Professional Documents
Culture Documents
Contents
1
Introduction
1.1
1.3
Objective
Supplier Reference Documents
Necessary Material
Procedures
1.2
3.1
3.1.1
3.1.2
3.1.3
3.1.4
Mechanical Checklist
Package General
Piping
Vessels
Access
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
Instrument Checklist
Level Gauges
Level Control Valves
Differential Pressure Transmitters
Pressure Indicators/Pressure Differential Indicator/Temperature Indicators/Flow Indicators
Pressure Relief Valves
Level Switches
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
Electrical Checklist
Junction Boxes
General Inspections
Documentation
Conformity
Cable Installation and Tests
3.4
Document Verification
Manufacturer: CPE
Client PO:10-118-26
FAT PROCEDURE
Abu Qir Thermal Power Plant
Supplier: DPS
1
1.1
Objective
The Objective of this document is to provide a detailed Factory Acceptance Test Plan for DPS purchase order PO-2010-1105-001, which consist of a Filter
Separator and Drain Tank Skid Assembly. The major components of the package include the following:
1. Filter Separator Skid Assembly
a .Filter Separator Vessel 6-FG-MT001
b. Filter Separator Vessel 7-FG-MT001
c. Drain Tank 9-FG-MT-001
The test procedures containted in Section 3 of this document will be utilized to determine the following:
1. Product compliance with the purchase order document
2. Product compliance with the purchase order specifications
3. Acceptability of workmanship
4. Integrity if components
5. Verification of Functionality
It should be noted that process control is being performed in the Plant Control System. The instruments and valving
associated with these functions will be checked for calibration and functionality using a hand held communicator.
FAT will be considered complete when all items on the checklist have be brought into conformity.
All Equipment from sub-vendors will have been tested and calibrated prior to delivery.
1.2
Client PO:10-118-26
Introduction
Document Title
Instrument List Rev H
Manufacturer's Hydrotest Reports
Manufacturer's NDE Reports
Manufacturer's Coating Reports
Material Test Certificates
Cause & Effect Matrix / Logic Function
Pipe & Instrument Diagrams (P&ID)
Piping GA (Plans & Elevations)
Filter Separator GAt Drawing
Drain Tank GA Drawing
Skid Assembly Drawing
Structural Skid Drawing
Filter Separator Platform Drawing
Electrical / Wiring Drawings
Junction Box Layout Drawing
Instrument Calibrations and Certification
Document Title
Purchase Order Number
Fuel Gas Filter Separator Data Sheet
Drain Tank Data Sheet
Design of Piping on skids
Instrumentation & Electrical Requirements for
packaged equipment
ITP Form
Surface Preparation and Painting
1.3
Client PO:10-118-26
Necessary Material
HART COMMUNICATOR FOR PDIT
MANOMETER PRESSURE SET FOR PDIT
24VDC POWER SUPPLY
FLUKE MULTIMETER
WATER SOURCE
COMPRESSED AIR SOURCE
3
3.1
Client PO:10-118-26
Procedures
Mechanical Checklist
Checklist
3.1.1
3.1.2
3.1.3
3.1.4
Package General
Verify package completed to P&ID: DPS-2010-1105-500
All tagging to be checked in position and correct to P&ID for all items.
Verify package completed to all General Arrangement drawings.
Confirm all TP locations.
Check for any visible signs of damage.
Review project documentattion.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________
SIGN
DATE
TS
TS
TS
TS
TS
TS
TS
3/31/2011
Piping
Confirm that all flanged joints are made up correctly.
Confirm pipe routing, supporting and painting are in accordance to Project Specifications.
Confirm all paintwork is undamaged.
Confirm piping color banding and identification is correct (if applicable).
Review project documentation.
Check for any required actions: Conforming _________X_________ Non-Conforming _______________
TS
TS
TS
TS
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TS
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Vessels
Confirm all hold down bolts are correctly fitted.
Confirm vessel nameplates are correct and securely fitted
Confirm vessel hand hole bolts and gaskets are correctly fitted.
Confirm all paintwork is undamaged.
Review project documentation.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________
TS
TS
TS
TS
TS
TS
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Access
Confirm access for operation and maintenance of all valves,and instruments.
Review project documentation.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________
TS
TS
TS
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Checklist
3.2
3.2.1
3.2.2
Instrument Checklist
SIGN
DATE
Level Gauges
Check mechanical mounting is correct and firm.
Check instrument for any visible sign of damage.
Verify material certification available with instrument
Verify nameplate is correct and securely fitted.
Review project documentattion.
Check for any required actions: Conforming _______X________ Non-Conforming _______________
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TS
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3.2.3
3.2.4
3.2.5
3.2.6
Client PO:10-118-26
TS
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Level Switches
Check mechanical mounting is correct and firm.
Check instrument installed in correct position.
Check for any visible sign of damage.
Verify nameplate is correct and securely fitted.
Review manufacturers set pressure certification.
Review project documentattion.
Check for any required actions: Conforming _______X________ Non-Conforming _______________
TS
TS
TS
TS
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TS
TS
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Checklist
3.3
3.3.1
3.3.2
3.3.3
3.3.4
Electrical Checklist
SIGN
DATE
TS
Confirm all junction boxes are adequately supported and the installation does not foul operators access.
Verify junction box is tagged as per the cable schedule.
Confirm all items are correctly earth bonded.
TS
TS
TS
Confirm all electrical equipment is certified for the hazardous environment and that correct certification is available for review.
TS
Confirm that all spare entries are plugged with certified plugs
Review project documentattion.
Check for any required actions: Conforming ______X_________ Non-Conforming _______________
TS
TS
TS
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General Inspections
Verify materials agree with Bill of Material
Verify dimensions agree with Assembly
Verify component layout agrees with Assembly
Verify fuses are installed and ratings
Verify equipment grounding connections to chassis and instrument ground busses
TS
TS
TS
TS
TS
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Documentation
Junction Box Layout drawing number DSP-2010-1105-401
Junction Box Wiring drawing number DSP-2010-1105-402
TS
TS
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Conformity
Check for any required actions: Conforming _______X________ Non-Conforming _______________
TS
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3.3.5
Client PO:10-118-26
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Checklist
3.4
Documentation Verification
Verify completion of hydrotest record and stamp from customer inspector.
Verify completion of NDE record and stamp from customer inspector..
Verify completion of coating record and stamp from customer inspector..
Verify availability of Material Test Record and stamp from customer inspector..
Verify availability of instrument calibrations and verification, and stamp from customer inspector..
Verify all instruments' data against the instrument list.
Verify Cause & Effect is approved with no customer comments.
Verify P&ID is approved with no customer comments.
Verify Junction Box Diagram is approved with no customer comments.
Verify Instrument Calibrations and Certification is approved with no customer comments.
Verify on-skid cable routing and earthing is approved with no customer comments.
CPE Representative:
Date:
Client Representative:
Date:
SIGN
DATE
DD
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DD
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DD
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DD
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DD
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