRAIN INSTALLED PIPING SLOPE AS PER STANDARDS TUBES CONNECTED TO THE CORRECT PORTS LEAKAGE TEST

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 65 of 222

REMARKS

FORM YERP - J-014

SHT 1 of 2

YERP PRE-COMMISSIONING FORM LOOP CHECK COVER SHEET EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

INSTALLATION INSPECTION (J-013) PRIMARY ELEMENT INSTALLATION AND CALIBRATION TRANSMITTER (J-001) IMPULSE LINES (J-010) WIRING (J-015) WIRES AND TERMINALS TAGGING AT INSTRUMENT, JUNCTION BOX, MARSHALING CABINET AND INPUT/OUTPUT CABINET CONNECTIONS AND SETTINGS ARE DONE AS SHOWN ON THE ILD ELECTRICAL/AIR SUPPLY CONTROLLER (J-009) TRANSDUCER (J-002) TABLE IS CONTINUED ON THE NEXT PAGE

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 66 of 222

REMARKS

FORM YERP - J-014

SHT 2 of 2

YERP PRE-COMMISSIONING FORM LOOP CHECK COVER SHEET EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

CONTROL VALVE (J-006) SWITCHES (J-003) ALARM INDICATION CONTROLLER SET POINT IN ADDITION TO THE ABOVE, THE FOLLOWING SIMULATION SHOULD BE DONE •

DRIVE SIGNAL INTO THE CONTROLLER FROM TRANSMITTER

•

DRIVE OUTPUT FROM CONTROLLER TO THE VALVE

•

WATCH ALARMS, SHUTDOWNS, ETC.

•

FAIL SENSOR AND WATCH ALARM AND SUBSEQUENT ACTION

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 67 of 222

REMARKS

FORM YERP - J-015

SHT 1 of 1

YERP PRE-COMMISSIONING FORM INSTRUMENT AND CONTROL CABLES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CABLE TAG NO.:

CABLE GLANDING:

CABLE TYPE:

CABLES EALING:

CABLE SIZE:

CABLE ROUTING:

CABLE MARKING:

MEGGERING PAIR NO.

INSULATION RESISTANCE M Ω CORE TO CORE

CONTINUITY

RESULT

CORE TO SCREEN

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS: WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 68 of 222

REMARKS

FORM YERP - J-016

SHT 1 of 1

YERP PRE-COMMISSIONING FORM VIBRATION EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE: TRANSDUCER TYPE:: MONITOR TYPE: ALARM SETTING TRIP SETTING: BYPASS INDICATION:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

TRANSDUCER OUTPUT MONITOR RANGE: ALARM RELAY CONTACT TRIP RELAY CONTACT: SENSOR GAP ADJUSTMENT

DOES THE EXTENSION CABLE LENGTH MATCH THE TRANSDUCER?

YES

NO

USE THE FOLLOWING TABLE TO CHECK THE RESPONSE OF THE TRANSDUCER AND THE MONITOR INPUT (%)

OUTPUT SIMULATED INPUT

UPSCALE READING

DOWNSCALE

ERROR

READING

ERROR

0 25 50 75 100

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 69 of 222

REMARKS

FORM YERP- J-017

SHT 1 of 1

YERP PRE-COMMISSIONING FORM TEMPERATURE MONITOR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

TEMPERATURE ELEMENT TYPE: MONITOR TYPE: ALARM SETTING: TRIP SETTING: BYPASS INDICATION:

TEMPERATURE ELEMENT RANGE: MONITOR RANGE: ALARM RELAY CONTACT: TRIP RELAY CONTACT:

USE THE FOLLOWING TABLE TO CHECK THE RESPONSE OF THE MONITOR

INPUT (%)

INPUT

OUTPUT UPSCALE DOWN SCALE

0 25 50 75 100 FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 70 of 222

REMARKS

FORM YERP - J - 0 1 8

SHT 1 o f 3

YERP PRE-COMMISSIONING FORM H2S MONITORING SYSTEM EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SENSOR TYPE:

SENSOR RANGE :

MONI TOR TYPE:

MONI TOR RANGE:

LOW ALARM SET POI NT:

LOW ALARM RELAY CONTACT

HI GH ALARM SET POI NT:

HI GH ALARM RELAY CONTACT:

BYPASS I NDI CATI ON:

EQUI PMENT FAULT ALARM:

SENSOR OUTPUT •

APPLY A KNOWN CONCENTRATION OF H2S TO THE SENSOR AND CHECK READING AT THE FRONT PANEL OF THE MONITOR

INPUT (PPM)

•

READING (PPM)

PERFORM THE FOLLOWING CHECKS TO THE SYSTEM: CHECKS TO BE PERFORMED

RESULT PASS

FAIL

IN A MULTI CHANNEL DESIGN, EVERY SENSOR HAS ITS CONTROLLER THE DETECTION SYSTEM IS FAIL SAFE

TABLE CONTINUES ON PAGE NO. 2

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 71 of 222

REMARKS

FORM YERP - J - 0 1 8

SHT 2 o f 3

YERP PRE-COMMISSIONING FORM H2S MONITORING SYSTEM EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

SENSOR IS INSTALLED ON A VIBRATION FREE SURFACE POWER IS 120 V AC, 60 HZ FROM UPS. ELSE, POWER IS FROM A RELIABLE 120 V AC SOURCE AND A BACKUP BATTERY IS AVAILABLE. SENSOR IS INSTALLED CLOSE TO THE GROUND 20 % CAPACITY IS AVAILABLE IN THE CONTROL RACK HOUSING IS EXPLOSION PROOF IN MANNED FACILITY, A HORN AND A BLUE BEACON IS LOCATED AT EACH SENSOR AND ACTUATED ONLY BY THAT SENSOR AT HIGH ALARM. IN MANNED FACILITY, THE ALARM CAN BE ACKNOWLEDGED IN THE CONTROL ROOM ONLY. TABLE CONTINUES ON PAGE NO. 3

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 72 of 222

REMARKS

FORM YERP - J - 0 1 8

SHT 3 o f

3

YERP PRE-COMMISSIONING FORM H2S MONITORING SYSTEM EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

IN UNMANNED FACILITY, ALARM AND BEACON ARE LOCATED AT EACH SENSOR AND ACTUATED BY ANY CONTROL UNIT AT LOW OR HIGH ALARM IN UNMANNED FACILITY, A FLASHING BEACONS IS INSTALLED AT THE GATE. IN UNMANNED FACILITY, THE ALARM CAN BE ACKNOWLEDGED AT EITHER THE CONTROL ROOM OR AT THE SENSOR..

FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 73 of 222

REMARKS

FORM YERP J - 0 1 9

SHT 1 o f 3

YERP PRE-COMMISSIONING FORM COMBUSTIBLE GAS MONITORING SYSTEM EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SENSOR TYPE:

SENSOR RANGE:

MONI TOR TYPE:

MONI TOR RANGE:

LOW ALARM SET POI NT:

LOW ALARM RELAY CONTACT:

HI GH ALARM SET POI NT:

HI GH ALARM RELAY CONTACT:

BYPASS I NDI CATI ON:

EQUI PMENT FAULT ALARM:

SENSOR OUTPUT GAS COMPOSI TI ON: • APPLY A KNOWN CONCENTRATION OF H2S TO THE SENSOR AND CHECK READING AT

THE FRONT PANEL OF THE MONITOR

INPUT (% LEL)

•

READING (% LEL)

PERFORM THE FOLLOWING CHECKS TO THE SYSTEM: CHECKS TO BE PERFORMED

RESULT PASS

FAIL

IN A MULTI CHANNEL DESIGN, EVERY SENSOR HAS ITS CONTROLLER THE DETECTION SYSTEM IS FAIL SAFE TABLE CONTINUES ON PAGE NO. 2

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 74 of 222

REMARKS

FORM YERP J - 0 1 9

SHT 2 o f 3

YERP PRE-COMMISSIONING FORM COMBUSTIBLE GAS MONITORING SYSTEM EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

SENSOR IS INSTALLED ON A VIBRATION FREE SURFACE POWER IS 120 V AC, 60 HZ FROM UPS. ELSE, POWER IS FROM A RELIABLE 120 V AC SOURCE AND A BACKUP BATTERY IS AVAILABLE. SENSOR IS INSTALLED CLOSE TO THE GROUND 20 % CAPACITY IS AVAILABLE IN THE CONTROL RACK HOUSING IS EXPLOSION PROOF IN MANNED FACILITY, A HORN AND A BLUE BEACON IS LOCATED AT EACH SENSOR AND ACTUATED ONLY BY THAT SENSOR AT HIGH ALARM. IN MANNED FACILITY, THE ALARM CAN BE ACKNOWLEDGED IN THE CONTROL ROOM ONLY. TABLE CONTINUES ON PAGE NO. 3

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 75 of 222

REMARKS

FORM YERP J – 0 1 9

SHT 3 o f 3

YERP PRE-COMMISSIONING FORM COMBUSTIBLE GAS MONITORING SYSTEM EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CHECKS TO BE PERFORMED

RESULT PASS

FAIL

IN UNMANNED FACILITY, ALARM AND BEACON ARE LOCATED AT EACH SENSOR AND ACTUATED BY ANY CONTROL UNIT AT LOW OR HIGH ALARM IN UNMANNED FACILITY, A FLASHING BEACONS IS INSTALLED AT THE GATE. IN UNMANNED FACILITY, THE ALARM CAN BE ACKNOWLEDGED AT EITHER THE CONTROL ROOM OR AT THE SENSOR.. FOR THE TEST EQUIPMENT USED, PLEASE ENTER THE FOLLOWING: EQUIPMENT NAME: MANUFACTURER:

DATE CALIBRATED:

REMARKS:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 76 of 222

REMARKS

FORM YERP- K-001

SHT 1 of 2

YERP PRE-COMMISSIONING FORM HVAC EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

HEATING VENTILATION & AIR CONDITIONING (HVAC) Yes

No

N.A

1 Verify that engineering drawings, calculations, specifications, data sheets, performance curves and diagrams are provided and complete, in accordance with the design documents and Saudi Aramco requirements. 2 Verify that all Vendor documentation including installation, start-up, and operation and maintenance manuals are provided and complete, in accordance with the documents and Saudi Aramco requirements. 3 Verify that all design drawings are certified " as-built " 4 Verify that the following components and systems installed in accordance with design documents, Saudi Aramco Standards, and manufacturer's recommendations, including: Packaged A/C units, Air Handling units, Condensing units, Fans, Filters, Hydronic coils, Electric coils, Humidifiers, Pumps, Chillers, Cooling Towers, Hydronic Piping, Refrigerant Piping, Piping attachments and accessories, Ductwork attachments and accessories, Thermostats, Valves, and Fire dampers and operating dampers.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 77 of 222

REMARKS

FORM YERP- K-001

SHT 2 of 2

YERP PRE-COMMISSIONING FORM HVAC EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

HEATING VENTILATION & AIR CONDITIONING (HVAC) (Continued) Yes

No

N.A

5 Ensure that all equipment is clean and all debris and foreign matter are removed. 6 Check if any of the equipment and components are damaged. 7 Ensure that adequate clearances are provided for service and maintenance as required by the manufacturer and design drawing. 8 Ensure that all nameplate data and equipment tags are in accordance with the design documentation, certified vendor's documents, and Saudi Aramco Standard. 9 Ensure that spare parts provided in accordance with the design and vendor's documents, and spare parts are original and the same as the parts they are to replace. 10 Check that all safety systems and devices are in place and functional, in accordance with the design documents and Saudi Aramco Standard. 11 Verify that Testing, Adjusting and Balancing (TAB) of the HVAC System is completed in accordance with the requirements of the design documentation. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 78 of 222

REMARKS

FORM YERP - K-402

SHT 1 of 3

YERP PRE-COMMISSIONING FORM CENTRIFUGAL COMPRESSOR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CENTRIFUGAL COMPRESSOR

Yes

1

RECEIPT INSPECTION FOR DAMAGES AND SHORTAGES.

2

STORAGE PROTECTION. ( INSPECT BEARINGS AND SEALS. RENEW FLUSHING OIL WHERE NECESSARY.)

3

BASE PLATE CHECKED FOR LEVELING.

4

BASE PLATE CHECKED FOR GROUTING.

5

COUPLING RUNOUT CHECKED ON ALL COUPLINGS. ( SHOULD BE WITHIN 0.001" ) 6 COUPLING GAP CHECKED IN FOUR POSITIONS. ( SHOULD BE WITHIN 0.002" )

7

BLOWER AND DRIVER CHECKED FOR FREEDOM OF MOVEMENT.

8

SOFT FOOT CHECKED ON EACH HOLD DOWN BOLT. ( SHOULD BE WITHIN 0.002" )

9

COLD ALIGNMENT CHECKED AS PER REQUIRED.

10

JACKSCREWS REMOVED & FOUNDATION BOLTS TIGHTENED.

11

THE COLD ALIGNMENT RECHECKED.

12

SUCTION LINES CLEANED AND MAGNA-COATED AS REQUIRED.

13

PIPE SUPPORTS, SPECIFICALLY SPRING SUPPORTS, CHECKED TO BE WITHIN THE LOAD RANGE SPECIFIED ON THE PIPING DRAWINGS.

14

SPECIAL SPOOL PIECES INSTALLED. NO PIPING STRAIN ALLOWED.

15

CONE SUCTION STRAINER INSTALLED.

No

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 79 of 222

REMARKS

FORM YERP - K-402

SHT 2 of 3

YERP PRE-COMMISSIONING FORM CENTRIFUGAL COMPRESSOR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

16

FLANGE BOLT HOLE OFFSETS AND FACE PARALLELISM CHECKED. - VERTICAL BOLT HOLE OFFSET : - HORIZONTAL BOLT HOLE OFFSET : - ROTATIONAL OFFSET : - FLANGE FACE PARALLELISM : - FLANGE FACE SEPARATION :

17

LUBE AND SEAL OIL SYSTEM FLUSHED. RESERVOIR REFILLED WITH NEW OIL AND FILTERS CHANGED. OIL TYPE_________.

18

RESERVOIR OIL HEATER CHECKED.

19

COOLING WATER SYSTEM CHECKED.

20

ALL PROCESS PIPING CONNECTED TO THE MACHINE AT THE SAME TIME. ( IT IS NOT ACCEPTABLE TO CONNECT ONE PIPE ONE DAY, ANOTHER THE NEXT DAY, ETC.)

21

THE MAX MOVEMENT AT THE COUPLING DURING PIPING INSTALLATION IS 0.002".

22

GROUNDING STRAPS INSTALLED.

23

DRIVER DIRECTION OF ROTATION CHECKED.

24

ROTOR FLOATS CHECKED TO BE WITHIN THE MANUFACTURERS TOLERANCES.

25

COUPLING LUBRICATION AS REQUIRED.

26

COUPLING HUB FIT ON THE SHAFTS CHECKED FOR DISTANCE PUSHED ONTO THE YES SHAFT/ INTERFERENCE AND SQUARENESS TO THE SHAFT. ( FACE RUNOUT)

Yes

No

Yes

No

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 80 of 222

REMARKS

FORM YERP - K-402

SHT 3 of 3

YERP PRE-COMMISSIONING FORM CENTRIFUGAL COMPRESSOR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes 27

THE KEYS AND THE KEY WAYS CHECKED FOR THE CORRECT FIT.

28

MECHANICAL & ELECTRICAL RUNOUT CHECKED AT THE VIBRATION

No

PROBE AREAS INCLUDING THE THRUST PROBES IF FITTED. 29

COUPLING GUARD INSTALLED.

30

COMPRESSOR AND DRIVER DOWELED

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 81 of 222

REMARKS

FORM YERP - K-403

SHT 1 of 3

YERP PRE-COMMISSIONING FORM POSITIVE DISPLACEMENT COMPRESSORS (RECIPROCATING) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Yes

1

RECEIPT INSPECTION FOR DAMAGES AND SHORTAGES.

2

STORAGE PROTECTION (INSPECT CRANKCASE, CROSSHEADS AND CYLINDERS. RENEW RUST PREVENTIVE, WHERE NECESSARY.

3

FOUNDATION INCLUDING GROUTING CHECKED PER DWG.

4

FRAME SET ON RAILS OR SOLEPLATE AND LEVELED.

5

CROSS-HEADS SET ON SOLE PLATES AND LEVELED WITH CHOCKS.

6

CROSS-HEAD SLIDE CLEARANCE CHECKED.

7

DISTANCE PIECES INSTALLED.

8

CYLINDERS INSTALLED.

9

CYLINDER DISCHARGE RELIEF VALVES INSTALLED.

10

PISTON ROD RUNOUT INSTALLED.

11

ROD WIPER PACKING INSTALLED AND CLEARANCE CHECKED.

12

ROD INTERMEDIATE PACKING INSTALLED AND CLEARANCE CHECKED.

13

ROD PRESSURE PACKING INSTALLED AND CLEARANCE CHECKED.

14

PISTON RADIAL CLEARANCE CHECKED.

15

PISTON END CLEARANCE CHECKED.

16

PISTON RING/RIDER BAND SIDE/END CLEARANCE CHECKED.

17

PISTON/PISTON ROD ATTACHMENT VERIFIED CORRECT.

No

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 82 of 222

REMARKS

FORM YERP - K-403

SHT 2 of 3

YERP PRE-COMMISSIONING FORM POSITIVE DISPLACEMENT COMPRESSORS (RECIPROCATING) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Yes

18

CONNECTING ROD BEARING CLEARANCE CHECKED.

19

COLD CRANKSHAFT WEB DEFLECTIONS CHECKED.

20

AIR GAP IN MOTOR (PER MANUFACTURER'S SPEC.)

21

MOTOR BEARING(S) CLEARANCE CHECKED. YES

22

MOTOR SHAFT END PLAY.(FLEXIBLY COUPLED MOTOR)

23

MOTOR DOWELS INSTALLED.

24

NITROGEN PURGE SYSTEM CHECKED.

25

SUCTION LINES CLEANED.(PER SPEC.)

26

PULSATION DAMPERS INSTALLED, AFTER CLEANLINESS CHECKED.

27

CONE SUCTION STRAINERS INSTALLED.

28

PIPING PULSATION ORIFICES INSTALLED. (IF APPLICABLE)

29

CYLINDER, PIPE AND PULSATION DAMPER SUPPORTS CHECKED. 30 JACKING GEAR OPERATION CHECKED.

31

UNLOADING SYSTEM SEQUENCING FUNCTIONAL CHECKED.

32

UNLOADERS ADJUSTED.

33

MAIN BEARING CLEARANCES CHECKED.

34

CRANKSHAFT AXIAL BEARING CLEARANCE CHECKED.

35

VIBRATION SYSTEM INSTALLED AND FUNCTIONAL.

No

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 83 of 222

REMARKS

FORM YERP - K-403

SHT 3 of 3

YERP PRE-COMMISSIONING FORM POSITIVE DISPLACEMENT COMPRESSORS (RECIPROCATING) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes 36

LUBE SYSTEM CHECKS COMPLETED.

37

LUBE OIL SYSTEM FLUSHED .

38

FILTER CHANGED

39

CYLINDER LUBRICATOR SYSTEM FLUSHED. (NOTE :LUBE OIL USED)

40

COOLING WATER SYSTEM CHECKED.

41

FRAME AND CYLINDER LUBRICATOR OIL HEATERS CHECKED.

42

LOCAL INSTRUMENTATION CHECKED.

43

GROUNDING STRAP INSTALLED.

44

DIRECTION OF ROTATION OF MOTOR DRIVER OR SOLO TURBINE YES DRIVER CHECKED.

45

COUPLING AND GUARD INSTALLED.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 84 of 222

No

REMARKS

FORM YERP - K-501

SHT 1 of 5

YERP PRE-COMMISSIONING FORM STEAM TURBINES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

STEAM TURBINES 1.

RECEIVING INSPECTION CHECK FOR ANY EQUIPMENT DAMAGE DURING SHIPPING/TRANSIT VERIFY MATERIALS RECEIVED AGREE WITH PACKING SLIPS/ SHIPPING DOCUMENTS.

2.

REMOVE SHAFT MOVEMENT STOPS.

3.

INSPECT BEARINGS.

4.

APPLY NEW RUST PRESERVATIVE OIL TO EXPOSED MACHINED SURFACES AND ANY MACHINED METAL SURFACES INSIDE OF BEARING HOUSINGS, APPLY STP OIL TREATMENT TO BEARING JOURNALS.

5.

ROTATE SHAFT WEEKLY IF SHAFT MOVEMENT STOPS HAVE BEEN REMOVED.

6.

VERIFY FOUNDATION BOLTS ARE AT PROPER POSITION FOR BASEPLATE ANCHOR BOLT LOCATIONS.

7.

PREPARE FOUNDATION SURFACES FOR GROUTING.

8.

PREPARE BASEPLATE BOTTOM SURFACES WITH APPROPRIATE PRIMER FOR EPOXY GROUT.

9.

LIFT BASEPLATE ONTO FOUNDATION.

Yes

No

10. LEVEL BASEPLATE. 11. PREPARE GROUT FORMS. 12. GROUT BASEPLATE AND ALLOW SUFFICIENT TIME FOR CURE. 13. REMOVE LEVELING SCREWS AND TIGHTEN ANCHOR BOLTS TO SPECIFIED TORQUE.

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 85 of 222

REMARKS

FORM YERP - K-501

SHT 2 of 5

YERP PRE-COMMISSIONING FORM STEAM TURBINES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Yes

No

14. INSTALL COUPLING HUB AND VERIFY PULL-UP. 15. SET EQUIPMENT SHAFTS LEVEL BY ADJUSTING SHIMS AT SUPPORT FEET. 16. CHECK DISTANCE BETWEEN SHAFT ENDS WITH SHAFTS IN NORMAL RUNNING POSITIONS AND IF NECESSARY MOVE EQUIPMENT POSITIONS. 17. ALIGN EQUIPMENT SHAFTS TO BE COLLINEAR, I.E. PERFECT ALIGNMENT. 18. MAKE COLD OFFSET CORRECTIONS REQUIRED BY MANUFACTURERS TO ALLOW FOR EQUIPMENT THERMAL GROWTH TO A HOT RUNNING CONDITION WITH SHAFTS LEVEL. 19. CHECK COLD ALIGNMENT AND MAKE FINE ADJUSTMENTS. 20. TEMPORARY DOWEL EQUIPMENT FEET, SET CLEARANCE ON EQUIPMENT HOLD DOWN BOLTS AND SPACERS AS REQUIRED,SET CENTERLINE ALIGNMENT KEY CLEARANCES,SET RADIAL GROWTH KEY CLEARANCES AS REQUIRED. 21. INSTALL STEAM SUPPLY AND EXHAUST PIPING MAKING LAST FIELD WELD WELL AWAY FROM TURBINE. 22. BREAK MAIN PIPING FLANGES ONE AT A TIME YES WHILE MONITORING SHAFT ALIGNMENT FOR ANY POSITION CHANGES INDICATIVE OF PIPING STRAIN, VERIFY FLANGES ARE PARALLEL. DO NOT USE COME-A LONG'S TO PULL PIPING INTO POSITION FOR BOLT UP OR TO HOLD PIPING WHILE CHECKING FOR PIPING STRAIN.

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 86 of 222

REMARKS

FORM YERP - K-501

SHT 3 of 5

YERP PRE-COMMISSIONING FORM STEAM TURBINES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Yes

No

23. MAKEUP LUBE OIL INTERCONNECTING PIPING FOR OIL CONSOLE. 24. CLEAN INTERCONNECTING AND ANY OTHER FIELD FABRICATED OIL PIPING PER AES-G-116. 25. INSTALL FLUSHING SCREENS AT EACH EQUIPMENT OIL CONNECTION OR JUMPER EACH OIL CONNECTION TO DRAIN AND COVER AND PROTECT ANY OPEN CONNECTION FROM THE ENTRANCE OF FOREIGN MATERIAL. 26. FLUSH OIL SYSTEM. 27. FABRICATE ALL AUXILIARY PIPING FROM BASEPLATE CONNECTION TO OFF SKID LOCATION, BE CERTAIN AUXILIARY PIPING HAS ROOM FOR THERMAL EXPANSION AND WILL NOT CAUSE PIPING STRAIN WHEN HOT. 28. CONNECT ALL INSTRUMENTS AND ELECTRICAL SIGNALS FROM BASEPLATE JUNCTION BOXES TO REMOTE LOCATIONS. 29. CALIBRATE ALL INSTRUMENTS: - VIBRATION PROBES, PROXIMETERS, AND PANEL READOUT - RTD'S & T/C'S - TRIP & THROTTLE VALVE POSITION MICRO SWITCH - PRESSURE SWITCHES, DIFFERENTIAL PRESSURE SWITCHES, AND TEMPERATURE SWITCHES - SEALING AND LEAK OFF STEAM PRESSURE CONTROL LOOPS AND VALVES - BEARING AND CONTROL OIL PRESSURE CONTROL LOOPS AND VALVES - BEARING OIL TEMPERATURE CONTROL LOOP AND VALVE - LEVEL SWITCHES - I/P TRANSDUCER CALIBRATIONS 30. VERIFY ALL RESTRICTED ORIFICE'S ARE INSTALLED.

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 87 of 222

REMARKS

FORM YERP - K-501

SHT 4 of 5

YERP PRE-COMMISSIONING FORM STEAM TURBINES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Yes

No

31. SET TACHOMETER AND GOVERNOR MAGNETIC PICKUP CLEARANCES. 32. SET MECHANICAL OVERSPEED TRIP CLEARANCE. 33. VERIFY TOTAL SHAFT AXIAL FLOAT. 34. VERIFY RADIAL AND THRUST BEARING CLEARANCE ACCORDING TO INSTALLATION MANUAL. 35. CHECK GOVERNOR DRIVE GEAR BACKLASH,BEARING CLEARANCE, AND COUPLING. 36. CHECK TURNING GEAR, ADJUST ENGAGEMENT, VERIFY MOTOR DIRECTION, ADJUST DISENGAGEMENT MECHANISM, ADJUST INDICATING MICRO SWITCH 37. CHECK INSTRUMENT AND ELECTRICAL LOOPS BETWEEN LOCAL PANEL AND CONTROL ROOM. 38. VERIFY GOVERNOR REMOTE SPEED SET POINT SIGNAL LOOP. 39. REMOVE ALL LUBE SYSTEM JUMPERS AND SCREENS, RECONNECT ALL OIL PIPING FOR NORMAL SERVICE,DRAIN RESERVOIR AND CLEAN OUT ALL DEBRIS,REPLACE FILTER CARTRIDGES, REFILL OIL RESERVOIR WITH CLEAN OIL. 40. VERIFY LUBE SYSTEM PUMP STARTING/STOPPING AND TEST SYSTEM PRESSURE CONTROLS DURING UPSET, ADJUST ACCUMULATOR PRECHARGE PRESSURE TO MINIMIZE SYSTEM UPSETS. 41. VERIFY LUBE SYSTEM RUNDOWN TANK FUNCTIONALITY. 42. PROGRAM GOVERNOR IF REQUIRED, STATIC TEST

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 88 of 222

REMARKS

FORM YERP - K-501

SHT 5 of 5

YERP PRE-COMMISSIONING FORM STEAM TURBINES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Yes

No

43. CHECK GOVERNOR VALVES, PREPILOT (GOVERNOR ACTUATOR), PILOT, AND MAIN SERVOMOTORLINKAGE, VERIFY TOTAL TRAVEL OF VALVES AGREES WITH PREPILOT TRAVEL. 44. VERIFY GOVERNOR ACTUATOR/PREPILOT ACTION ON TRIP AND ACTION OF EMERGENCY SHUTDOWN CYLINDERFOR VALVE CLOSURE. 45. FABRICAT(D) BLOWDOWN PIPING WITH APPROPRIATE ANCHORS AND TARGETS, BLOWDOWN MAIN STEAM SUPPLY,EXHAUST STEAM HEADER, LEAKOFF AND SEALINGSTEAM HEADERS, GLAND EJECTOR STEAM SUPPLY; AIR REMOVAL SYSTEM STEAM SUPPLY. 46. TEST EXHAUST PRESSURE RELIEF VALVE AND INSTALL IN EXHAUST PIPING BETWEEN TURBINE AND FIRSTDOWNSTREAM BLOCK VALVE. 47. VERIFY OPERATION OF MAIN CONDENSER CONDENSATE LEVEL CONTROL LOOP WHEN APPLICABLE.

PUMPS AND

48. VERIFY OPERATION OF AIR REMOVAL SYSTEM EJECTORS, INTER/AFTER CONDENSER, DRAIN TRAPSOR DRAIN PIPING LOOPS, VENT SYSTEM; CHECK RELIEF VALVE OPERATION FOR EACH STAGE; VERIFY HOGGER IS ABLE TO ACHIEVE VACUUM IN REASONABLE TIME. 49. CONNECT ALL PIPING WHILE MONITORING FOR PIPING STRAINS. 50. VERIFY ALL ALARMS AND TRIPS (ESD) ARE FUNCTIONAL, TEST LOCAL PANEL AND CONTROL ROOM EMERGENCY STOP BUTTONS SIMULATED TRIP, VERIFY ACTION OF TRIP AND THROTTLEVALVE EXERCISING SYSTEM. 52

VERIFY OPERATION OF EXTRACTION/INDUCTION NON RETURN VALVE SHUTDOWN CYLINDER AND VALVE DISK CLOSURE SYSTEM, CHECK THAT DISK COUNTERWEIGHT IS FIXED IN POSITION AND ADJUSTED PROPERLY.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 89 of 222

REMARKS

FORM YERP - K-502

SHT 1 of 2

YERP PRE-COMMISSIONING FORM COMBUSTION GAS TURBINES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes

No

1

RECEIPT INSPECTION FOR DAMAGES AND MISSING PARTS.

2

COLD ALIGNMENT CHECKED AS PER REQUIRED.

3

BASEPLATE GROUTED.

4

JACKSCREWS AND TIGHTEN FOUNDATION BOLTS REMOVED.

5

COLD ALIGNMENT RECHECKED. YES

6

SPECIAL SPOOL PIECES INSTALLED. NO PIPING STRAIN ALLOWED.

7

FILTERS FOR FUEL INSTALLED.

8

PIPE SUPPORTS CHECKED.

9

COLD ALIGNMENT RECHECKED.

10

FLUSH LUBE AND SEAL OIL SYSTEMS. REFILL RESERVOIR WITH NEW OIL AND CHANGE FILTERS. OIL TYPE __________.

Yes 11

RESERVOIR OIL HEATER CHECKED.

12

INSTRUMENTATION LOOPS CHECKED.

13

GROUNDING STRAP INSTALLED.

15

STARTER MOTOR AND DIRECTION OF ROTATION CHECKED.

16

COUPLING AND GUARD INSTALLED.

No

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 90 of 222

REMARKS

FORM YERP - K-502

SHT 2 of 2

YERP PRE-COMMISSIONING FORM COMBUSTION GAS TURBINES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes 17

INLET PLENUM CHECKED AND VACUUM CLEANED.

18

CLEAN AIR HOUSE INSPECTED.

19

ALL SITE FABRICATED PIPE WORK PRESSURE TESTED. Y

20

ALL FABRICATED PIPE WORK CHEMICALLY CLEANED.

21

C.G.T. OIL PROTECTION UNIT SET UP.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 91 of 222

No

REMARKS

FORM YERP - K-511

SHT 1 of 2

YERP PRE-COMMISSIONING FORM DIESEL ENGINE EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Yes

1.

CERTIFICATION DOCUMENTATION RECEIVED.

2.

NAME PLATE DATA CHECKED.

3.

LOCATION IS PER DWG.

4.

RESILIENT MOUNTING FITTED.

5.

COUPLING FITTED.

6.

COUPLING BOLTS FITTED.

7.

COLD ALIGNMENT CHECKED.

8.

DOWELS FITTED.

9.

HOLDING DOWN BOLTS FITTED.

10.

SHIMS MOUNTED CORRECTLY.

11.

COUPLING GUARD FITTED.

12

AIR INLET FILTER INSTALLED AND ACCESSIBLE FOR MAINTENANCE.

13.

EXHAUST SILENCER FITTED, INCLUDING PERSONNEL PROTECTION.

14.

EXPANSION JOINTS CHECKED FOR FREE MOVEMENT.

15.

LUBRICATION CHECKED (OIL TYPE___________ AND LEVEL__________).

16.

NEW LUBE FILTER FITTED.

No

(To be continued) WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 92 of 222

REMARKS

FORM YERP - K-511

SHT 2 of 2

YERP PRE-COMMISSIONING FORM DIESEL ENGINE EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Yes

17.

COOLING RADIATOR ACCESS FOR FILL AND DRAIN.

18.

CRANKCASE VENT INSTALLED.

19.

OIL RELIEF VENT INSTALLED.

20.

INSTRUMENTS INSTALLED.

21.

THEORETICAL ROTATION SAME AS DRIVEN EQUIPMENT.

22.

STARTING SYSTEM CORRECT (BATTERY OR AIR SYSTEM READY FOR START).

23.

COOLING SYSTEM IS CHARGED WITH THE CORRECT COOLANT MIXTURE.

24.

THE GAUGE BOARD HAS BEEN CHECKED AGAINST P&ID's.

25.

THE ESD STATION AND/OR THE FUEL SHUTOFF VALVES AT THE UNIT ARE OPERATIONAL.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 93 of 222

No

REMARKS

FORM YERP - K-600

SHT 1 of 1

YERP PRE-COMMISSIONING FORM MIXERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Yes

No

1. LEVEL, PLUMB OR ANGLE OF MOUNTING FLANGE. 2. LEVEL, PLUMB OR ANGLE OF SHAFT. 3. STRAIGHTNESS OF SHAFT. 4. SHAFT TURNS FREELY BY HAND. 5. FINAL COLD ALIGNMENT TO MANUFACTURER'S TOLERANCE. 6. DRIVER CHECKED FOR CORRECT ROTATION (UNCOUPLED) 7. GEAR UNIT CHECKED PER GEAR UNIT CHECK LIST (WHEN APPLICABLE). 8. BEARING HOUSING FLUSHED AND RE LUBRICATED. LUBRICATOR FILLED AND OPERABLE.LUBRICANT ___________ 9. MOTOR BEARING LUBRICATION CHECKED. LUBRICANT_____. 10. MECHANICAL SEAL OR PACKING INSTALLED TYPE____. 11. BELT INSTALLED AND CORRECTLY TENSIONED. 12. BELT OR COUPLING GUARD IN PLACE AND SECURED. 13. DRIVER DOWELED (WHEN SPECIFIED). 14. MIXER BLADES CHECKED(CORRECT & SECURED TO THE SHAFT.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 94 of 222

REMARKS

FORM YERP - L-001

SHT 1 of 8

YERP PRE-COMMISSIONING FORM PIPING, GENERAL EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Piping Piping, General

Yes

1

Ensure that application of the proper color coding and text to indicate service, or other information, has been completed on all lines.

2

For process lines with operating temperatures above 66 0C, ensure that insulation, or other personnel protection, has been installed.

3

For lines that operate at high temperature, include the checkout items listed in Form #L002.

4

Ensure that all lines have been adequately cleaned, prior to hydro test or placing them in service.

5

Ensure that all valves and blind flanges are properly installed and aligned.

6

Ensure that all lines have been hydro tested in accordance with the construction drawings and Company standards.

7

Check that all vent and drain plugs have been refitted and welded in as specified.

8

Check that all reinforcing pad weep holes are filled with grease.

9

Check that all test blinds or temporary spool pieces etc. have been removed after hydro test.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 95 of 222

No

REMARKS

FORM YERP - L-001

SHT 2 of 8

YERP PRE-COMMISSIONING FORM PIPING, GENERAL EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Piping Arrangement

Yes

1

Check that the diameter, wall thickness and material of all piping and fittings is as required on the installation drawings.

2

Check that the piping layout and position is in accordance with the construction drawings. Adequate clearance between adjacent pipes should exist, to prevent them from coming in contact with each other during all operating conditions.

3

Spot check that tolerances on pipe fit-up, length, flange alignment are generally being met.

4

Check that adequate clearance is provided for bolt removal at all flanges joints.

5

Spot check that small piping is adequately supported and protected from physical abuse.

6

Check that piping alignment around pumps, turbines, compressors, and other machinery is within acceptable limits by disconnecting, measuring and recording offsets. If excessive misalignment occurs, the best remedy is to cut the pipe near the flange, in one or more locations, and reconstruct starting with the flange centered and bolted to the equipment.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 96 of 222

No

REMARKS

FORM YERP - L-001

SHT 3 of 8

YERP PRE-COMMISSIONING FORM PIPING, GENERAL EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Piping Arrangement (Continued) 7

Spot check adequacy of branch reinforcement for obvious omissions.

8

Check piping arrangements which appear to be inadequate for temperatures encountered during startup, steam-out, normal operations and upset conditions. The following piping should be included in the first spot checks:

Yes No

- Piping that operates with a temperature range greater than 260 0C - 4" diameter, and greater, piping attached to machinery operating above 93 0C - Piping attached to centrifugal and reciprocating compressors, turbines and air cooled heat exchangers. - Piping with diameters greater than 12" or longer than 45 mt 9

Ensure that all piping has high point vents and low point drains installed.

10 Check for piping dead legs. 11 Check for thermal relief valve. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 97 of 222

REMARKS

FORM YERP - L-001

SHT 4 of 8

YERP PRE-COMMISSIONING FORM PIPING, GENERAL EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Piping Connections Yes

1

Check that flange bolts are the correct material and size.

2

Spot check that threads on mating sections (thermo wells, pressure gauges, plugs, couplings, etc.) engage properly.

3

Following hydro test, ensure that screwed fittings are seal welded per design drawings and Company standards.

4

Spot check that flange bolts are fully engaged by extending completely through the nuts.

5

Check that proper bolt-tightening procedures are used, and that all bolts are tight prior to pressurization of system.

6

Spot check that gasket materials and type are in accordance with design drawings and Company specifications.

7

Check wall thickness and flange ratings at all specifications breaks.

8

Spot check size and ratings of flanges.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 98 of 222

No

REMARKS

FORM YERP - L-001

SHT 5 of 8

YERP PRE-COMMISSIONING FORM PIPING, GENERAL EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Piping Connections (Continued) 9

Yes No

Where flange jacking screws are required, check that they are installed.

10 Where pipes are joined together with different materials, check for proper installation of insulation flanges and gaskets. 11 Spot check that the flange installation tolerances are within the limits specified in YERP-SAES-L-050. 12 Check whether PZV's are properly supported and restrained.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 99 of 222

REMARKS

FORM YERP - L-001

SHT 6 of 8

YERP PRE-COMMISSIONING FORM PIPING, GENERAL EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Pipe Supports 1

Determine that the location and type of supports, anchors, and guides are in accordance with the design drawings, specifications, and Company standards. NOTE: be sure to check all overhung valves, or valves with heavy masses that are mounted several feet above the main line for adequate bracing and support.

2

Determine that field supplied brackets, gussets, and other welded attachments are compatible with equipment material and PWHT requirements.

3

Check that piping supports can accommodate thermal expansion without imposing excessive weight, force, or flexibility loads on pump, compressor, turbine, or vessel flanges. Stops and restraints are usually provided to force thermal expansion away from machinery. (Note: improperly located restraints can cause higher loads due to leverage effects.)

4

Check that supports and guides allow the pipe to move as designed. They should not be tack welded or attached to the pipe with fireproofing, as can easily happen.

WITNESS

CONTRACTOR

INSPECTION

Yes No

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 100 of 222

REMARKS

FORM YERP - L-001

SHT 7 of 8

YERP PRE-COMMISSIONING FORM PIPING, GENERAL EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Pipe Supports (Continued) Yes No 5

Check support spans.

6

Determine that essential pipe supports sustain the pipe loads, regardless of thermal movement.

7

Spot check that supports are adequate for hydrostatic test loads. (Note: temporary supports may need to be provided for the hydro test of vapor lines, and then removed after completion of the test.)

8

Determine that spring hangers and other special supports are properly set and that shipping pins have been removed after hydro test and flushing operations. The range of travel should be able to accommodate pipe thermal movement. (Note: Record final installed position prior to start-up.)

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 101 of 222

REMARKS

FORM YERP - L-001

SHT 8 of 8

YERP PRE-COMMISSIONING FORM PIPING, GENERAL EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Expansion Joints Yes No 1

Check that expansion joints, if used, have not been damaged during shipping or installation. If they are installed during the hydro test, ensure that they are adequate for the test pressure, and are completely drained of all test fluids afterwards.

2

Record installed position and offset of all expansion joints prior to start-up.

Pipe Welding Yes No 1

Review electrode selection for field alloy welds or dissimilar metal welds.

2

Review field weld hardness test procedures and results for field welds.

3

Ensure that radiography has been performed and documented in accordance with Saudi Aramco Specification.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 102 of 222

REMARKS

FORM YERP - L-002

SHT 1 of 2

YERP PRE-COMMISSIONING FORM PIPING, SPECIAL PURPOSE EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SPECIAL PURPOSE PIPING High Temperature, Low Temperature, Corrosive1 or Caustic Services, Includes Wet H2S. Yes

1

Include checklist items from General Piping. See FORM #L001 for details.

2

Review high temperature piping (particularly piping that operates at or above 4000C.), to ensure that correct material has been used. Pay particular attention to instances of material substitutions.

3

Determine that field supplied brackets, gussets, and other welded attachments are compatible with equipment material and PWHT requirements.

4

Review electrode selection for field alloy welds, and for dissimilar metal welds. Confirm that hardness tests of field welds have been satisfactorily conducted, with acceptable results.

5

Spot check qualifications of field welders.

6

For corrosive and caustic service, check that equipment welding, material and PWHT meets project construction drawings and Company standards.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 103 of 222

No

REMARKS

FORM YERP - L-002

SHT 2 of 2

YERP PRE-COMMISSIONING FORM PIPING, SPECIAL PURPOSE EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SPECIAL PURPOSE PIPING (Continued) Yes No 7

For piping in H2S, also check that hardness testing has been completed and all construction and Company requirements have been met.

8

For low temperature piping ( piping that operates at or below −18 0C.), check for selection and use of correct material. Also check piping, flanges, bolts, other system elements, and connected equipment to confirm that impact testing requirements have been met. After testing, confirm that there are adequate controls in place to ensure that impact tested pipe is installed in its proper location.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 104 of 222

REMARKS

FORM YERP - L-003

SHT 1 of 3

YERP PRE-COMMISSIONING FORM VALVES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

VALVES Yes

1

Check that access to all valves is adequate.

2

Ensure that there is adequate clearance around all valves to operate them. Especially note that the travel of risingstem valves is not obstructed.

3

Check that quarter-turn valves have been located so that they cannot be turned accidentally.

4

Check that all valves are marked with body and trim material designation, either on the body or identification plate.

5

Spot check that the pressure rating and body, trim, and stem packing material of all valves is in accordance with construction drawings and Company requirements.

6

Ensure that each valve supplied with a power operator (i.e., MOV, GOV, AOV, or HOV) is clearly marked with its valve number, in a suitable location.

7

Check that valves in sour service are marked with "NACE" on their identification plate.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 105 of 222

No

REMARKS

FORM YERP - L-003

SHT 2 of 3

YERP PRE-COMMISSIONING FORM VALVES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

VALVES (Continued) Yes

8

Ensure that all threaded body connections, except those that are frequently removed (such as vent and drain plugs) or those that contain moving parts (such as injection fittings, relief valve, etc.), are seal welded in accordance with company standards.

9

Check that bolts on bonnet valves have adequate thread engagement, and are securely tightened.

No

10 Following pressure testing, ensure that all valves are completely drained of test fluid and thoroughly dried. 11 Ensure that check valves are installed in the correct direction. 12 Ensure that check valves that were blocked open or had their closure member removed for system pressure testing, have all been returned to full operational status again. 13 Check that safety relief valves installed in double block and bleed valves are properly set, and that valve discharge does not constitute a fire or health hazard. 14 For insulated valves, check that all drain, vent, relief and sealant fittings extend to outside the insulation.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 106 of 222

REMARKS

FORM YERP - L-003

SHT 3 of 3

YERP PRE-COMMISSIONING FORM VALVES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

VALVES (Continued) Yes

No

15 Ensure that all drain, vent and by-pass valves installed on a parent valve have a minimum body rating equivalent to API 602, class 800. 16 Ensure that double block and bleed valves have drain and vent connections, as called for on the construction drawings. 17 Ensure that all drain and vent connections are fitted with valves, as required, and piped to a safe location. 18 Ensure that buried double block and bleed valves have their drain and vent connections and sealant injection fittings extended above ground, and adequately supported. 19 For fixed-position valves (i.e., locked-open or lockedclosed), ensure that their position is in accordance with the construction drawings and that it is securely restrained from being changed. 20 Ensure that all valves are in their correct operational position, as shown on construction drawings, or other specific start-up documentation.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 107 of 222

REMARKS

FORM YERP - L-004

SHT 1 of 2

YERP PRE-COMMISSIONING FORM PLUMBING EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

PLUMBING & NON-ELECTRIC UTILITIES 1

A job file should be started, properly identified job name and number. All data memorandums, approved deviations, project instructions, check list, design criteria, etc. related to the job, should be filed in the job folder.

2

Location of the building or job site, including property lines, legal descriptions and address be approved by legal authorities, and ready before commissioning.

3

Contractor must submit an affidavit of compliance of all Saudi Aramco Engineering Standard, codes and ordinances, including any amendments and deviations.

4

Engineering drawings, calculations, construction specifications and detail layout of all equipment requiring pluming connections must be complete and ready.

5

All equipment installed in accordance with Manufacturer's instructions and approved design documents.

6

All equipment are clean and all debris and foreign matters are removed.

WITNESS

CONTRACTOR

INSPECTION

Yes

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 108 of 222

No

REMARKS

FORM YERP - L-004

SHT 2 of 2

YERP PRE-COMMISSIONING FORM PLUMBING EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: COMMISSIONING DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

PLUMBING & NON-ELECTRIC UTILITIES (Continued) Yes No 7

All safety systems and devices are in place and functional.

8

Safety clearance from the authorities having jurisdictions is required.

9

System testing and balancing is completed in accordance with design documentation, and the reports are approved by the concerned legal authorities

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 109 of 222

REMARKS

Form YERP - P-000 Issue Date:

Sheet 1 of 3

YERP PRE-COMMISSIONING FORM TESTING GUIDE LINES TESTING GUIDE LINES INTRODUCTION YERP-SAGI-GI 2.710, Mechanical Completion and Performance Acceptance of Facilities, defines mechanical completion as being achieved when a facility defined in the approved project scope, construction documentation, drawings and specification and material requisitions has been installed and Precommissioned and is available for commissioning and start-up. The following Precommissioning forms are based on industry standards (IEEE, ANSI, NEMA, UL, and IEC) as well as the basic requirements of several major equipment manufacturers. The Precommissioning forms describe the minimum requirements to ensure that the electrical equipment addressed will perform reliably and in accordance with industry standards.

Electrical Tests Reference Information Insulation Resistance Test Equipment Voltage Rating 100 - 250 251 - 600 601 - 5000 Over 5000

Recommended Test Voltage 500 1000 2500 5000

Measure the insulation resistance of electrical equipment phase to phase and phase to ground for one (1) minute. Test voltage and minimum acceptable values. Values of insulation resistance less than manufacturer's minimum or rated voltage + 1kV in megohms should be investigated. Over potential or high potential tests should not proceed unless insulation resistance levels are equal to or above the listed minimum values. High potential Test Direct Current A DC high potential test (controlled over voltage test) is one in which the increase of applied direct voltage is controlled. The measured current is continuously observed for abnormalities with the intention of stopping the test before breakdown occurs. • A polarization index test should be performed on large rotating equipment by applying an initial voltage step of about one-third of the recommended maximum voltage from the above table and maintain the voltage at a constant level for General Confidential Page 110 of 222

Form YERP - P-000 Issue Date:

Sheet 2 of 3

YERP PRE-COMMISSIONING FORM TESTING GUIDE LINES 10 minutes. The polarization index is calculated by dividing the one-minute resistance value by the ten-minute resistance value. The index value should be 2 or greater values less than this should be investigated. After the initial ten-minute test, the D. C. test voltage should be increased in 10 uniform steps, each step being one-minute in duration, up to the maximum recommended D. C. value.

• In high potential testing of cable, the D. C. test voltage is applied in a minimum of four steps (each step approximately equal to the rated rms voltage of the cable) of one (1) minute duration each, except for the final test voltage which shall be maintained for fifteen (15) minutes. Alternating Current Perform AC high potential test phase to ground and phase to phase. Potential application shall be for one (1) minute. Test voltage shall be in accordance with the manufacturer's recommendations. When the manufacturer's recommended values are not available the values in the values listed in the following table can be used but should be considered the maximum voltage to be applied. Increase the voltage at the rate of 1 kV per second until the maximum recommended test voltage is reached. MAXIMUM HIGH-POTENTIAL TEST VOLTAGES Equipment Rated KV

2.5 5.0 15 35

Test Voltage KV A. C. 6.0 14.0 27.0 60.0

D. C. 10.0 24.0 46.0 102.0

Recommended maximum values of field test voltages are determined by the following: A. C. test volts = 0.75 X (2 X equipment maximum voltage + 1kV). The D. C. test voltage is 1.4 X [0.75 X (2 X equipment maximum voltage + 1kV)] The AC high potential test results are evaluated on a go, no-go basis by slowly raising the test voltage to the required value of final test voltage and maintaining for one (1) minute, Low Voltage Cables Perform DC High Potential Testing on critical cables after installation. Test each cable with respect to ground and adjacent cables. Test value shall be reviewed with the proponent. The DC test voltage shall not exceed 1.4 X (2 X rated voltage + 1000). Switchgear and Metal Enclosed Bus General Confidential Page 111 of 222

Form YERP - P-000 Issue Date:

Sheet 3 of 3

YERP PRE-COMMISSIONING FORM TESTING GUIDE LINES Perform AC high potential tests on each bus section, phase to phase and phase to ground for one (1) minute. Maximum test voltage shall be as listed above. Contact Resistance. Measure and record the contact resistance of each phase line to load, of bus, breakers and contactors. For equipment 600 amps and higher, values of resistance in excess of 200 microohms and deviations of more than +/- 20% must be investigated. The contact resistance is measured with the circuit breaker/contactor in the closed position. The contactor must be closed and latched not held closed by hand pressure. Thermo-vision Inspection Electrical equipment safely accessible and visible such as outdoor bus connections, isolation switches, terminations on circuit breakers and transformers should be checked with Thermovision for temperature abnormalities. New Insulating Oil Test Requirements The following table lists the Dielectric Fluid Specifications for new insulating Oil as Received from the supplier. Note that the values listed are described as minimum or maximum recommended values. The oil must be tested before oil filling of the equipment begins and, depending on the results of the test and the operating voltage of the equipment, may require processing before it is put into the equipment. See P-051 for additional information. Dielectric Fluid Specification (New Insulating Oil as Received Before Transformer Filling) TEST Dielectric strength D-877, kV, minimum Power Factor, D924, 25 deg., % maximum. 100 deg., % maximum Interfacial Tension D 971, mN/M minimum Color, D-1500 ASTM Units maximum Visual Examination D1524 Acid Number D974, mg KOH/g, maximum Water Content, D 1533, ppm, maximum

LIMIT VALUE 30 0.05 0.30 40 0.5 Bright and Clear 0.03 35

Bolt Torgue The manufacturer’s recommended bolt torgue values should be used.

General Confidential Page 112 of 222

TEST RESULTS

Form YERP - P-001 Issue Date:

Sheet 1 of 4

YERP PRE-COMMISSIONING FORM BATTERY SYSTEM

Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

FIELD INSTALLATION CHECK LIST FOR BATTERIES AND BATTERY CHARGERS VISUAL Yes

No

1. Battery racks and battery cells installed dry per YERP SAES standards and IEEE-484. 2. Battery room is in compliance with all Saudi Aramco and applicable standards and design. 3. Battery tools and all required safety equipment is provided and readily available. 4. Sufficient quantity of battery electrolyte available to fill all battery cells. 5. Batteries and racks installed and checked for proper mechanical installation, including mechanical connections and grounding. 6. Battery charger checked for proper installation, wiring is complete and properly connected and torqued to manufacturer's specifications. 7. Accessory equipment such as hydrometer, thermometer, special wrenches and spare electrolyte accounted for. 8. Batteries, battery racks and charger cleaned. Terminals and inter-connectors covered with protective coating (grease). 9. Safety eyewash is available and operating properly and protective clothing provided. 10. Charger operates in accordance with manufacturer's recommendations. Current output, charging voltage (float and boost) and operation of control components checked. 11. Batteries filled with electrolyte to proper level and charged in accordance with manufacturer's recommendations. 12. Lead acid batteries checked with hydrometer for correct specific gravity. NOTE: Batteries shall not be filled until the battery charger is ready for operation. Initial charge is critical and requires full procedure and documentation. When batteries are placed in service while work is still being performed around them, protection should be provided. Metal objects laid or dropped on them could cause a short or an explosion. Tarpaulin, plastic sheet or similar material should not be used, because batteries in service require ventilation. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 113 of 222

REMARKS

Form YERP - P-001 Issue Date:

Sheet 1 of 4

YERP PRE-COMMISSIONING FORM BATTERY SYSTEM

Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date: Electrical Tests

User Reference: Equipment Description: Plant No. / Location:

Serial No:

Yes

No

1. Check out and verify proper operation of battery charger with vendor-supplied instructions. 2. Set and verify battery Low, High, and Ground Alarm functions. 3. Verify circuit breaker shunt trip function (battery isolator). 4. Verify all volt/amp meters are calibrated and correct. 5. Test and record battery cell inter-cell connector resistance per IEEE-484. 6. Initial battery filling and charging to be performed as recommended by the manufacturer. 7. Document initial charging of battery on the attached form. 8. Verify that the battery has had an equalizing charge completed more than 3 days and less than 7 days prior to the start of the test. 9. Read and record the specific gravity and float voltage of each cell just prior to the test. 10. Read and record the temperature of the battery electrolyte for an average temperature (suggested every sixth cell). 11. Read and record the battery terminal float voltage. 12. Disconnect the charger from the battery. 13. Take adequate precautions (such as isolating the battery to be tested from other batteries and critical loads) to ensure that a failure will not jeopardize other systems or equipment. 14. Provide the following test equipment, Load bank with variac to provide constant current discharge sized to battery capacity, D. C. ammeter, D. C. voltmeter, and timing clock. 15. Discharge the battery at its rated current for its rated time or until the battery reaches 1.75 volts per cell minimum cell voltage. (Maintain the battery discharge current throughout the test.) 16. Record cell voltage (to include inter-cell connector voltage drop), and battery voltage (voltage at battery terminals) at the intervals specified the following Test Data. Readings should be taken with the load applied.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 114 of 222

REMARKS

Form YERP - P-001 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 1 of 4

BATTERY SYSTEM Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

Test data Initial battery readings Yes

No

10 minutes 30 minutes 1 hour 2 hours 4 hours 8 hours

On conclusion of the test review the results to determine acceptance of the battery. Weak cells that cannot pass the test shall be replaced. BATTERY CHARGING RECORD PLANT SUBSTATION CHARGER MANUFACTURE SERIAL NO ACCOUNTING NO VOLTAGE CHARGING CURRENT FLOAT BOOST BATTERY TERMINAL Volts .D.C.

WITNESS

CONTRACTOR

B.I. NO BATTERY SERIAL NO TYPE

TEST TIME INTERVAL

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 115 of 222

REMARKS

Form YERP - P-001 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 1 of 4

BATTERY SYSTEM Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

Provide the following data for each cell tested CELL NO. TEMP. DEG F/C AT TIME OF TEST SPECIFIC GRAVITY VOLTAGE TIME CELL NO. TEMP. DEG F/C AT TIME OF TEST SPECIFIC GRAVITY VOLTAGE TIME CELL NO. TEMP. DEG F/C AT TIME OF TEST SPECIFIC GRAVITY VOLTAGE TIME CELL NO. TEMP. DEG F/C AT TIME OF TEST SPECIFIC GRAVITY VOLTAGE TIME CELL NO. TEMP. DEG F/C AT TIME OF TEST SPECIFIC GRAVITY VOLTAGE TIME

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 116 of 222

REMARKS

Form No. P- 002 Issue Date:

Sheet 1 of 2

YERP PRE-COMMISSIONING FORM

UNINTERRUPTIBLE POWER SUPPLY SYSTEM Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

FIELD INSTALLATION CHECK LIST VISUAL AND MECHANICAL INSPECTION Yes

No

Yes

No

1. All components have been checked against one-line diagram and have been signed off by all agencies. 2. Safety equipment in place and serviceable per SAES standards. 3. All power and control wiring tested, marked, color coded and properly phased (AC/DC circuits). 4. HVAC checked out, operational and on. 5. All cabinets, enclosures and rooms clean. 6. Replacement power and control fuses, control boards available for both inverter and rectifier. 7. Normal power is available for start-up and commissioning. 8. All vendor (manufacturer) manuals and factory test documents are available. 9. Batteries tested per Manufacturers instructions or P-001. ELECTRICAL INSPECTION 1. UPS start-up procedure approved and available. 2. Verify inverter check-out by vendor Representative. 3. Witness and verify output wave forms are correct. 4. Witness and verify output voltage is set and correct. 5. Witness and verify all alarm functions. 6. Witness and verify static switch function. 7. Verify operation of manual bypass switch. 8. Verify all voltmeters/ammeters are calibrated and correct. 9. Insure Operations has sufficient operator training on UPS system. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 117 of 222

REMARKS

Form No. P- 002 Issue Date:

Sheet 1 of 2

YERP PRE-COMMISSIONING FORM

UNINTERRUPTIBLE POWER SUPPLY SYSTEM Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No: Electrical

Function Testing Equipment Required Digital Voltmeter (DVM) Multi-amp tester 1. UPS on line and unloaded.

Spectrum Analyzer to 10 Khz Dual trace Oscilloscope, (ungrounded plug) Yes

No

Yes

No

a. Connect Oscilloscope and DVM to UPS output, compare reading to the installed output meter. b. Take Polaroid photo or draw wave form and compare wave form of output to vendor illustration. c. Make adjustments per vendor instruction manual if required. 2. UPS on line and loaded.

a. Repeat steps a, b, and c in (1) above. b. Switch "off" Primary feed, monitor Oscilloscope for switching transients, voltage level, and wave from purity. Make adjustments per static switch vendor instruction manual if required. c. Reinitialize UPS inverter per vendor manual, check synchronization indicator and time to synchronize d. Perform vendor under voltage and over-current switching checks, using multi-amp test set. Monitor the UPS output with DVM and Oscilloscope. Adjust if necessary. e. Connect Spectrum Analyzer to UPS output. Set to 7th harmonic and log vertical scale. Calculate the amplitude of each harmonic. If harmonic amplitudes exceed 4% corrections must be made. f.

Remove Primary and Alternate power supplies and monitor UPS output. Repower the system with Primary and Alternate power supplies when the output amplitude starts decreasing.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 118 of 222

REMARKS

FORM YERP - P-003 ISSUE DATE:

SHT 1 of 2

YERP PRE-COMMISSIONING FORM LOW VOLTAGE CABLES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.: Field Installation Tests

Visual and Mechanical Inspection Yes

No

1. Inspect cables for physical damage and proper connection in accordance with single line diagram. 2. Cable connections shall be torque tested to manufacturer's recommended values or values recommended in P-000. 3. Verify proper terminals and crimping die are used on cable and that crimping procedure is proper. 4. Verify cable color coding or phasing. Electrical Tests Yes

No

1. Perform Megger Test on each cable with respect to ground and adjacent cables. For cables 250 volt and less use 500 volt megger; for cables 250 volt to 600 volt use 1000 volt megger; for cables above 600 volts and less than 1200 volts use 2500 volt megger. 2. Perform D. C. High Potential Test on critical cables after installation. Test each cable with respect to ground and adjacent cables. Test value shall be reviewed with proponent. The DC test voltage shall not exceed 1.4 X (2 X rated voltage + 1000). 3. Perform continuity test to insure proper cable connection.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 119 of 222

REMARKS

FORM YERP - P-003 ISSUE DATE:

SHT 2 of 2

YERP PRE-COMMISSIONING FORM LOW VOLTAGE CABLES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Field Test Data CABLE IDENT.

CABLE SIZE

CABLE TYPE

CABLE VOLTAGE RATING

CONNECTION

MEGGER RESULTS MEGOHMS

DC HIPOT RESULTS MICROAMPS

A-B, to C & GRD B-A, to C & GRD C-A, to B & GRD A-B, to C & GRD B-A, to C & GRD C-A, to B & GRD A-B, to C & GRD B-A, to C & GRD C-A, to B & GRD A-B, to C & GRD B-A, to C & GRD C-A, to B & GRD A-B, to C & GRD B-A, to C & GRD C-A, to B & GRD A-B, to C & GRD B-A, to C & GRD C-A, to B & GRD A-B, to C & GRD B-A, to C & GRD C-A, to B & GRD

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 120 of 222

REMARKS

FORM YERP - P-004 ISSUE DATE:

SHT 1 of 5

YERP-COMMISSIONING FORM MEDIUM VOLTAGE CABLES (5KV-15KV-35KV) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Field Installation Checklist Visual and Mechanical Inspection Yes

No

1. Check cable reel assignments and cutting schedules. 2. Check cable pulling schedule for direction of pull and method of pulling in conduit for medium voltage cable. 3. Check arrows on cable reels for direction for pulling off reel. 4. Check for correct cable test voltages , minimum pulling temperature and type of pulling compound. 5. Inspect cables for jacket damage. 6. The conductors are identified as per specification and drawings. 7. Cable ends sealed after cutting. 8. All water and debris must be removed from underground conduit before pulling cable. 9. Cable supports and spacing as per specifications and drawings. 10. Cable supports are adjacent to terminal fittings. 11. Conduits clean, stub-ups protected, open ends plugged, damage during construction repaired. 12. Field bend radius correct per specification and codes. Bends free of deformities. 13. Expansion joints as shown on drawings.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 121 of 222

REMARKS

FORM YERP - P-004 ISSUE DATE:

SHT 2 of 5

YERP-COMMISSIONING FORM MEDIUM VOLTAGE CABLES (5KV-15KV-35KV) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Visual and Mechanical Inspection (Continued) Yes

No

Yes

No

14. Spacing between instrument and power conduit and /or cables as per specifications. 15. Spacing from hot pipes and from hot surfaces maintained. 16. Proper fittings are installed with threads fully engaged, proper sealing compound is used, there are no wrench cuts, conduit ends have bushings and covers installed. 17. Seals and drains are installed per drawings. 18. PVC or PVC coated conduits are installed where specified on drawings. 19. Metal junction boxes leveled and supported per drawings with proper hubs, locknuts and bushings installed. 20. Seals poured.

Electrical test

1. Cables on reels must be isolated and meggered before unreeling. 2. Prepare installed cables for test by ensuring the circuit is de-energized , remove any temporary grounds and disconnect cable form equipment. If equipment cannot be disconnected, a reduced voltage should be used for the test. 3. Insulate cable cores from ground.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 122 of 222

REMARKS

FORM YERP - P-004 ISSUE DATE:

SHT 3 of 5

YERP-COMMISSIONING FORM MEDIUM VOLTAGE CABLES (5KV-15KV-35KV) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Electrical test (Continued) Yes

No

4. Erect safety barriers and post safety man at cable end remote from the test equipment. 5. Check the insulation resistance of the cable using a megger tester. The test voltage should be 5000 volts for 5000 volt and above cables. Measure the insulation resistance of each core and any metallic armor or sheath grounded at one end only. 6. Each cable shall be high potential tested as follows: each core to ground, with the shield, other cores and any metallic armor or sheath grounded at one end only. 7. For commissioning new cables, the final D. C. test voltage is the 80% test voltage in the tables below. 8. For commissioning new cables that are spliced to old cables, and for testing old cables, the final D. C. test voltage shall be determined by the proponent of the cables, and should not exceed the 65% test voltage in the tables below( 40% of these values is recommended after 5 years ). A voltage equal to 1.7 X the operating voltage is recommended for extremely old cables with low megger readings. 9. The D. C. high voltage shall be applied in a minimum of four steps (each step approximately equal to the rated rms voltage of the cable) of one (1) minute duration each except for the final test voltage which shall be maintained for fifteen (15) minutes. 10. On completion of tests the cable shall be left with all cores and shields grounded for one hour to allow the residual charge to dissipate.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 123 of 222

REMARKS

FORM YERP - P-004 ISSUE DATE:

SHT 4 of 5

YERP-COMMISSIONING FORM MEDIUM VOLTAGE CABLES (5KV-15KV-35KV) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

RECOMMENDED TEST VALUES XLPE OR EPR CABLES MANUFACTURED TO AEIC CS5 OR CS6 AND YERP-15SAMSS-502 RATED VOLTAGE 5 KV 15 KV 35 KV

INSULATION THICK. 115 MILS 220 MILS 345 MILS

80% TEST VOLTAGE 36 KV 64 KV 100 KV

65% TEST VOLTAGE 29 KV 52 KV 81 KV

40% TEST VOLTAGE 18 KV 32 KV 50 KV

XLPE OR EPR CABLES MANUFACTURED TO IEC-502 AND YERP-15-SAMSS502 RATED VOLTAGE 6/10 KV 12/20 KV

INSULATION THICK. 3.4 MM 5.5 MM

80% TEST VOLTAGE 36 KV DC 64 KV DC

65% TEST VOLTAGE 29 KV DC 52 KV DC

40% TEST VOLTAGE 18.5 KV 32 KV

NOTES: 80% and 65% refer to percentages of the factory test voltages specified in AEIC CS5 and CS6. AEIC CS5 and CS6 permit testing at the 65% test voltage "at anytime during the period of the guarantee. Maximum test values for cables older than 5 years are listed in the 40% column. CABLE TEST RECORD B.I. or W.O. NO. PLANT

WITNESS

CABLE NO. SIZE & TYPE

CONTRACTOR

INSPECTION

VOLTAGE RATING

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 124 of 222

REMARKS

FORM YERP - P-004 ISSUE DATE:

SHT 5 of 5

YERP-COMMISSIONING FORM MEDIUM VOLTAGE CABLES (5KV-15KV-35KV) EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

E HIGH POTENTIAL TEST (D. C.) TEST VOLTAGEand HOLD TIME Step 1 Step 2 Step 3 Step 4

PHASE 1 TO GND CURRENT MICRO AMPS

PHASE 2 TO GND CURRENT MICRO AMPS

PHASE 3 TO GND CURRENT MICRO AMPS

KV KV KV KV 15 SEC 30 SEC 45 SEC 1 MIN 2 MIN 3 MIN 4 MIN 5 MIN 6 MIN 7 MIN 8 MIN 9 MIN 10 MIN 11 MIN 12 MIN 13 MIN 14 MIN 15 MIN

WITNESS

RESISTANCE (MEGGER)

TEST

PHASE PHASE 1 TO 2 PHASE 2 TO 3 PHASE 3 TO 1 PHASE 1 TO G PHASE 2 TO G PHASE 3 TO G

MEGOHMS

TEST VOLTAGE (MEGGER) 500/1000/2500/5VOLT GENERAL DATA: TEMP.DEG.F/C % REL. HUM. INSUL THICK. CABLE TEST VOLTAGE

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 125 of 222

REMARKS

FORM YERP - P-006 ISSUE DATE:

SHT 1 of 4

YERP PRE-COMMISSIONING FORM MOLDED CASE CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION TESTS VISUAL AND MECHANICAL INSPECTION Yes

No

1. Check circuit breaker for proper mounting, conductor size and feeder designation. 2. Inspect case for cracks or other defects. 3. Check tightness of connection with torque wrench in accordance with manufacturer's recommendations or requirements of P-000. 4. Operate circuit breaker to insure smooth operation.

ELECTRICAL TESTS Yes

No

1. Measure contact resistance. For circuit breakers 600 amps and larger values in excess of 200 micro-ohms or deviation of more than twenty percent (20%) shall be investigated. For circuit breakers less than 600 amps values may be higher and deviation should not any greater than 50%. 2. Perform time-current characteristic test by passing three hundred percent (300%) rated current through each pole separately. Record results on field data test sheet. All trip times shall fall within values listed in the attached table, or the circuit breaker shall be replaced. 3. Check instantaneous (magnetic) pickup current by run-up of pulse method. Clearing time and pickup current levels should be within manufacturer's published values. 4. Insulation resistance should be determined pole to pole , line to load across pole the pole, and pole to ground. Test voltage shall be 1000 volts DC Insulation resistance shall not be less than fifty (50) megohms. 5. Check auxiliary devices that may be supplied i.e., shunt trip, ground fault, under voltage.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 126 of 222

REMARKS

FORM YERP - P-006 ISSUE DATE:

SHT 2 of 4

YERP PRE-COMMISSIONING FORM MOLDED CASE CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

RECOMMENDED OVER-CURRENT TRIP TEST VALUES (at 300 Percent of Rated Continuous Current of Breaker) Rated Voltage, Volts

240 240 600 600 240 600 600 600 600 600

Range of Rated Continuous Current, Amperes 15-45 50-100 15-45 50-100 110-225 110-225 250-450 500-600 700-1200 1400-2500

Thermal Minimum Tripping Time seconds

Thermal Maximum Tripping Time seconds

3 5 5 5 10 10 25 25 25 25

50 70 80 150 200 200 250 250 450 600

Magnetic trip or MCP Trip (instantaneous) Set and tested at 3X -----------

Note: MCP’s only have magnetic pickup. Therefore, only the instantaneous trip is checked. Few circuit breakers rated less that 600 amps have thermal and magnetic trip units. Usually they contain only thermal trip units. Therefore, only the long delay or thermal trip time is checked.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 127 of 222

REMARKS

FORM YERP - P-006 ISSUE DATE:

SHT 3 of 4

YERP PRE-COMMISSIONING FORM MOLDED CASE CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MOLDED CASE CIRCUIT BREAKER TEST DATA BREAKER TYPE BREAKER MANUFACTURE VOLTAGE RATING FRAME RATING AMPS TRIP UNIT RATING AMPS

TRIP UNIT SETTING

PUBLISHED TRIP TIME MINIMUM

PUBLISHED TRIP TIME MAXIMUM

PHASE A

PHASE B

PHASE C

MIN SEC Micro-ohms

MIN SEC Micro-ohms

MIN SEC Micro-ohms

Meg-ohms

Meg-ohms

Meg-ohms

INSTANTANEOUS TRIP SETTING

INVERSE TIME SETTING INSTANTANEOUS PICK-UP

NORMAL PICK-UP TRIP TIME AT 300% CURRENT CONTACT RESISTANCE INSULATION RESISTANCE OTHER

WITNESS

---------------------------------------

CONTRACTOR

---------------------------------------

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 128 of 222

REMARKS

FORM YERP - P-006 ISSUE DATE:

SHT 4 of 4

YERP PRE-COMMISSIONING FORM MOLDED CASE CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

INSULATED CASE CIRCUIT BREAKER TEST DATA BREAKER TYPE BREAKER MANUFACTURE VOLTAGE RATING FRAME RATING AMPS TRIP UNIT RATING AMPS Trip Unit Functions

Trip Unit Settings

Manufacturers Published Trip Current & Times Min Max

Long Delay Current Pickup Long Delay Time Short Delay Current Pickup Short Delay Time Instantaneous Current Pickup Ground Fault Current Pickup Ground Fault Time Delay Contact Resistance Insulation Resistance

WITNESS

CONTRACTOR

INSPECTION

Test Result Trip Times Phase A

Phase B

Phase C

At 3 X PU

At 3 X PU

At 3 X PU

At 6 X PU

At 6 X PU

At 6 X PU

Micro-ohms

Micro-ohms

Micro-ohms

Meg-ohms

Meg-ohms

Meg-ohms

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 129 of 222

REMARKS

FORM YERP - P-007 ISSUE DATE:

SHT 1 of 4

YERP PRE-COMMISSIONING FORM LOW VOLTAGE POWER CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION TESTS VISUAL INSPECTION Yes

No

1. Remove from the cell and inspect for physical damage and nameplate compliance with single line diagram. 2. Remove arc boxes and inspect for damage or missing segments. 3. Check arc splitter grids and ceramics. 4. Inspect the breaker for defects or damage especially to insulation. 5. Check primary bushings, porcelains and finger clusters. 6. Check contact make and break. 7. Check for adequate electrical clearances. 8. Check mounting frame and all castings for cracks. MECHANICAL INSPECTION Yes

No

1. Check contact alignment over travel and contact pressure. 2. Check shunts and all brazed or soldered connections. 3. Check the operating mechanism for friction. 4. Check push rods, and the latch mechanism.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 130 of 222

REMARKS

FORM YERP - P-007 ISSUE DATE:

SHT 2 of 4

YERP PRE-COMMISSIONING FORM LOW VOLTAGE POWER CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MECHANICAL INSPECTION (CONTINUED) Yes

No

5. Check the trip mechanism latch load and sneak settings. 6. Check manual close, latch and trip operation. 7. Check trip free operation. 8. Check auxiliary switches for sequence, good contact alignment, and check operating linkage. 9. Check terminal blocks and connections. 10. Check the mechanical condition of auxiliary devices, shock absorbers, bumpers, position indicators, latch checking switches , key lock out, etc. 11. Check alignment of secondary contacts of circuit breaker to cell. 12. Check for correct operation of shutters. 13. Check lock out mechanism operation of circuit breaker when installed in the cell. 14. Check that primary contacts are properly lubricated. 15. Use a calibrated torque wrench to check all bolted connections. Torque value's per vendor's specifications or P-000 recommendations. 16. Withdraw the circuit breaker from the connected to the test and fully withdrawn position verifying ease of movement between positions and that the breaker is trip free between the connected and test positions, and between the tested and withdrawn positions.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 131 of 222

REMARKS

FORM YERP - P-007 ISSUE DATE:

SHT 3 of 4

YERP PRE-COMMISSIONING FORM LOW VOLTAGE POWER CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ELECTRICAL INSPECTION (CONTINUED) Yes

No

1. Measure and record contact resistance. Investigate any values more than 200 micro-ohms or deviations more than 20%. Values must be consistent with those specified by the manufacturer. 2. Perform an insulation resistance test with 1000 volt megger for one (1) minute from pole to pole and from each pole to ground and across open contacts of each phase. 3. Check minimum pickup current by primary current injection. 4. Check long time delay by primary current injection at three times (3X) current pick up. 5. Short time pickup and time delay shall be determined by primary injection. Primary current injection at (6X) current pickup. 6. Instantaneous pickup current shall be determined by primary injection. 7. Trip unit reset characteristics shall be verified. 8. Adjustments shall be made for final settings in accordance with protection specifications. 9. Auxiliary protective devices, such as ground fault or under voltage relays, shall be activated to insure operation of shunt trip devices. Nominal Torque Values for Machine Screws Screw size Tightening Torque #8-32 10-15 inch pounds #10-32 15-20 inch pounds

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 132 of 222

REMARKS

FORM YERP - P-007 ISSUE DATE:

SHT 4 of 4

YERP PRE-COMMISSIONING FORM LOW VOLTAGE POWER CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CIRCUIT BREAKER TEST DATA BREAKER TYPE BREAKER MANUFACTURE VOLTAGE RATING FRAME RATING AMPS TRIP UNIT RATING AMPS Trip Unit Functions

Trip Unit Settings

Manufacturers Published Trip Current & Times Min Max

Test Result Trip Times Phase A

Phase B

Phase C

Long Delay Current Pickup Long Delay Time Short Delay Current Pickup

At 3 X PU

At 3 X PU

At 3 X PU

Short Delay Time Instantaneous Current Pickup

At 6 X PU

At 6 X PU

At 6 X PU

Micro-ohms

Micro-ohms

Micro-ohms

Meg-ohms

Meg-ohms

Meg-ohms

Ground Fault Current Pickup Ground Fault Time Delay Contact Resistance Insulation Resistance

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 133 of 222

REMARKS

FORM YERP - P-008 ISSUE DATE:

SHT 1 of 4

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION TESTS VISUAL INSPECTION Yes

No

Yes

No

1. Inspect for physical damage and nameplate compliance with single line diagram. 2. Inspect the breaker for defects or damage especially to inter phase insulation. 3. Inspect primary bushings and porcelains for cracks and damage. 4. Inspect primary disconnects, finger clusters etc. for damage and proper installation. 5. Check contact wear indicator on vacuum circuit breakers. 6. Check for adequate electrical and mechanical clearances. 7. Check mounting frame, all castings, vacuum bottles for cracks. 8. Check MOC and TOC switches in the cell if so equipped. 9. Check for proper lubrication of the mechanism, and that mechanism parts are rust free. MECHANICAL INSPECTION/TESTS 1. Check shunts and all brazed or soldered connections. 2. Check the operating mechanism for friction. 3. Check the push rods, and the latching mechanism. 4. Check the trip mechanism, latch load, and sneak settings if applicable.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 134 of 222

REMARKS

FORM YERP - P-008 ISSUE DATE:

SHT 2 of 4

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MECHANICAL INSPECTION/TESTS ( CONTINUED) Yes

No

5. Check manual close, latch and trip operation. 6. Check trip free operation. 7. Check auxiliary switches for proper operating sequence, good contact alignment, and proper adjustment of the operating linkage. 8. Check terminal blocks and connections. 9. Check the mechanical condition of auxiliary devices, shock absorbers, bumpers, position indicators, latch checking switches , key lock out, etc. 10. Check alignment of secondary contacts of circuit breaker to cell. 11. Verify correct operation of the shutter mechanism. 12. Verify primary contacts are properly aligned and lubricated. 13. Check lock out mechanism operation of circuit breaker when installed in the cell. 14. Rack breaker into the cell checking for proper operation in the test, transient, and connected positions. Verify trip-free operation in transient position. Verify breaker moves in and out of position with ease. 15. Measure and record moving contact travel. (wear indicator) 16. Check and record opening and closing speed (timing) of the circuit breaker. 17. Verify that all circuit breakers of the same rating are interchangeable by racking each circuit breaker into each cell of the designated size.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 135 of 222

REMARKS

FORM YERP - P-008 ISSUE DATE:

SHT 3 of 4

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Nominal Machine Screw Torque Screw size Tightening Torque #8-32 10-15 inch pounds #10-32 15-20 inch pounds ELECTRICAL INSPECTION/TESTS Yes

No

1. Measure and record contact resistance of each pole with the test probes connected to the main current carrying bus .at the back of the breaker. Do not connect to the disconnecting stabs or finger clusters for measurements. Values must be consistent with manufacturers recommendations. 2. Perform an insulation resistance test with a 1000 megger for one (1) minute from pole to pole and from each pole to ground and across open contacts of each phase. 3. Check for vacuum integrity by testing with high potential AC from line to load with the breaker in the open position. The test voltage shall be determined by the voltage rating of the interrupter. The minimum test voltage for 5 KV interrupters is 14.3 KV AC and 27 KV AC for interrupters above 5 kV, up to and including 15 KV. 4. Perform AC high potential tests line to load, phase to phase, line to ground and load to ground. 5. Megger test circuit breaker control wiring per recommended values in P-000. 6. Close and open the breaker using the control switch, trip the breaker from each protective relay and trip device. 7. Auxiliary protective devices, such as ground fault or under voltage relays, shall be activated to insure operation of shunt trip devices.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 136 of 222

REMARKS

FORM YERP - P-008 ISSUE DATE:

SHT 4 of 4

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE CIRCUIT BREAKERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

TEST DATA Electrical Mechanical tests INSULATION RESISTANCE

Manufacturers recommended test values

PHASE A

PHASE B

PHASE C

Breaker closed Phase to ground Megohms

Breaker closed Phase to ground

Breaker closed Phase to ground

CONTACT RESISTANCE

Breaker closed Micro-ohms

Megohms Breaker closed Micro-ohms

Megohms Breaker closed Micro-ohms

INTERRUPTER AC HIGHPOT

PASS FAIL

PASS FAIL

PASS FAIL

TIMING TESTS 100% Voltage CLOSE 100% Voltage TRIP 50% Voltage CLOSE 50% Voltage TRIP High Potential Test Breaker Closed A Phase to gnd B Phase to gnd C Phase to gnd Phase A to B Phase A to C Phase B to C

WITNESS

Current

CONTRACTOR

Breaker Open Phase A line to load Phase B line to load Phase C line to load

INSPECTION

Current

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 137 of 222

REMARKS

FORM YERP - P-009 ISSUE DATE:

SHT 1 of 5

YERP PRE-COMMISSIONING FORM DEHYDRATOR-DESALTER TRANSFORMER EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION TESTS TRANSFORMER NAMEPLATE DATA MANUFACTURER PRIMARY VOLTAGE TERTIARY VOLTAGE

KVA RATING SECONDARY VOLTAGE METERING C.T. RATIO

TRANSFORMER CONNECTION DIAGRAM Typical values used as reference only: H3

23KV

H2

16.5KV

X1

H1

Internally grounded

PRI

4.16 KV

Y2 X2 110V

Y1

Internally grounded

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 138 of 222

REMARKS

FORM YERP - P-009 ISSUE DATE:

SHT 2 of 5

YERP PRE-COMMISSIONING FORM DEHYDRATOR-DESALTER TRANSFORMER EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

VISUAL INSPECTION Yes

No

1. Verify nameplate data of transformer is in accordance with job specifications. 2. Inspect for oil leaks and any external damage to the transformer and bushings. Take oil sample and send to YERP lab for testing and evaluation. 3. Verify the correct bushings are used and terminations are correct. 4. Verify the exterior painting/coating is per YERP specifications. 5. Perform visual inspection on feed through bushing and precipator grid and connections. 6. Make sure the man-way covers are open, place the off/on push button at the vessel in the off position and lock and tag out the circuit breaker. 7. Make sure there is no combustible gas or vapor mixture inside the vessels. 8. Make sure no one is inside the vessel; post a guard or assign a safety man outside the vessel.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 139 of 222

REMARKS

FORM YERP - P-009 ISSUE DATE:

SHT 3 of 5

YERP PRE-COMMISSIONING FORM DEHYDRATOR-DESALTER TRANSFORMER EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ELECTRICAL TESTS Yes

No

1. Measure and record the resistance of each winding primary, secondary, and tertiary. 2. Measure and record the insulation resistance of each winding primary, secondary, and tertiary.

3. Using primary voltage injection measure and record the induced voltage in the secondary. tertiary and the phase relationship between the secondary and the primary and secondary. 4. Perform and record insulation resistance, ratio and magnetization tests on each C.T. 5. Megger, then perform high potential test on grid to test for dielectric breakdown. 6. Megger and high potential test feed through bushings 7. Perform impedance test on secondary and tertiary by energizing the primary with the secondary and tertiary each separately short circuited.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 140 of 222

REMARKS

FORM YERP - P-009 ISSUE DATE:

SHT 4 of 5

YERP PRE-COMMISSIONING FORM DEHYDRATOR-DESALTER TRANSFORMER EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Test Data Metering C.T.'s Insulation Resistance test Ratio

Transformer T1 Volts = Megohms = primary secondary

Transformer T2 Volts = Megohms = primary secondary

Transformer T3 Volts = Megohms = primary secondary

Ammeter reading C.T. Magnetization curve: Voltage Current ma T1 Current ma T2 Current ma T3 Impedance or Short Circuit Test Transformer T1 Transformer T2

Transformer T3

Voltage Current

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 141 of 222

REMARKS

FORM YERP - P-009 ISSUE DATE:

SHT 5 of 5

YERP PRE-COMMISSIONING FORM DEHYDRATOR-DESALTER TRANSFORMER EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM YERP - P-009 ISSUE DATE: (04/09)

SHT 5 of 5

Test Data Transformer serial no. primary = secondary = tertiary =

Transformer serial no. primary = secondary = tertiary = meg-ohms =

Transformer serial no. primary = secondary = tertiary = meg-ohms =

meg-ohms =

meg-ohms =

meg-ohms =

meg-ohms =

meg-ohms =

meg-ohms =

X1 to X2= 20.8 volts

X1 to X2= 20.8 volts

X1 to X2= 20.8 volts

volts =

volts =

volts =

H2 to ground

volts =

volts =

volts =

Y2 to ground

volts =

volts =

volts =

H3 to X2

volts =

volts =

volts =

H3 to Y2

volts =

volts =

volts =

Y2 to X2

volts =

volts =

volts =

Winding resistance

5 KV megger X1 &X2 to ground Megger primary to secondary Megger primary to tertiary apply 20.8 volts between X1 and X2 with X1 at gnd measure voltage on H3 to ground

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 142 of 222

REMARKS

Form YERP - P-010 Issue Date:

Sheet 1 of 1

YERP PRE-COMMISSIONING FORM PROTECTIVE RELAYS

Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

FIELD INSTALLATION CHECK LIST VISUAL AND MECHANICAL INSPECTION Yes

No

1. Relays shall be inspected for physical damage and compliance with specifications. 2. Insure up to date metering and relaying one-line diagrams are available. 3. Insure up to date relay and control AC and DC schematics, both vendor and Saudi Aramco, are available. 4. Insure up to date relay and control panel layout diagrams with relay locations are available 5. Insure vendor operating /maintenance instruction manuals and PC software are available 6. Check relay nameplate against drawings and specifications. 7. Verify relay wiring is installed, connected, as per the drawings. ELECTRICAL TESTS Yes

No

1. Verify that only one grounding point per CT circuit is available. Disconnect the grounding point and conduct resistance measurement between the CT circuit and ground. This shall read open circuit. 2. Follow all commissioning procedures as per the relay instruction manual. 3. Apply or download the relay settings in accordance with the settings sheets or the software setting file provided by the relay engineer. 4. Perform pickup test on the functions activated by the relay settings and make sure that the relay trips the correct output contacts and activate the corresponding indicating LED as per the relay settings. 5. Perform timing tests on the functions activated by the relay settings and make sure that the relay trips the correct output contacts and activate the corresponding indicating LED as per the relay settings. 6. Perform stability test for all differential and directional protection schemes via primary injection for in zone and out zone faults to verify correct CT and VT connections. 7. Activate the digital inputs and verify their correct functions 8. Exercise the flex logic equations if applied by activating the required inputs and verify the outputs. 9. If utilized verify analogue output from relay to DCS and calibrate if necessary. 10. If utilized verify communication connectivity to DCS computer system. Manufacturers completed relay field test form to be attached to this test report. WITNESS Signature & Date

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

General Confidential Page 143 of 222

REMARKS

Form YERP -. P- 012 Issue Date:

Sheet 1 of 1

YERP PRE-COMMISSIONING FORM METERING

Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

FIELD INSTALLATION CHECK LIST VISUAL AND MECHANICAL Yes

No

Yes

No

1. Examine all devices for broken parts, indication of shipping damage and wire connection tightness. 2. Verify meter connections in accordance with single line meter and relay diagram. 3. Verify meter scale is compatible with Current Transformer, Voltage Transformer and/or transducer ratings. ELECTRICAL TESTS

1. Calibrate all meters and transducers in accordance with manufacturer's instructions. Verify meter deflection and accuracy at 0, 1/4, 1/2, 3/4, and 100% full scale values. Provide calibration data. 2. Verify all meter multipliers. 3. Verify instrument transformer secondary wiring terminal to terminal.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 144 of 222

REMARKS

FORM YERP - P-013 ISSUE DATE:

SHT 1 of 3

YERP PRE-COMMISSIONING FORM LIGHTING EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION CHECK LIST VISUAL AND MECHANICAL INSPECTION Yes

No

1. Lighting system is installed in conformance to the drawings and specifications. 2. Check that light fixtures are installed in such a fashion that they can be easily and safely relamped. 3. Check that smallest wire is not less than AWG # 12. 4. Lighting fixtures in Class 1 Division II areas are provided with suitable guards for mechanical protection. 5. All indoors fluorescent lighting fixtures shall be provided with integral thermally protected ballast’s and have appropriate temperature rating for any gasses present under abnormal conditions. 6. Expansion joints shall be installed for long runs exposed to high temperature variations. 7. Lighting fixtures suitable for the area and application. 8. Lighting levels are per Saudi Aramco standard YERP-SAES-P-123. 9. Lighting fixtures are clean.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 145 of 222

REMARKS

FORM YERP - P-013 ISSUE DATE:

SHT 2 of 3

LIGHTING YERP PRE-COMMISSIONING FORM EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ILLUMINATION LEVEL RECORD 1. Maintained illumination levels for YERP installations shall conform with YERP-SAES-P-123 Chapter 5 Tables. The height and plane at which the illumination level shall be measured is also listed 2. When illumination level checks are made on new installations allowance should be made for lamp lumen depreciation and dirt depreciation, dependent upon the amount of time that the installation has been in service. A rough rule of thumb is the initial lighting level on a completely new installation should be 50- to 40% above the installation level listed in YERP-SAES-P-123. If however, the installation has been in service or installed for some time before the illumination levels are checked this figure will be considerably lower 3. During the illumination level check a note should be made of black spots (which could cause a safety hazard) and any additional task lighting that may be required. 4. Illumination levels should be taken with a "weston" light meter calibrated in foot candles or similar.

DATA LOCATION IN PLANT

HEIGHT

WITNESS

INSPECTION

CONTRACTOR

PLANE V/H

ACTUAL

YERP-SAES-P-123 RECOMMENDATION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 146 of 222

REMARKS

FORM YERP - P-013 ISSUE DATE:

SHT 3 of 3

YERP PRE-COMMISSIONING FORM LIGHTING EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

LOCATION IN PLANT

WITNESS

CONTRACTOR

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

DATA HEIGHT

PLANE V/H

INSPECTION

ACTUAL

YERP-SAES-P-123 RECOMMENDATION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 147 of 222

REMARKS

FORM YERP - P-014 ISSUE DATE:

SHT 1 of 2

YERP PRE-COMMISSIONING FORM METAL ENCLOSED BUS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION CHECK LIST VISUAL AND MECHANICAL Yes

No

1. Inspect the entire assembly, including auxiliary equipment, for any apparent damage or missing parts. 2. Remove shipping blocks, braces and parts. 3. Inspect for proper bracing, suspension alignment and enclosure ground. 4. Torque the connections as per manufacturer recommendations or per values in YERP-P-000. 5. The bus shall be inspected for physical damage and proper connection in accordance with the single line diagram. 6. Check the location and type of drain plug. 7. Check current rating (cross section) of flexible connectors used at transformer and or switchgear terminations of metal-enclosed bus.

ELECTRICAL TESTS Yes

No

1. Measure insulation resistance of each bus run phase to phase and phase to ground for one (1) minute. Test voltage and minimum acceptable values in accordance with YERP-P-000 2. Perform A. C. high potential tests on each bus run phase to phase and phase to ground. Potential application shall be in accordance with manufacturer’s instructions or as specified in YERP-P-000. 3. Perform phase rotation and phase cross voltage tests on each bus tie section energized by separate sources. Performed tests when bus sections are powered by permanent source. 4. Measure bus joint resistance.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 148 of 222

REMARKS

FORM YERP - P-014 ISSUE DATE:

SHT 2 of 2

YERP PRE-COMMISSIONING FORM METAL ENCLOSED BUS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ELECTRICAL TESTS (CONTINUED) Yes

No

5. Connect space heaters and check operability ( when applicable ). 6. Verify operation of ammeter and control power switch.

Field Test Record Bus phase A Phase to Ground

Megger Test Results

High Potential Test Results

B Phase to Ground C Phase to Ground A Phase to B Phase B Phase to C Phase C Phase to A Phase

Number of bus joints. Joint no.

WITNESS

Resistance

CONTRACTOR

. Joint no.

INSPECTION

Resistance

Joint no.

Resistance

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 149 of 222

REMARKS

FORM YERP - P-016 ISSUE DATE:

SHT 1 of 5

YERP PRE-COMMISSIONING FORM LOW VOLTAGE MOTOR CONTROL CENTERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION TESTS VISUAL INSPECTION Yes

No

Yes

No

1. Inspect primary and auxiliary equipment for physical damage, missing parts and proper assembly.. 2. Compare equipment nameplate data with design plans or starter schedule. 3. Check nameplate voltage and current ratings for breaker, contactors and fuses. 4. Compare overload heaters with motor full load current for proper size. 5. Verify component sizing versus load. 6. Check stab finger to bus tightness on draw-out cubicles. 7. Protective grounding is correctly installed and connected to main ground. 8. Remove shipping and blocking material from Motor Control Center/Switchboard. 9. Check draw-out cubicles and wireways for cleanliness.

MECHANICAL INSPECTION 1. Torque all accessible bolted connections. 2. Check insulators and the insulation system.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 150 of 222

REMARKS

FORM YERP - P-016 ISSUE DATE:

SHT 2 of 5

YERP PRE-COMMISSIONING FORM LOW VOLTAGE MOTOR CONTROL CENTERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MECHANICAL INSPECTION (CONTINUED) Yes

No

Yes

No

3. Inspect main bus and bus taps to switches and potential transformers. 4. Manually operate breakers and contactors. Check for freedom of movement of all moving parts. 5. Check for main contact pressure alignment and full contact area on contactors. 6. Check operation of door mechanical C.B. trip and reset linkage.

ELECTRICAL INSPECTION

1. Check wiring point to point and megger. 2. Check wire markers, and that terminal block connections are secure and properly identified. 3. Megger test main bus phase to ground and phase to phase. 4. Measure bus resistance and joint contact resistance. 5. Inspect all protective relays and devices for correct operation and settings. 6. Check to see that space heaters are connected and operable. 7. Megger horizontal and vertical bus and outgoing feeder circuits.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 151 of 222

REMARKS

FORM YERP - P-016 ISSUE DATE:

SHT 3 of 5

YERP PRE-COMMISSIONING FORM LOW VOLTAGE MOTOR CONTROL CENTERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ELECTRICAL INSPECTION (CONTINUED) Yes

No

8. Check calibration of voltmeters and ammeters. 9. Check rating of all fuses. 10. Verify under voltage relay trip/alarm function. 11. Verify ground fault protection for 22 KW (30 HP) motors and larger. 12. Set motor circuit protectors. 13. Check effectiveness of tripping devices. 14. Megger and high potential test contactors and circuit breakers phase to phase and phase to ground. 15. Measure the contact resistance of each power circuit breaker. 16. Measure the contact resistance of each contactor. 17. Check the Phase Rotation of the voltage on the main bus.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 152 of 222

REMARKS

FORM YERP - P-016 ISSUE DATE:

SHT 4 of 5

YERP PRE-COMMISSIONING FORM LOW VOLTAGE MOTOR CONTROL CENTERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

NAMEPLATE INFORMATION Equipment Identification/manufacturer Serial number/model number Rated Voltage Rated current Interrupting Rating ( TESTS PERFORMED IN ACCORDANCE WITH VALUES RECOMMENDED BY VENDOR OR VALUES IN P-000)

MOTOR CONTROL CENTER RECORDED TEST DATA ITEMS TESTED

MEGGER TEST INSULATION RESISTANCE IN MEG-OHMS

Phase A to Ground Phase B to Ground Phase C to Ground Phase A to Phase B Phase B to Phase C Phase C to Phase A MOTOR CONTROL CENTER CONTACT RESISTANCE FEEDER NO.

WITNESS

BREAKER NO. OR CONTACTOR NO.

CONTRACTOR

A PHASE LINE TO LOAD MICRO-OHMS

INSPECTION

B PHASE LINE TO LOAD MICRO-OHMS

C PHASE LINE TO LOAD MICRO-OHMS

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 153 of 222

REMARKS

FORM YERP - P-016 ISSUE DATE:

SHT 5 of 5

YERP PRE-COMMISSIONING FORM LOW VOLTAGE MOTOR CONTROL CENTERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MOTOR CONTROL CENTER DATA SHEET Voltage Rating: DEVICE NO.

WITNESS

HORSE POWER

FULL LOAD CURRENT

CONTRACTOR

MOTOR OVERLOAD RELAY TYPE

INSPECTION

RATING

FEEDER NO.

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 154 of 222

FEEDER INSULATION RESISTANCE

REMARKS

FORM YERP - P-017 ISSUE DATE:

SHT 1 of 6

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE MOTOR CONTROLGEAR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION TESTS VISUAL INSPECTION Yes

No

Yes

No

1. Inspect primary and auxiliary equipment for physical damage, missing parts and proper assembly. 2. Compare equipment nameplate data with one-line, design plans and starter schedule. 3. Check nameplate voltage and current ratings for breakers, contactors and primary and secondary fuses. 4. Compare overload protection with motor full load current for proper sizing. 5. Verify component sizing versus load. 6. Check contactor finger stab alignment and tightness on draw- out designs. 7. Protective grounding is correctly installed and connected to main ground. 8. Remove shipping and blocking material from starter and vertical sections. 9. Check draw-out cubicles and wireways for cleanliness. MECHANICAL INSPECTION 1. Torque all accessible bolted connections. 2. Check insulators and the insulation system. 3. Inspect main bus and bus taps to switches and potential transformers.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 155 of 222

REMARKS

FORM YERP - P-017 ISSUE DATE:

SHT 2 of 6

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE MOTOR CONTROLGEAR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MECHANICAL INSPECTION (CONTINUED) Yes

No

4. Manually operate breakers and contactors. Check for freedom of movement of all moving parts. 5. Check for main contact pressure alignment and full contact area on contactors. 6. Check operation of door mechanical interlocking linkage.

ELECTRICAL INSPECTION Yes

No

1. Check wiring point to point and megger. 2. Check wire markers, and that terminal block connections are secure and properly identified. 3. Megger and high potential test main bus phase to ground and phase to phase. 4. Measure bus resistance and joint contact resistance. 5. Inspect all protective relays and devices for correct operation and settings. 6. Check to see that space heaters are connected and operable. 7. Megger outgoing circuits. 8. Check PT and CT rating, ratio, and insulation resistance, test in accordance with procedures.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 156 of 222

REMARKS

FORM YERP - P-017 ISSUE DATE:

SHT 3 of 6

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE MOTOR CONTROLGEAR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ELECTRICAL INSPECTION (CONTINUED) Yes

No

9. Check calibration of voltmeters and ammeters. 10. Check rating of all fuses. 11. Verify relay trip/alarm functions. 12. Verify motor ground fault protection. 13. Check effectiveness of tripping devices. 14. Megger contactors and circuit breakers phase to phase and phase to ground. 15. Measure the contact resistance of each contactor and circuit breaker. 16. Check the Phase Rotation of the voltage on the main bus.

Equipment Identification/manufacturer Serial number/model number Rated Voltage Rated current Interrupting Rating

NAMEPLATE INFORMATION ( TEST PERFORMED IN ACCORDANCE WITH VALUES RECOMMENDED BY VENDOR OR VALUES IN P-000)

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 157 of 222

REMARKS

FORM YERP - P-017 ISSUE DATE:

SHT 4 of 6

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE MOTOR CONTROLGEAR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MOTOR CONTROL CENTER RECORDED TEST DATA ITEMS TESTED

MEGGER TEST INSULATION RESISTANCE IN MEG-OHMS

DC HI-POT LEAKAGE CURRENT IN MICRO-AMPS

Phase A to Ground Phase B to Ground Phase C to Ground Phase A to Phase B Phase B to Phase C Phase C to Phase A

MOTOR CONTROL CENTER CONTACT RESISTANCE FEEDER NO.

WITNESS

BREAKER NO. OR CONTACTOR NO.

CONTRACTOR

A PHASE LINE TO LOAD MICRO-OHMS

INSPECTION

B PHASE LINE TO LOAD MICRO-OHMS

C PHASE LINE TO LOAD MICRO-OHMS

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 158 of 222

REMARKS

FORM YERP - P-017 ISSUE DATE:

SHT 5 of 6

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE MOTOR CONTROLGEAR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MOTOR CONTROL CENTER CONTACT RESISTANCE FEEDER NO.

WITNESS

BREAKER NO. OR CONTACTOR NO.

CONTRACTOR

A PHASE LINE TO LOAD MICRO-OHMS

INSPECTION

B PHASE LINE TO LOAD MICRO-OHMS

C PHASE LINE TO LOAD MICRO-OHMS

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 159 of 222

REMARKS

FORM YERP - P-017 ISSUE DATE:

SHT 6 of 6

YERP PRE-COMMISSIONING FORM MEDIUM VOLTAGE MOTOR CONTROLGEAR EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MOTOR CONTROL CENTER DATA SHEET Voltage Rating: DEVICE NO.

WITNESS

HORSE POWER

FULL LOAD CURRENT

CONTRACTOR

MOTOR PROTECTION RELAY TYPE

INSPECTION

RATING

FEEDER NO.

FEEDER INSULATION RESISTANCE

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 160 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 1 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

NEMA FRAME MOTORS VISUAL INSPECTION Yes

No

1. Check for damaged and missing parts. 2. Verify that motor is suitable for the area classification. 3. Screens, guards and other personnel protective devices are in place.

4. Verify all foreign material is removed and inspect for cleanliness. 5. Verify motor is compatible with project documents. 6. Verify motors above 190 KW (250 H.P). use identical bearings.

MECHANICAL INSPECTION Yes

No

1. Verify the motor mounting bolts are securely fastened. 2. Verify the motor has been properly aligned to the driven equipment. 3. Verify the motor is properly lubricated. 4. Verify the motor shaft rotates freely.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 161 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 2 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ELECTRICAL INSPECTION Yes

No

1. Measure winding resistance phase to phase. 2. Perform megger test on windings checking the insulation resistance and determining the polarization index. 3. Verify the motor is correctly connected for the available supply voltage. 4. Motor leads are properly terminated, insulated and the motor is properly grounded. 5. Motor heaters are installed and operating properly. 6. Bump motor and check for proper rotation. (Use proper precaution for vertical motors). 7. Measure and record initial bearing temperatures and the ambient temperature and record temperatures during testing. 8. Energize the motor and record no-load starting current and running current in each phase and the voltage phase to phase. 9. Measure and record motor speed. 10. Measure and record vibration on drive end and non-drive end bearings. 11. Run motor for 4 hours and record the temperature rise , vibration levels, voltage and current.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 162 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 3 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

Manufacturer Serial No. Purchasers order no. Voltage

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

NEMA FRAME MOTOR NAMEPLATE DATA Mfg.'s., location Mfg.'s., order number Year of manufacture Current

Frequency Rating :H.P./K.W. Insulation class NEMA design Speed D.E. bearing no. Temperature rise

Phases Service factor Weight Frame Full load efficiency N.D.E. bearing no.

Motor winding resistance Phase 1 to 2 ohms

Phase 2 to 3

Insulation Resistance @ 500 volts. 1 Min megs

2 Min megs

3 Min megs

ohms

Phase 3 to 1

ohms

Ambient Temperature =. 4. Min megs

5 Min megs

6 Min megs

7 Min megs

. 8 Min megs

9 Min megs

10 Min megs

0 10 20 30 40 50 60 70 80 90 100 Winding Temp.,C Kt 0.03 0.06 0.12 0.25 0.5 1 2 4 8 16 32 o o Correct for 50 C. Rc= Kt x Rt; Rc = insul. resis. corrected to 50 C, Rt = insul. resis. at temp "t", Kt = insul. resis. temperature coefficient at temperature "t". Polarization Index = Insulation resistance at 10 min/1 min= megohms / megohms = Rotation facing D.E. shaft: Clockwise

. Counter Clockwise

110 64

.

NEMA FRAME MOTOR NO LOAD TEST DATA

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 163 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 4 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE: TIME - MINUTES PHASE CURRENT

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

START

0

30

60

90

120

150

180

210

240

30

60

90

120

150

180

210

240

A B C PHASE VOLTAGE A-B B-C C-A % VOLTAGE UNBALANCE D. E. BRNG VIBRATION N. D. E. BRNG VIBRATION D. E. BRNG TEMP. N. D. E. BRNG TEMP AMBIENT TEMP WINDING TEMP NEMA FRAME MOTOR LOAD TEST DATA (For reference: tests done after commissioning) TIME - MINUTES PHASE CURRENT

START

0

A B C PHASE VOLTAGE A-B B-C C-A % VOLTAGE UNBALANCE D. E. BRNG VIBRATION N. D. E. BRNG VIBRATION D. E. BRNG TEMP. N. D. E. BRNG TEMP AMBIENT TEMP WINDING TEMP

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 164 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 5 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS FIELD INSTALLATION TESTS VISUAL INSPECTION Yes

No

1. Check for damaged and missing parts. 2. Verify that shipping braces and packing has been removed. 3. Ensure that all foreign material is removed and inspect for cleanliness. 4. Verify that the motor nameplate ratings are consistent with project specifications, voltage , and frequency of the power source. 5. Screens, guards and other personnel protective devices are in place. 6. Verify protective grounding is correctly installed and connected to the main ground system. 7. Verify the motor classification is consistent with area classification. MECHANICAL INSPECTION Yes

No

1. Verify the motor is properly installed and aligned to the load. 2. Hold down bolts and dowels are in place and secured and ground is properly attached to the motor frame and ground grid connection. 3. Verify that drive end and non-drive end bearings are installed properly. 4. Verify internal/external lubrication system is installed and functions properly.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 165 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 6 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MECHANICAL INSPECTION (CONTINUED)

5. Measure and record the air gap on motors >5000 horsepower.

Y e s

No

6. Verify the cooling system is properly installed. 7. Vibration monitors are correct type and are installed properly. 8. Synchronous motors: measure and record exciter air gap.

ELECTRICAL TESTS Yes

No

1. Check and record the stator winding resistance. 2. Synchronous motors: check and record motor rotating field resistance. 3. Synchronous motors: check and record exciter rotor and stator resistance. 4. Synchronous motors: check and record the resistance of the diodes on the rotating rectifier assembly. 5. Measure and record the heater resistance. 6. Measure and record the RTD resistance( use digital high impedance meter). 7. Measure and record the drive end and non-drive end bearing insulation resistance. 8. Prepare for the megger and high potential test by disconnecting and grounding the motor heaters, RTD's, CT's, ( and rotating field leads on synchronous motors).

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 166 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 7 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ELECTRICAL TESTS (CONTINUED) Yes

No

9. Perform Polarization Index test with megger by measuring the insulation resistance and recording the test data. Correct readings to 50 degree C. Calculate P.I. and record value, expect minimum value no less than 2.0. Stop test and report findings to supervisor if lower value is found. 10. If the insulation resistance and PI test results are satisfactory, perform high potential test recording test data and monitoring the leakage current. Stop the test if leakage current starts increasing rapidly and report to supervisor. 11. Ground the motor leads after the test and discharge motor windings. 12. Synchronous motors: disconnect the motor rotating field winding leads and measure the insulation resistance of the motor rotating field. 13. Synchronous motors: measure and record the impedance of the motor rotating field if applicable by applying 110 or 220 volts alternating current to the field winding leads and measuring the current. 14. Synchronous motors: megger exciter field and rotor winding with the diode ring disconnected and record the insulation resistance. 15. Verify motor is ready to energize for no-load test run, motor shaft rotates freely, coupling is secured, motor controller and auxiliary circuits have been tested and are working properly, motor heater circuits are working properly. Bump motor and check for proper rotation. Correct if necessary. 16. Start motor for 4 hour test run, verify lubrication and ventilation systems are functioning correctly. Measure and record the following values: voltage phase to phase, current in each phase, power factor, speed, winging temperature, drive end and non-drive end bearing vibration and temperature, and ambient temperature. Stop the test if any abnormalities occur that would damage the motor. 17. Synchronous motors: in addition to the quantities mentioned above, record the exciter field current and motor field current if possible, % speed when excitation is applied, and the reactive power, KVAR. 18. If the no-load test is satisfactory perform on-load test measuring items previously measured and record the test results.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 167 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 8 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

NAMEPLATE DATA INDUCTION MOTOR Manufacturer

Mfg.'s., location

Serial No. Purchasers order no. Voltage Frequency Rating :H.P./K.W. Insulation class Maximum Ambient Temp. Max Winding Temperature Rise Bearing Manufacturer Bearing Number

Mfg.'s., order number Year of manufacture Current Phases Total Weight Rotor Weight Speed Full load efficiency Class, Group, Division Max Bearing Temp. Rise

FORM WOUND INDUCTION MOTOR DATA SHEET Insulation Resistance Test: Megger Voltage 500/1000/2500/5000:

. Ambient Temperature. MEGOHMS

INS. RESIS. PHASE 1 TO GND PHASE 2 TO GND PHASE 3 TO GND PHASE 1 TO 2 PHASE 2 TO 3 PHASE 3 TO 1 (USE 500 VOLT D. E. BEARING N. D. E. BEARING

WITNESS

1 MINUTE

POLARIZATION INDEX 10 MINUTES

MEGGER FOR

CONTRACTOR

.

THIS TEST)

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 168 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 9 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM WOUND INDUCTION MOTOR DATA SHEET( CONTINUED) Winding Temp., o C 0 10 20 30 40 50 60 70 80 90 100 Kt 0.03 0.06 0.12 0.25 0.5 1 2 4 8 16 32 o o Correct for 50 C. Rc= Kt x Rt; Rc = insul. resis. corrected to 50 C, Rt = insul. resis. at temp "t", Kt = insul. resis. temperature coefficient at temperature "t". Polarization Index = Insulation resistance at 10 min/1 min= megohms / megohms =

110 64

Minimum acceptable insulation resistance at 50 deg. C. MOTOR RATED VOLTAGE 138000 4000 2400 460 MINIMUM I.R. (MEGOHMS) 15 5.5 3.5 1.5 The minimum acceptable polarization index for class B and F insulation is 2.0, however higher values are preferred. Stator winding resistance in micro-ohms. Measured phase to phase with wye point connected then each phase is measured with the wye point open and the motor leads separated. PHASE A TO B

PHASE B TO C

PHASE C TO A

Motor heaters: Insulation Resistance Voltage: volts Current:

PHASE A

megohms. amps.

PHASE B

PHASE C

Continuity:

ohms.

RTD continuity measurements: Winding RTD number and location. 1 2 3 4 5 6 Stator Air Gap Clearance: Position on Stator Clearance

WITNESS

CONTRACTOR

Resistance measured with a digital high impedance ohmmeter.

12:00

1:30

3:00

INSPECTION

4:30

6:00

7:30

9:00

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 169 of 222

10:30

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 10 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM WOUND INDUCTION MOTOR DATA SHEET ( CONTINUED) DC HIGH POTENTIAL TEST Time Minutes

DC Test Volts 2300 rated 4000 rated 13200 rated motor volts motor volts motor volts 1 2300 3700 12000 2 2300 3700 12000 3 2300 3700 12000 4 2300 3700 12000 5 2300 3700 12000 6 2300 3700 12000 7 2300 3700 12000 8 2300 3700 12000 9 2300 3700 12000 10 2300 3700 12000 11 2800 4400 14000 12 3300 5100 17000 13 3800 5900 19000 14 4300 6600 21000 15 4800 7300 24000 16 5300 8000 26000 17 5800 8800 28000 18 6300 9500 30000 19 6800 10300 33000 20 7000 11000 35000 Test Voltage is 1.7X[.75(2 X rated voltage + 1KV)]

WITNESS

CONTRACTOR

INSPECTION

Leakage Current; micro-amps Phase # 1 Phase # 2 Phase # 3

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 170 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 11 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM WOUND INDUCTION MOTOR DATA SHEET NO LOAD TEST DATA TIME - MINUTES PHASE CURRENT AaㅁA

START

0

A B C PHASE VOLTAGE A-B B-C C-A % VOLTAGE UNBALANCE D. E. BRNG VIBRATION N. D. E. BRNG VIBRATION D. E. BRNG TEMP. N. D. E. BRNG TEMP AMBIENT TEMP WINDING TEMP

30

60

90

120

150

180 210

240

ON LOAD TEST DATA TIME - MINUTES PHASE CURRENT

START

0

30

60

90

120

150

180

210

240

A

B C PHASE VOLTAGE A-B B-C C-A % VOLTAGE UNBALANCE D. E. BRNG VIBRATION N. D. E. BRNG VIBRATION D. E. BRNG TEMP. N. D. E. BRNG TEMP AMBIENT TEMP WINDING TEMP

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 171 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 12 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM WOUND SYNCHRONOUS MOTOR DATA SHEET Insulation Resistance Test: Megger Voltage 500/1000/2500/5000:

. Ambient Temperature. READING CORRECT TO megohms

DIRECT

INS. RESIS. PHASE 1 TO GND PHASE 2 TO GND PHASE 3 TO GND PHASE 1 TO 2 PHASE 2 TO 3 PHASE 3 TO 1 (USE 500 VOLT D. E. BEARING N. D. E. BEARING MOTOR FIELD EXCITER ROTOR EXCITER FIELD RECTIFIER RING

megohms 1 MINUTE

10 MINUTES

MEGGER FOR

THIS TEST)

.

50 DEG. C.

1 MINUTE

POLARIZATIO N INDEX

10 MINUTES

NOTE: Temperature Correction: To correct to 50 deg. C; Rc= Kt x Rt; Rc = insul. resis. corrected to 50 deg. C, Rt = insul. resis. at temp "t", Kt = insul. resis. temperature coefficient at temperature "t". Winding Temp., C Kt

WITNESS

0.0 0.03

10.0 0.06

CONTRACTOR

20.0 0.12

30.0 0.25

40.0 0.50

INSPECTION

50.0 1.0

60.0 2.0

70.0 4.0

80.0 8.0

90.0 16.0

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 172 of 222

100.0 32.0

110.0 64.0

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 13 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SYNCHRONOUS MOTOR NAME PLATE DATA Manufacturer Serial No. Purchasers order no. Voltage Frequency Rating :H.P./K.W. Insulation class Maximum Ambient Temp. Max Winding Temperature Rise Bearing Manufacturer Bearing Number Field Resistance Field Volts Field Current FIELD EXCITER KW/KVA OUTPUT VOLTS OUTPUT CURRENT SYNCHRONOUS MOTOR DATA SHEET

Mfg.'s., location Mfg.'s., order number Year of manufacture Current Phases Total Weight Rotor Weight Speed Full load efficiency Class, Group, Division Max Bearing Temp. Rise

EXCITER FIELD RESISTANCE

Minimum acceptable insulation resistance at 50 deg. C. Motor Rated Voltage 138000 4000 2400 460 Minimum I.R. (MEGOHMS) 15 5.5 3.5 1.5 The minimum acceptable polarization index for class B and F insulation is 2.0, however higher values are preferred. Stator winding resistance in micro-ohms. Measured phase to phase with wye point connected then each phase is measured with the wye point open and the motor leads separated. PHASE A TO B PHASE B TO C PHASE C TO A PHASE A PHASE B PHASE C

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 173 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 14 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

SYNCHRONOUS MOTOR DATA SHEET (CONTINUED Motor rotating field resistance ohms. Motor rotating field impedance: apply 220 volts A.C. between the field leads and measure the current. Impedance = 220 volts / amps = ohms. Exciter Field resistance = Rotating rectifier diode check:

ohms.

Forward resistance

Reverse resistance

Phase A Phase B Phase C Motor heaters: Insulation Resistance Voltage volts

megohms. Continuity volts. Current amps.

RTD continuity measurements: Winding RTD number and location.

ohms.

Resistance measured with a digital high impedance ohmmeter.

1 2 3 4 5 6 Stator to Rotor Air Gap Clearance: Position 12:00 1:30 Motor clearance Exciter clearance

WITNESS

CONTRACTOR

3:00

INSPECTION

4:30

6:00

7:30

9:00

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 174 of 222

10:30

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 15 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM WOUND SYNCHRONOUS MOTOR DATA SHEET DC HIGH POTENTIAL TEST Time Minutes

DC Test Volts 2300 rated 4000 rated 13200 rated motor volts motor volts motor volts 1 2300 3700 12000 2 2300 3700 12000 3 2300 3700 12000 4 2300 3700 12000 5 2300 3700 12000 6 2300 3700 12000 7 2300 3700 12000 8 2300 3700 12000 9 2300 3700 12000 10 2300 3700 12000 11 2800 4400 14000 12 3300 5100 17000 13 3800 5900 19000 14 4300 6600 21000 15 4800 7300 24000 16 5300 8000 26000 17 5800 8800 28000 18 6300 9500 30000 19 6800 10300 33000 20 7000 11000 35000 Test Voltage is 1.7X[.75(2 X rated voltage + 1KV)]

WITNESS

CONTRACTOR

INSPECTION

Leakage Current; micro-amps Phase # 1 Phase # 2 Phase # 3

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 175 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 16 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM WOUND SYNCHRONOUS MOTOR DATA SHEET NO LOAD TEST DATA TIME - MINUTES PHASE CURRENT

START 0

30

60

90

120

150

180

210

240

A B C PHASE VOLTAGE A-B B-C C-A % VOLTAGE UNBALANCE D. E. BRNG VIBRATION N. D. E. BRNG VIBRATION D. E. BRNG TEMP. N. D. E. BRNG TEMP AMBIENT TEMP WINDING TEMP % SYN. SPEED AT EXCITATION EXCITER FIELD CURRENT MOTOR FIELD CURRENT POWER FACTOR REACTIVE POWER (kvar) Comments:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 176 of 222

REMARKS

FORM YERP - P-018 ISSUE DATE:

SHT 17 of 17

YERP PRE-COMMISSIONING FORM NEMA FRAME, FORM WOUND INDUCTION AND SYNCHRONOUS MOTORS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FORM WOUND SYNCHRONOUS MOTOR DATA SHEET ON LOAD TEST DATA TIME - MINUTES

START

0

30

60

90

120

150

180

210

240

PHASE CURRENT

A B C PHASE VOLTAGE A-B B-C C-A % VOLTAGE UNBALANCE D. E. BRNG VIBRATION N. D. E. BRNG VIBRATION D. E. BRNG TEMP. N. D. E. BRNG TEMP AMBIENT TEMP WINDING TEMP % SYN. SPEED AT EXCITATION EXCITER FIELD CURRENT MOTOR FIELD CURRENT POWER FACTOR REACTIVE POWER (kvar) Comments:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 177 of 222

REMARKS

FORM YERP - P-019 ISSUE DATE:

SHT 1 of 1

YERP PRE-COMMISSIONING FORM OUTDOOR BUS STRUCTURES EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Field Installation Check List Visual and Mechanical Tests Yes

No

Yes

No

1. Inspect bus arrangement for compliance with plans. 2. Examine bus and supports for defects, such as cracked or porous welds, chipped porcelains, etc. 3. Check expansion joints for freedom of movement. 4. Check tightness of accessible bolted bus joints by calibrated torque wrench method. Refer to manufacturer's instruction for proper torque values or reference values in YERP-P-000. Electrical Tests

1. Measure resistance of bolted bus sections, joints and tee's with a ductor or digital low reading ohmmeter. 2. Measured bus joint resistance shall be less than 0.5 micro-ohms.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 178 of 222

REMARKS

Form YERP - P- 020 Issue Date:

Sheet 1 of 2

YERP PRE-COMMISSIONING FORM SWITCHGEAR-GENERAL

Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

FIELD INSTALLATION CHECK LIST Mfg. Location Voltage Class Main Bus Current Rating Total Breakers and Types Total Relays and Types VISUAL INSPECTION Yes

No

Yes

No

1. 2. 3. 4. 5.

General inspection of exterior of equipment. Check panel lights for operation, burned out or missing bulbs LED's and covers. Inspect for damaged, bent, or twisted doors and verify ground bonding. Inspect for broken instrument, relay cover glass and damaged phase indicator lights. Inspect bus for physical damage, missing insulation, connections at joints, confirm plating is acceptable. 6. Check cleanliness of interior of cubicle 7. Inspect insulation, stand-off insulators, and bus separators for damage or clearance problems. 8. Inspect for proper compartmentalization as required. MECHANICAL SWITCHGEAR INSPECTION 1. 2. 3. 4. 5. 6.

Check control knobs and switches for freedom of movement and contact condition. Inspect door handles, locking bars, and mechanism. Check door interlocks for positive operation. Torque test bolted bus. (Exposed Connections only.) Check bus for support & spacing. Remove all shipping bracing. Remove draw out breakers. Check draw out mechanism for freedom of movement.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 179 of 222

REMARKS

Form YERP - P- 020 Issue Date:

Sheet 2 of 2

YERP PRE-COMMISSIONING FORM SWITCHGEAR-GENERAL

Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

MECHANICAL SWITCHGEAR INSPECTION (Continued) Yes

No

7. 8. 9. 10. 11.

Check rails, guides, rollers, and shutter mechanism. Lubricate draw out assembly parts as required. Inspect breaker and cell primary and secondary contacts and alignment. Close and trip breakers manually in the connected, test and disconnected positions. When applicable, check metering transformers compartments for proper operation of racking in/out, isolation features. Check for proper grounding of fuses in the withdrawn position. 12. Verify that all breakers of the same rating are inter-changeable by racking each breaker into each cell of the proper rating. ELECTRICAL SWITCHGEAR INSPECTION Yes 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

No

Inspect for proper grounding of equipment and neutral bus. Measure insulation resistance to ground. Inspect and megger power cable or bus to switchgear. Clean bus insulators, Megger test for grounds. Dielectric test cables/terminations and bus work as specified. Inspect and test control and metering transformers and fuses as required. Verify operation of resistors, grid assemblies (if applicable) and space heaters. Verify the condition of wiring & terminal connections (point to point wire check). Note and report any unmarked circuits. Verify proper operation of cell interlocks and auxiliary contact assemblies. Perform breaker inspection and tests as specified. Inspect and test meters, transducers, and relays as specified. Perform relay calibration and settings. Check relays and protective devices for positive tripping of circuit breaker. Test annunciator, alarm and/or target operation. Verify proper phasing of bus. Verify all control fuse types and ratings. Verify control circuits operate according to engineering specifications.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 180 of 222

REMARKS

Form YERP - P- 023 Issue Date:

Sheet 1 of 2

YERP PRE-COMMISSIONING FORM AUTOMATIC TRANSFER SWITCHES

Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

EQUIPMENT NAMEPLATE DATA Manufacturer Model No. Serial No. Voltage Rating Current Rating

Visual and Mechanical Inspection Yes

No

1. Inspect for physical damage. 2. Compare equipment nameplate information and connections with single line diagram and report any discrepancies. 3. Check switch to insure positive interlock between normal and alternate sources. 4. Check tightness of all cable connections and bus joints. 5. Perform manual transfer operation. 6. Transfer switch and compartment are clean and dust free. 7. Verify all vendor control cable wiring. 8. Check terminations and tagging.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 181 of 222

REMARKS

Form YERP - P- 023 Issue Date:

Sheet 2 of 2

YERP PRE-COMMISSIONING FORM AUTOMATIC TRANSFER SWITCHES

Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

ELECTRICAL TESTS Yes

No

1. Perform insulation resistance tests phase to phase and phase to ground with switch in both alternate and source positions. 2. Perform electrical insulation and contact resistance tests as referenced in P000. 3. Set and calibrate the Voltage Sensing relays. Contact PDD for settings. 4. Set and calibrate the Transfer Time delay relay. Contact PDD for settings. 5. Perform automatic transfer by simulating loss of normal power. 6. Perform automatic transfer by return to normal power. 7. Monitor and verify correct operation and timing of Normal Voltage sensing relays. 8. Monitor and verify correct operation and time delay upon transfer. 9. Monitor and verify correct operation and timing of Alternate voltage sensing relays. 10. Monitor and verify correct operation and timing of Automatic transfer operation. 11. Monitor and verify correct operation and timing of mechanical and electrical interlocks and limit switches 12. Monitor and verify correct operation and timing, of time-delay and retransfer upon normal power restoration.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 182 of 222

REMARKS

FORM YERP - P-025 ISSUE DATE:

SHT 1 of 8

YERP PRE-COMMISSIONING FORM OIL FILLED POWER TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION CHECKLIST VISUAL INSPECTION Yes

No

1. Inspect for physical damage to main tank, radiators, bushings, control cabinet tap changer compartment and ancillary equipment. 2. Compare transformer nameplate information with latest single line diagram and project specifications. 3. Check and record transformer main tank pressure. 4. If the transformer is shipped with oil, Check and record the oil level in the main tank, reservoir, load tap changer, and bushings. 5. Check and record oil temperature. 6. Inspect transformer main tank, tap changer, radiators, pumps, bushings, fittings, and auxiliary oil reservoir for oil leaks. Record and report any leaks. 7. Check that instrument, control cabinet, and tank grounding is correctly installed and connected to the main ground system. 8. Wiring from CT's, VT's, pumps, fans, temperature guages/alarms, oil level indicators, and pressure relief devices is properly terminated in the control cabinet. 9. Verify dehydrating breather is correctly installed.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 183 of 222

REMARKS

FORM YERP - P-025 ISSUE DATE:

SHT 2 of 8

YERP PRE-COMMISSIONING FORM OIL FILLED POWER TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MECHANICAL INSPECTION Yes

No

Yes

No

1. Check mechanical operation of off load tap changer or on-load tap changer through complete tap range. Verify the movement is positive and there is no dragging or binding between steps. 2. Cooling fans and circulating pumps are properly installed and lubricated and rotate freely. 3. Check primary, secondary and ground connections. 4. Inspect arresters for proper connection and alignment. 5. Verify correct operation of all electro-mechanical, thermal, hydraulic, pneumatic, and pressure relays and/or devices on or incorporated into the transformer. ELECTRICAL TESTS

1. C. T.'s checked for proper polarity, ratio and burden. 2. VT's checked for proper polarity, ratio and burden. 3. Radiator fans and oil circulating pumps rotate in the correct direction. 4. Measure and record relief and reset pressure of pressure relief devices. Check operation of electrical alarm contacts. Verify proper resetting of pressure relief device. 5. Check operation of auxiliary relays and alarm setting. 6. Take oil sample and test per ANSI/IEEE C57.106. See table of acceptable test values in the data section of this form. 7. Check insulation power factor of bushings and windings with a Doble. Values of 0.5% and lower are acceptable for transformers. Bushings should be within manufacturer's published tolerance.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 184 of 222

REMARKS

FORM YERP - P-025 ISSUE DATE:

SHT 3 of 8

YERP PRE-COMMISSIONING FORM OIL FILLED POWER TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

ELECTRICAL TESTS (CONTINUED) Yes

No

8. Megger the core to ground with a 250 volt megger by removing the intentional core ground and megging between the ground shunt and the transformer case. 9. Measure and record the resistance of each winding at each tap position. 10. Measure and record the turns ratio on each tap. Deviation of not more than +/- 0.5% are allowed. 11. Megger test high to low & ground, low to high & ground, high and low to ground. 12. Using a Doble Power factor test set, measure the exciting current for each winding. Two similar current readings for the outside phases and a lower current reading for the center phase of a three unit. 13. Polarity of transformers will be verified to confirm agreement with the nameplate and contract specifications. 14. If provided, function check the electrical operation of the on-load tap changer, local and remote operation and indication and operation of voltage sensing relay. DATA SHEET Dielectric Fluid Specification (New Insulating Oil as Received Before Transformer Filling). TEST LIMIT VALUE Dielectric strength D-877, KV, minimum 30 Power Factor, D924, 25 deg., % maximum. 0.05 100 deg., % maximum 0.30 Interfacial Tension D 971, mN/M minimum 40 Color, D-1500 ASTM Units maximum 0.5 Visual Examination D1524 Bright and Clear Acid Number D974, mg KOH/g, maximum 0.03 Water Content, D 1533, ppm, maximum 35

WITNESS

CONTRACTOR

INSPECTION

TEST

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 185 of 222

RESULTS

REMARKS

FORM YERP - P-025 ISSUE DATE:

SHT 4 of 8

YERP PRE-COMMISSIONING FORM OIL FILLED POWER TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Dielectric Fluid Specification (Insulating Oil Received in New Transformers or as Tested After Final Oil Filling). TEST

LIMIT VALUE

Dielectric strength D-877, KV, minimum Power Factor, D924, 25 deg., % maximum. 100 deg., % maximum Interfacial Tension D 971, mN/M minimum Color, D-1500 ASTM Units maximum Visual Examination D1524 Acid Number D974, mg KOH/g, maximum Water Content, D 1533, ppm, maximum

TEST RESULTS

30 0.1 1.0 40 1.0 Clear 0.04 25 below 115kV class 20 115kV - 230kV class

NAMEPLATE DATA Manufacturer: Serial No.: Date: Voltage Rating: High: Low: KVA rating: OA: FA: Basic Impulse Level High Voltage: Low Voltage:

WITNESS

CONTRACTOR

Temperature Rise: Impedance: OIL: Main tank gals: Radiators gals: Total Gallons oil: WEIGHT: Core and Coils: Tank and Fittings: Oil: Total Weight: Connection: Rated Tank Pressure:

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 186 of 222

REMARKS

FORM YERP - P-025 ISSUE DATE:

SHT 5 of 8

YERP PRE-COMMISSIONING FORM OIL FILLED POWER TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

MEGGER TEST Temperature ( deg. C) Megger voltage Core ground shunt to transformer tank High voltage to low voltage and ground Low voltage to high voltage and ground High voltage and low voltage to ground

Meghoms: Meghoms: Meghoms: Meghoms:

WINDING RESISTANCE TEST DELTA CONNECTION H1 to H2 H2 to H3 H3 to H1 X1 to X2 X2 to X3 X3 to X1 WINDING RATIO TEST Tap Winding High Voltage to Low Voltage 1 High Voltage to Low Voltage 2 High Voltage to Low Voltage 3 High Voltage to Low Voltage 4 High Voltage to Low Voltage 5

WYE CONNECTION H1 to H0 H2 to H0 H3 to H0 X1 to X0 X2 to X0 X3 to X0

Phase

Calculated Ratio

Measured Ratio

1 2 3 1 2 3 1 2 3 1 2 3 1 2

3 WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 187 of 222

REMARKS

FORM YERP - P-025 ISSUE DATE:

SHT 6 of 8

YERP PRE-COMMISSIONING FORM OIL FILLED POWER TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Transformer polarity verification:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 188 of 222

REMARKS

FORM YERP - P-025 ISSUE DATE:

SHT 7 of 8

YERP PRE-COMMISSIONING FORM OIL FILLED POWER TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

AUTOMATIC ON LOAD TAP CHANGER TAP CHANGER MOTOR H.P. Amps Duty Voltage Phases

RPM Manufacturer Frequency INS. Class Nema Design

OPERATION SETTINGS: (If applicable) Voltage setting

Bandwidth setting

Volts

Volts Other:

Time delay setting Volts FUNCTION CHECKS: (If applicable) Alarms Local operation:

Trips Remote operation

Parallel operation

Block Operation :

Under voltage

Over current

Megger control wiring: megohms

Megger field wiring: megohms

Disconnect electronic equipment and: REMOTE POSITION INDICATOR

TIME TO OPERATE TAP TO TAP: RAISE: Sec. – LOWER: Sec. MECHANICAL CHECK: OIL, GREASE ETC.: HAND CRANK-NUMBER OF TURNS TO COMPLETE TAP CHANGE: RAISE LOWER

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 189 of 222

REMARKS

FORM YERP - P-025 ISSUE DATE:

SHT 8 of 8

YERP PRE-COMMISSIONING FORM OIL FILLED POWER TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

GENERAL HEATERS CHECKED: LIMIT STOPS: RAISE: LOWER: HAND OPERATE INTERLOCK:

COUNTER OPERATION

EXTERNAL COOLING FANS Manufacturer Serial no. Fan temperature on: Fan No.

H.P. Voltage Fan temperature off:

Amps No. phases

winding

resistance (ohms)

overload

ins.

phase 1 phase 2

phase 2phase 3

heater size

resistance current

phase 3phase 1

on-load

minimu m vibration

safety guards

Insulation Power factor tests: Attach Doble transformer power factor test sheet showing winding and bushing power factor and capacitance test results. Winding insulation powerfactor shall be less than 0.5%. No Load Primary current: WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 190 of 222

REMARKS

FORM YERP - P-027 ISSUE DATE:

SHT 1 of 4

YERP PRE-COMMISSIONING FORM VOLTAGE AND CURRENT TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

FIELD INSTALLATION TESTS VISUAL AND MECHANICAL INSPECTION Yes

No

1. Inspect for physical damage and compliance with design drawings. 2. Check mechanical clearances and proper operation of all disconnecting and grounding devices associated with voltage transformers. 3. Verify proper operation of grounding devices for withdrawable voltage transformer and shorting devices for current transformers. ELECTRICAL TESTS Yes

No

1. Current transformers shall have secondary saturation tests done and the test results recorded. 2. Confirm transformer polarity electrically. 3. Burden tests will be made at the secondary leads of the CT. to assure accurate translation of primary current. 4. Verify connection at the secondary CT leads by driving a low current through the leads and checking for this current at applicable devices. 5. Confirm transformer winding ratio(s). 6. Measure insulation resistance of transformer winding with five hundred volt megger 7. Measure transformer primary insulation with applicable over-potential tests see manufacturers instructions or refer to form YERP P-000. 8. Verify connection of secondary VT leads by applying a low voltage to the leads and checking for this voltage at applicable devices. 9. Check for VT secondary load with secondary voltage and current measurements. Make sure load is less than VA of the VT.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 191 of 222

REMARKS

FORM YERP - P-027 ISSUE DATE:

SHT 2 of 4

YERP PRE-COMMISSIONING FORM VOLTAGE AND CURRENT TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

CURRENT TRANSFORMER TEST DATA PLANT SUBSTATION CIRCUIT B.I. NO. MAGNETIZATION CURVE VOLTS

CT 1 mA

CT-2 mA

CT 3 mA

CT 4 mA

CT 5 mA

CT 6 mA

CT 7 mA

CT 8 mA

CT 9 mA

CT 10 mA

CT 11 mA

CT 12 mA

RATIO TEST ( CURRENT ) CT 1

CT 2

CT 3

CT 4

CT 5

CT 6

CT 7

CT 8

CT 9

CT 10

CT 11

CT 12

PRI AMPS SEC AMPS RATIO

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 192 of 222

REMARKS

FORM YERP - P-027 ISSUE DATE:

SHT 3 of 4

YERP PRE-COMMISSIONING FORM VOLTAGE AND CURRENT TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

DATA PAGE 2. CT 1

CT 2

CT 3

CT 4

CT 5

CT 6

CT 7

CT 8

CT 9

CT 10

CT 11

CT 12

CT. BURDEN VOLTAGE ACROSS CT. INSUL. RES.

POLARITY IDENTIFICATION MARKS

CIRCUIT BREAKER STARTER OR TRANSFORMER

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 193 of 222

REMARKS

FORM YERP - P-027 ISSUE DATE:

SHT 4 of 4

YERP PRE-COMMISSIONING FORM VOLTAGE AND CURRENT TRANSFORMERS EQUIPMENT TYPE: EQUIPMENT TAG NO.: BI/JO NO.: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: TEST COMPLETION DATE:

USER REFERENCE: DESCRIPTION: PLANT NO. / LOCATION:

SERIAL NO.:

Voltage Transformer Test Data Manufacturer Serial No. Voltage Rating Rating (VA) Connection Polarity

Additive

Subtractive

Insulation Resistance Test Temperature ( deg. C) Megger voltage: 500/100/2500/5000. Connection High voltage to low voltage and ground Low voltage to high voltage and ground High and low voltage to ground

megohms measured

temperature corrected

WINDING RESISTANCE TEST SINGLE PHASE VT H1 to H2 H3 to H4

WITNESS

ohms ohms

CONTRACTOR

X1 to X2 X3 to X4

INSPECTION

ohms ohms

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 194 of 222

REMARKS

Form YERP - P-050 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 1 of 4

DRY TYPE POWER TRANSFORMERS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No: FIELD INSTALLATION TESTS

VISUAL INSPECTION Yes

No

Yes

No

Yes

No

1. Check complete assembly for damage and missing parts. 2. Compare equipment nameplate information with latest single line diagram and report discrepancies. 3. Ensure the enclosure is approved for the area classification. 4. Check conductor size and type. 5. Check for correct conduit connections. 6. Ensure that primary and secondary leads are connected for required voltage level. 7. Grounding installed. 8. Neutral wire correctly installed 9. Check mounting and supports per drawings. 10. The spare conductors (pigtails) properly insulated. MECHANICAL INSPECTION 1. Verify proper auxiliary device operation such as fans, indicators. 2. Check tightness of accessible bolted electrical joints in accordance with manufacturers specifications or YERP-P-000 guidelines. 3. Perform specific inspections and mechanical tests as recommended by the manufacture. 4. Check operation of tap changer or tap connection block for correct number of shorting bars. ELECTRICAL TESTS 1. Insulation resistance tests shall be performed winding to winding and winding to ground. Appropriate guard circuit shall be utilized under all bushings. Test voltage and minimum acceptable values in accordance with values in test section. 2. A dielectric absorption test shall be made winding to winding and winding to ground for ten (10) minutes. Compute the polarization index. The test voltages and minimum acceptable values are listed in the test section. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 195 of 222

REMARKS

Form YERP - P-050 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 2 of 4

DRY TYPE POWER TRANSFORMERS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

ELECTRICAL TESTS (Continued) Yes

No

Yes

No

3. A turn's ratio test shall be performed between windings for all tap positions. The final tap setting is to be determined by the engineer and set by the test engineer upon completion of the ratio testing. Acceptable values are in the test section. 4. Winding resistance tests shall be made for each winding on each tap position. 5. No load excitation current shall be measured for each phase in accordance with established procedure. 6. Perform special tests and adjustments as suggested by manufacturer for tap changer, fan and controls, and alarm functions. TEST VALUES

1. Perform Insulation Resistance and Polarization Index test. Final values will be temperature corrected. 2. The absorption test polarization index should be above 2.0 unless an extremely high value is obtained at the end of one (1) minute that when doubled will not yield a meaningful value with the available test equipment. 3. Winding resistance test results should compare within one percent (1%) of adjacent windings. 4. Turns ratio test results should not deviate more than one-half of one percent ( +/0.5%) from the calculated ratio.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 196 of 222

REMARKS

Form YERP - P-050 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 3 of 4

DRY TYPE POWER TRANSFORMERS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

Data Sheet Name plate data Manufacturer Serial No. Voltage Rating KVA rating Type ConnectionPolarity Impedance Total Weight Insulation resistance test: Megger Voltage: 500/100/2500/5000. Temperature ( deg. C) Megger voltage Connection Core ground shunt to transformer tank High voltage to low voltage and ground Low voltage to high voltage and ground High voltage and low voltage to ground

Megohms measured

Polarization Index

WINDING RESISTANCE TEST: record measured resistance DELTA CONNECTION WYE CONNECTION H1 to H2 OHMS H1 to H0 OHMS H2 to H3 OHMS H2 to H0 OHMS H3 to H1 OHMS H3 to H0 OHMS X1 to X2 X2 to X3 X3 to X1 WITNESS

OHMS OHMS OHMS CONTRACTOR

X1 to X0 X2 to X0 X3 to X0 INSPECTION

OHMS OHMS OHMS

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 197 of 222

REMARKS

Form YERP - P-050 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 4 of 4

DRY TYPE POWER TRANSFORMERS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

WINDING RATIO TEST Tap

Winding High Voltage to Low Voltage

1 High Voltage to Low Voltage 2 High Voltage to Low Voltage 3 High Voltage to Low Voltage 4 High Voltage to Low Voltage 5

Phase

Calculated Ratio

Measured Ratio

1 2 3 1 2 3 1 2 3 1 2 3 1 2 3

Energize transformer at no load, measure and record: Primary voltage: Secondary voltage: Primary current:

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 198 of 222

REMARKS

Form YERP - P-061 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 1 of 2

OUTDOOR SUBSTATIONS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

OUT-DOOR SUBSTATION EQUIPMENT AIR BREAK DISCONNECT SWITCHES Visual and Mechanical Inspection Yes

No

Yes

No

1. Check switch nameplate to verify it complies with system and project requirements. 2. Inspect switch bus supports (insulators) for damage, also check for missing parts and hardware. 3. Inspect for proper application of protective coatings, paint, plating etc. 4. Check blade alignment and contact make and break sequence. 5. Check for proper mechanical operation of the mechanism, smooth, no binding and provision for padlocking. 6. Verify the structure is properly grounded and that the switching platform is bonded to the switch structure.

Electrical Tests

1. Measure electrical continuity of switch blades and connections with a minimum 10 amp power supply utilizing a Ductor, Digital Low Reading Ohm Meter or similar test equipment. 2. Measure electrical continuity across switching elements with a 100 amp power supply utilizing a Ductor, Digital Low Reading Ohm Meter or similar test equipment.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 199 of 222

REMARKS

Form YERP - P-061 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 2 of 2

OUTDOOR SUBSTATIONS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

COUPLING CAPACITOR VOLTAGE TRANSFORMERS (CCVT's) Visual and Mechanical Inspection Yes

No

Yes

No

1. Check VT nameplate to verify it complies with system and project requirements. 2. Inspect Bushing for damage, chips or cracks. 3. Check bushing for proper creepage distance. 4. Check for oil leaks. 5. Inspect for proper application of protective coatings, paint, plating etc. 6. Verify VT is properly grounded. Electrical Tests 1. Check insulation power factor (DOBLE). 2. Check oil dielectric break down. 3. Check capacitance with DOBLE and compare with nameplate value. 4. Check insulation resistance with Megger.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 200 of 222

REMARKS

Form YERP - P- 062 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 1 of 1

SURGE ARRESTORS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

FIELD INSTALLATION CHECK LIST VISUAL AND MECHANICAL TESTS Yes

No

Yes

No

Yes

No

1. Inspect for physical damage, such as damaged insulation or mounting brackets. 2. Verify location and name plate rating with plans and specifications. 3. Inspect ground and discharge counter connections for integrity if supplied. 4. Clean porcelain or silicon rubber insulation with distilled water and dry before performing electrical tests. 5. Inspect for proper mounting and adequate clearance.

ELECTRICAL TESTS

1. Perform an insulation power-factor test. 2. Perform continuity test of ground connections from arrestor to ground grid system. RECOMMENDED TEST VALUES

1. Power factor tests should show similar dielectric loss between similar arresters. 2. Ground grid connections should not exceed 0.5 ohms.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date

General Confidential Page 201 of 222

REMARKS

Form YERP - P-071 Issue Date

YERP PRE-COMMISSIONING FORM

Sheet 1 of 7

VARIABLE FREQUENCY DRIVES FOR NEMA FRAME MOTORS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

FIELD TESTS FOR VARIABLE FREQUENCY DRIVES Visual Inspection Yes

No

Yes

No

1. Verify ratings of the Variable Frequency Drive and Motor are correct for the proposed installation by reviewing the engineering drawings and specifications. 2. Check nameplate voltage and current rating for breakers, contactors and fuses. 3. Compare over load devices (external and internal to VFD) with motor full load current for proper sizing. 4. Verify grounding is correctly installed and connected to the main grounding system. 5. Inspect for physical damage, missing or improper parts. Check compartments and equipment for cleanliness. 6. Verify wiring and conductor sizing is correct and are properly terminated. 7. Isolation transformer (if supplied) is properly rated. 8. Verify jumpers, overloads devices and parameter settings of AFD are properly set or programmed according to the manufacturer's instructions. 9. Verify speed, voltage, current transducers etc. are properly installed and wired. 10. If applicable, check that the rating of output inductors is correct and meet manufacturer recommended ratings for the motor cable length. 11. Check that parameter settings schedule is available and has been reviewed by engineering. 12. Vendor manuals are available. Mechanical Inspection 1. Motor is properly mounted and motor and load couplings are properly installed and aligned. 2. Motor shaft is free to rotate. 3. Contactors, switching devises, and isolation devices work properly. CAUTION: Read the general safety and caution information provided in the vendor manuals before conducting any electrical test. Voltage may still be present for a short time on the DC link capacitors after incoming AC power is turned off. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 202 of 222

REMARKS

Form YERP - P-071 Issue Date

YERP PRE-COMMISSIONING FORM

Sheet 2 of 7

VARIABLE FREQUENCY DRIVES FOR NEMA FRAME MOTORS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

Electrical Tests Yes

No

1. Verify insulation resistance (megger) of power cables, (reference YERP-P-004), from the AFD to the motor. Note: The power cables must be disconnected from the AFD. Do not (megger) AFD. Record (megger) readings. 2. Verify supply/isolation transformer is connected for proper voltage and has proper kVA rating, if applicable. 3. Verify ratio of current and voltage transformers and that voltage transformers are properly fused. 4. Megger motor winding. Record values. Refer to YERP-P-019 for recommendations for motor testing (use full speed for YERP-P-019 testing). 5. Verify transducers (if applicable) are properly calibrated. 6. Checked operation and calibration of thermal over loads by current injection. Functionally test AFD internal overload protection, if applicable. 7. Check operation of temperature measuring devices (e.g. thermostat) integral to the motor, if applicable. 8. Perform any start-up/testing checks recommended at the vendor operation manuals. ADJUSTABLE FREQUENCY DRIVE AND MOTOR NO-LOAD TESTS Yes

No

1. Verify motor is uncoupled and safely isolated against accidental contact by personnel. 2. Set speed/frequency control to minimum and energize the motor. Slowly increase speed/frequency control until motor runs approximately 5% rated speed. Run for a short time and Record Frequency: Voltage: Current: 3. Verify motor accelerates smoothly. Check motor for noise, vibration, heating. If any abnormality occurs check initial settings of AFD and consult manufactures drive installation setup instructions.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 203 of 222

REMARKS

Form YERP - P-071 Issue Date

YERP PRE-COMMISSIONING FORM

Sheet 3 of 7

VARIABLE FREQUENCY DRIVES FOR NEMA FRAME MOTORS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

ADJUSTABLE FREQUENCY DRIVE AND MOTOR NO-LOAD TESTS (Continued) Yes

No

4. Increase speed/frequency control until motor reaches 25% rated speed. Verify motor accelerates smoothly. Check motor for any noise, vibration or heating. Run for a short time and Record: Frequency: Voltage: Current: 5. Increase speed/frequency control until motor reaches 50% rated speed. Verify motor accelerates smoothly. Check motor for any noise, vibration or heating. Run for a short time and Record: Frequency: Voltage: Current: 6. Increase speed/frequency control until motor reaches 75% rated speed. Verify motor accelerates smoothly. Check motor for any noise, vibration or heating. Run for a short time and Record: Frequency: Voltage: Current: 7. Increase speed/frequency control until motor reaches 100% rated speed. Verify motor accelerates smoothly. Check motor for any noise, vibration or heating. Run for a short time and Record: Frequency: Voltage: Current: 8. Reduce speed to minimum and verify motor decelerates smoothly without any noise or vibration. 9. Actuate the AFD stop function to stop the motor. Verify motor stops and the contactor supplying the motor opens. 10. Record settings of jumpers and potentiometers on AFD. Record speed settings for speed/frequency control.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 204 of 222

REMARKS

Form YERP - P-071 Issue Date

YERP PRE-COMMISSIONING FORM

Sheet 4 of 7

VARIABLE FREQUENCY DRIVES FOR NEMA FRAME MOTORS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

ADJUSTABLE FREQUENCY DRIVE AND MOTOR NO-LOAD TESTS (Continued) Yes

No

11. Energize the AFD and increase speed/frequency control until the motor reaches 25% rated speed. Verify motor accelerates smoothly. Check motor for any noise, vibration and heating. Run the motor at no-load for 1 hour and record: Frequency: Voltage: Current: Temperature Start: After 1 hour: Vibration D.E.: N.D.E: current and voltage output waves. Verify stability factor and harmonic 12. Record content is within specified limits. 13. Increase speed/frequency control until the motor reaches 50% rated speed. Verify motor accelerates smoothly. Check motor for any noise, vibration and heating. Run the motor at no-load for 1 hour and record: Frequency: Voltage: Current: Temperature After 2nd hour: Vibration D.E.: N.D.E: 14. Record current and voltage output waves. Verify stability factor and harmonic content is within specified limits. 15. Increase speed/frequency control until the motor reaches 75% rated speed. Verify motor accelerates smoothly. Check motor for any noise, vibration and heating. Run the motor at no-load for 1 hour and record: Frequency: Voltage: Current: Temperature After 3rd hour: Vibration D.E.: N.D.E: 16. Record current and voltage output waves. Verify stability factor and harmonic content is within specified limits.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 205 of 222

REMARKS

Form YERP - P-071 Issue Date

YERP PRE-COMMISSIONING FORM

Sheet 5 of 7

VARIABLE FREQUENCY DRIVES FOR NEMA FRAME MOTORS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

ADJUSTABLE FREQUENCY DRIVE AND MOTOR NO-LOAD TESTS (Continued) Yes

No

17. Increase speed/frequency control until the motor reaches 100% rated speed. Verify motor accelerates smoothly. Check motor for any noise, vibration and heating. Run the motor at no-load for 1 hour and record: Frequency: Voltage: Current: Temperature After 4th hour: Vibration D.E.: N.D.E: 18. Record current and voltage output waves. Verify stability factor and harmonic content is within specified limits. 19. Verify emergency stop control works and motor stops as required and control relays operate to properly disconnect power from the motor. 20. Set speed/frequency control to 100% motor speed and energize AFD. Ensure motor accelerates to rated speed smoothly. Check and record the following: Acceleration time: peak current: Voltage: Vibration D.E.: N.D.E: 21) Check the stability of the motor speed and frequency. 22) Stop the motor and control relays operate to properly disconnect power from the motor. 23) Couple the motor to the load.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 206 of 222

REMARKS

Form YERP - P-071 Issue Date

YERP PRE-COMMISSIONING FORM

Sheet 6 of 7

VARIABLE FREQUENCY DRIVES FOR NEMA FRAME MOTORS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

ADJUSTABLE v DRIVE AND MOTOR FULL-LOAD TESTS Yes

No

1. Set the speed/frequency control for 25% speed and energize the AFD and motor. Verify the motor accelerates smoothly. Check the motor for any noise, vibration or heating. Run the motor for 1 hour and Record the following: Peak Starting Current: Voltage: Continuous Motor Current: Motor Temperature Start: After 1 Hour: Vibration D.E.: N.D.E: 2. Record current and voltage output waves. Verify stability factor and harmonic content is within specified limits. 3. Check AFD current limit setting and adjust as necessary. Record setting. 4. Press stop button. Verify motor stops Verify motor stops and control relays operate to properly disconnect power from the motor. 5. Set the speed/frequency control for 50% speed and energize the AFD and motor. Verify the motor accelerates smoothly. Check the motor for any noise, vibration or heating. Run the motor for 1 hour and Record the following: Peak Starting Current: Voltage: Continuous Motor Current: Motor Temperature After 2nd Hour: Vibration D.E.: N.D.E: 6. Record current and voltage output waves. Verify stability factor and harmonic content is within specified limits. 7. Press stop button. Verify motor stops and control relays operate to properly disconnect power from the motor. 9. Set the speed/frequency control for 75% speed and energize the AFD and motor. Verify the motor accelerates smoothly. Check the motor for any noise, vibration or heating. Run the motor for 1 hour and Record the following: Peak Starting Current: Voltage: Continuous Motor Current: Motor Temperature After 3rd Hour: Vibration D.E.: N.D.E: WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 207 of 222

REMARKS

Form YERP - P-071 Issue Date

YERP PRE-COMMISSIONING FORM

Sheet 7 of 7

VARIABLE FREQUENCY DRIVES FOR NEMA FRAME MOTORS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

ADJUSTABLE FREQUENCY DRIVE AND MOTOR FULL-LOAD TESTS (Continued) Yes

No

10. Record current and voltage output waves. Verify stability factor and harmonic content is within specified limits. 11. Press stop button. Verify motor stops. 12. Set the speed/frequency control for 100% speed and energize the AFD and motor. Verify the motor accelerates smoothly. Check the motor for any noise, vibration or heating. Run the motor for 1 hour and Record the following: Peak Starting Current Voltage Continuous Motor Current Motor Temperature After 4th Hour Vibration D.E. N.D.E 13. Record current and voltage output waves. Verify stability factor and harmonic content is within specified limits. 14. Verify current limit setting and acceleration time. 15. Record Potentiometer, jumper and control point settings. Retain oscillographs for future reference. 16. The above can be used to verify the AFD and motor operate properly. AFD's associated with processes may receive control signals from transducers related the process, i.e. speed or torque signals. Operation of the AFD for each of the process control input signals should be verified and pertinent data recorded.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 208 of 222

REMARKS

Form YERP - P- 080 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 1 of 3

GROUNDING SYSTEMS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

NEUTRAL GROUND RESISTOR NAME PLATE Voltage Current Rating Time Rating Ohms VISUAL INSPECTION Yes

No

Yes

No

Yes

No

1. Verify the grounding resistor complies with the drawings and specifications. 2. Verify the installation meets codes and standards. 3. Check all insulating parts and surfaces. They should be clean and free from chips and cracks. MECHANICAL INSPECTION 1. Check connection to transformer neutral bushing. 2. Check connection to neutral grounding resistor. 3. Check ground connections. 4. Check all mounting hardware for tightness. 5. In corrosive environments, coat spot welded terminal connections with silicon grease or paint to minimize corrosion. ELECTRICAL TESTS 1. Measure and record resistance.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 209 of 222

REMARKS

Form YERP - P- 080 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 2 of 3

GROUNDING SYSTEMS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

SYSTEM GROUND VISUAL INSPECTION Yes

No

Yes

No

2. Check for conformance to specifications and drawings. 3. Check thermal connections, no cold joints or burn-out's. 4. Check ground well locations per drawings. 5. Check ground conductor burial depth per specifications. 6. Verify the location, type and size of equipment taps per drawings and protected during construction. 7. Thermal connection insulation checked. MECHANICAL INSPECTION

1. Ground well connections checked. 2. Check for sufficient slack in ground conductor on motors with side rail or mounts. 3. Check for proper positioning and bonding of ground conductor on motor frames, transformer tanks, potential transformers surge arresters, towers and stands.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 210 of 222

REMARKS

Form YERP - P- 080 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 3 of 3

GROUNDING SYSTEMS Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

GROUND FAULT PROTECTION (NEC 230.95) VISUAL AND MECHANICAL INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. 9.

Yes

No

Yes

No

Yes

No

Inspect for physical damage and compliance with plans and specifications. Zero sequence system is grounded upstream of sensor i.e. ground wire does not go through sensor. Inspect neutral main bonding connection to assure that the ground strap systems are grounded through sensing device. Insure the neutral main bonding connection is made ahead of the disconnect link. Insure the control power transformer has adequate capacity for the system. Monitor panels, if present, shall be manually operated for trip test, no trip test and nonautomatic reset. Zero sequence systems shall be inspected for symmetrical alignment of core balance transformers about all current carrying conductors. The ground fault device shall be verified by device operation. Pickup and time delay settings in accordance with settings provided by PDD.

ELECTRICAL TEST 1.

2. 3.

4.

Measure system neutral insulation resistance to insure no shunt ground paths exist, neutralground paths exist, remove neutral ground disconnect link, measure resistance and replace link. Check GFR pickup current by primary current injection at the sensor and operating the circuitinterrupting device. Check the relay timing by injecting one hundred fifty percent (150%) and three hundred percent (300%) of pickup current into the sensor, electrically monitor the total trip time. Trip times shall be consistent with manufacturers specified values. Zone interlock systems shall be tested by simultaneous sensor current injection and monitoring zone blocking function.

TEST PARAMETERS 1.

System neutral insulation resistance shall not be less than one hundred (100) ohms.

2.

Relay pickup current shall be within ten percent (10%) of device dial or fixed setting.

3.

Relay timing shall be in accordance with manufacturer's published time current characteristic curves but in no case longer than one (1) second.

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 211 of 222

REMARKS

Form YERP - P-082 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 1 of 4

HEAT TRACING Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

FIELD INSTALLATION CHECK LIST VISUAL INSPECTION Yes

No

1. Check identification tag for correctness. 2. Heaters stored in dry location. 3. Cables protected from severe blows and welding slag. 4. The correct cable is on the right pipe and in the right location. 5. Heat Transfer cement applied as directed. 6. Thermostats installed so as not to interfere with insulation 7. Correct type thermostats and contactors installed in right location. 8. Verify heaters supplied satisfy specified requirements. 9. Check Correctness of wiring to heaters.

ELECTRICAL INSPECTION Yes

No

1. Check continuity to insure no conductors are broken. 2. Megger from conductor to sheath to check insulation (less than 20 megohms when received should not be used). 3. Megger and record on Field Test Record (1) before installation, (2) after installation and (3) after applying insulation. WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 212 of 222

REMARKS

Form YERP - P-082 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 2 of 4

HEAT TRACING Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

MEGGER READINGS (ELECTRIC HEAT TRACING) (1) BEFORE INSTALLATION HEATER NUMBER

WITNESS

TAG INFORMATION CHECKED

CONTRACTOR

DATE OF TEST

INSPECTION

CONTINUITY (OHMS)

INSULATION RESISTANCE (MEGOHMS)

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 213 of 222

REMARKS

Form YERP - P-082 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 3 of 4

HEAT TRACING Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

MEGGER READINGS (ELECTRIC HEAT TRACING) (2) AFTER INSTALLATION HEATER NUMBER

WITNESS

TAG INFORMATION CHECKED

CONTRACTOR

DATE OF TEST

INSPECTION

CONTINUITY (OHMS)

INSULATION RESISTANCE (MEGOHMS)

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 214 of 222

REMARKS

Form YERP - P-082 Issue Date:

YERP PRE-COMMISSIONING FORM

Sheet 4 of 4

HEAT TRACING Equipment Type: Equipment Tag No: BI/JO No: Ref. Drawings & Documents: Manufacturer: Model No: Test Completion Date:

User Reference: Equipment Description: Plant No. / Location:

Serial No:

MEGGER READINGS (ELECTRIC HEAT TRACING) (3) AFTER INSULATION HEATER NUMBER

WITNESS

TAG INFORMATION CHECKED

CONTRACTOR

DATE OF TEST

INSPECTION

CONTINUITY (OHMS)

INSULATION RESISTANCE (MEGOHMS)

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 215 of 222

REMARKS

FORM YERP - X-001

SHT 1 of 2

YERP PRE-COMMISSIONING FORM CATHODIC PROTECTION RECTIFIER EQUIPMENT TYPE: USER REFERENCE: EQUIPMENT TAG NO.: DESCRIPTION: BI/JO NO.: PLANT NO. / LOCATION: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: SERIAL NO.: COMMISSIONING DATE: SYSTEM DATA: TYPE:

Air cooled

RATING: SETTING TYPE:

V

Oil cooled A

Tap

PHASE:

OPERATING OUTPUT :

SCR NUMBER OF TAPS:

RATING OF RECTIFIER SHUNT:

AC INPUT

A

V V

TAP SETTING:

A C

M_______F

mV

PRIOR TO ENERGIZING Yes No 1

DC. Positive (+) cable between rectifier and anode bed properly labeled and connected ? DC. Negative (-) cable between rectifier and Structure properly labeled and connected ?

2 3 4 5 6

Cable terminals/connections tight? Rectifier case grounded? Oil level in rectifier acceptable ( for oil-cooled type)? Spare SCR card and fuses available? Additional requirements for SCR type rectifier: Output control board properly inserted ? Correct type of output control board? Move taps of rectifier to minimum setting or adjust Potentiometer to minimum before energizing

7

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 216 of 222

Remarks

REMARKS

FORM YERP - X-001

SHT 2 of 2

YERP PRE-COMMISSIONING FORM CATHODIC PROTECTION RECTIFIER EQUIPMENT TYPE: USER REFERENCE: EQUIPMENT TAG NO.: DESCRIPTION: BI/JO NO.: PLANT NO. / LOCATION: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: SERIAL NO.: COMMISSIONING DATE: AFTER ENERGIZING 1

Energize the rectifier.

2.

Record values shown on volt and amp meters

3.

Verify rectifier amp/volt meters with reliable portable meter(s)________ DC Volt ____________DC Amp Shunt rating_______Mv. ____________Amp: Increase rectifier output to obtain design output value: _____________DC Volt; __________DC Amp

4.

Note: Ensure that the rectifier output is set at the minimum value DC Amp

DC Volt

Notes 1) For three(3) phase system with separate taps in each phase, maintain phase balance by keeping tap positions identical in each phase. 2) Turn off the rectifier before changing the output setting. 5.

Check all DC connections to ensure that there is no excessive heat at the connections (loose connection generates excessive heat). If excessive heat present, turn off the system, then tighten the loose connections. Note: Excessive heat from a loose connection immersed in oil can generate bubbles.

6.

Adjust/Reduce rectifier output as necessary to obtain adequate protection levels at key locations

7.

Conduct Performance Evaluation of the anode bed ( Anode Bed Commissioning Data Sheet Form X-010 or X-011).

8.

Total anode bed resistance

9.

Perform CP. Potential Survey (Form X-007, X-008, or X-009)

10.

Check structure-to-soil potentials to detect C.P. interference. If interference present, identify locations by structure identification.

WITNESS

CONTRACTOR

ohm

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 217 of 222

REMARKS

FORM YERP - X-003

SHT 1 of 1

YERP PRE-COMMISSIONING FORM CATHODIC PROTECTION PLANT POTENTIAL SURVEY EQUIPMENT TYPE: USER REFERENCE: EQUIPMENT TAG NO.: DESCRIPTION: BI/JO NO.: PLANT NO. / LOCATION: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: SERIAL NO.: COMMISSIONING DATE: SYSTEM DATA RECTIFIER RATING: ANODE TYPE:

V

A

ANODE SYSTEM

ANODE NUMBER:

ANODE SYSTEM

OPERATING OUTPUT:__________ V_________A

Remote Deep

Distributed Distributed

INSULATING FLANGE PRESENT ___Yes _____No Reading on Insulation Checker:______

SURVEY DATA: TEST POINT NO.

STRUCTURE-TO-ELECTROLYTE POTENTIAL (mV) ON AS-FOUND/OFF

REMARK

NOTE: Attach a sketch to show locations of test points Page ____ of_____

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 218 of 222

REMARKS

FORM YERP - X-004

SHT 1 of 1

YERP PRE-COMMISSIONING FORM CATHODIC PROTECTION EXTERNAL TANK BOTTOM POTENTIAL SURVEY EQUIPMENT TYPE: USER REFERENCE: EQUIPMENT TAG NO.: DESCRIPTION: BI/JO NO.: PLANT NO. / LOCATION: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: SERIAL NO.: COMMISSIONING DATE: SYSTEM DATA RECTIFIER RATING: V_ A RECTIFIER OUTPUT: V A DESIGN CAPACITY: A ANODE TYPE: ANODE NUMBER___________ PERMANENT REFERENCE ELECTRODE TYPE:

SURVEY DATA REF. No.

TANK-TO-PERMANENT REFERENCE POTENTIAL (-mV) O N

1 2 3 4 5 6 7 8 9 ANODE No. 1

ANODE OUTPUT (AMP)

AS-FOUND/OFF

TANK-TO-Cu/CuSO4 REFERENCE POTENTIAL (-mV) ON

AS-FOUND/OFF

N N-E E S-E S S-W W N-W ANODE No. 9

ANODE OUTPUT (AMP)

ANODE No. 17

2

10

18

3

11

19

4

12

20

5

13

21

6

14

22

7

15

23

8

16

24

WITNESS

Location

CONTRACTOR

ANODE OUTPUT (AMP)

INSPECTION

TANK SKETCH

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 219 of 222

REMARKS

FORM YERP - X-005

SHT 1 of 1

YERP PRE-COMMISSIONING FORM CATHODIC PROTECTION TANK INTERNAL POTENTIAL SURVEY EQUIPMENT TYPE: USER REFERENCE: EQUIPMENT TAG NO.: DESCRIPTION: BI/JO NO.: PLANT NO. / LOCATION: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: SERIAL NO.: COMMISSIONING DATE: SYSTEM DATA CP SYSTEM TYPE: CAPACITY:

Galvanic

A

Impressed

RECT. RATING:

CURRENT ANODE TYPE

RECTIFIER TYPE: V

A

Oil Cooled

OPER. OUTPUT:

GALVANIC ANODE TYPE

Air Cooled DESIGN

V

A IMPRESSED-

REF. ELECTRODE__________

SURVEY DATA: SKETCH FOR LOCATIONS OF ANODES AND TEST POINTS ANODE No.

ANODE OUTPUT (AMPS)

1 2 3 4 5 6 7 8

LOCATION

TOP ON

STRUCTURE-TO-WATER POTENTIAL (-mV) MIDDLE BOTTOM OFF ON OFF ON OFF

1 2 3 4 5 6

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 220 of 222

REMARKS

FORM YERP - X-007

SHT 1 of 1

YERP PRE-COMMISSIONING FORM CATHODIC PROTECTION PIPELINE POTENTIAL SURVEY EQUIPMENT TYPE: USER REFERENCE: EQUIPMENT TAG NO.: DESCRIPTION: BI/JO NO.: PLANT NO. / LOCATION: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: SERIAL NO.: COMMISSIONING DATE: SYSTEM DATA: C.P.SYSTEM TYPE: Rectifier

, Photovoltaic______

ANODE BED TYPE: SURFACE DESIGN CAPACITY:

V,

RECTIFIER TYPE:

Oil Cooled,

Air Cooled

, DEEP

TYPE OF ANODE:___________________

A

NUMBER OF ANODES:______________

OPERATING OUTPUT:_______ V, ______ A

INSULATING FLANGE PRESENT: Yes____ No____ Reading on Insulation Checker:_______

COMMISSIONING DATA: PIPE-TO-SOIL POTENTIAL (-mV)

KM

WITNESS

FLOWLINE D.C. POWER ON OFF

CONTRACTOR

BOND BOX

CROSSING PIPELINE D.C. POWER NAME ON OFF

INSPECTION

SHUNT* RATING

A/mV

READING

mV

OPERATION/MAINTENANCE

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FORM YERP - X-010

SHT 1 of 1

YERP PRE-COMMISSIONING FORM ONSHORE ANODE BED PERFORMANCE EVALUATION EQUIPMENT TYPE: USER REFERENCE: EQUIPMENT TAG NO.: DESCRIPTION: BI/JO NO.: PLANT NO. / LOCATION: REF. DRAWINGS & DOCUMENTS: MANUFACTURER: MODEL NO.: SERIAL NO.: COMMISSIONING DATE: SYSTEM DATA CP SYSTEM TYPE: TYPE OF ANODE:

Rectifier

Photovoltaic TYPE OF ANODE BED:

RECTIFIER RATING:

C.P. SYSTEM CAPACITY: _____A

V

A

Deep

Surface

MODULE RATING:_____V _____A:

OPERATING OUTPUT:_________V_________A

SURVEY DATA ANODE NUMBER

CURRENT OUTPUT AT COMMISSIONING (A)

CURRENT OUTPUT AFTER POLARIZATION (A)

NOTE: RATING OF ANODE SHUNT: mV,

WITNESS

CONTRACTOR

INSPECTION

OPERATION/MAINTENANCE

Signature & Date General Confidential Page 222 of 222

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