MM Mechanical FINAL

7/30/2019 MM Mechanical FINAL

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Success in handing over a completely commissioned

facility to the operator, whether a new build or brown-

field modif ication, is contingent upon the completion

of numerous phases of the project, from the front end design and

engineering through fabrication and final commissioning. Before

final hookup and installation can be accomplished, three interrelated

phases are undertaken, Mechanical Completion (MC), Pre-

Commissioning and Commissioning (PC/C). Planning for them

is critical to the schedule adherence, cost containment, successful

installation and ultimate handoff for operation of the facility. This

article will focus on the important Mechanical Completion phase

in which Mustang plays an integral role.

Mechanical Completion DefinedTo be mechanically complete, the construction activities on a

specific portion of the project, such as the topsides, have been

completed and accepted by the appropriate parties. In most

instances, it is an integral part of the transition from construction

into the pre-commissioning phase, but Mechanical Completion has

specific attributes that lend themselves to being separately planned

and conducted. Mechanical Completion, as the f inal phase of

construction is, mostly undertaken by area or by discipline and is

performed by construction-type personnel with participation fromspecialized equipment suppliers, the engineering firm, and other

contractors as needed. It involves fabrication, assembly and non-

functional testing to confirm the integrity of the construction and

installation. To verify that a facility is mechanically completed,

inspection or an oversight team must ensure that the final con-

struction is in accordance with the project drawings, specifications,

industry standards as well as all regulatory requirements from the

authorities having jurisdiction. By mechanically completing the

scope of work and verifying with proper inspection prior to moving

the facility/equipment to the next phase of the work (e.g. the deck

fabricator, integration facility or offshore), considerable schedule

delays and excessive labor costs can be averted.

What Mechanical Completion (MC) EntailsThe MC phase addresses structural, mechanical, piping, electrical,

instrumentation and automation as well as topsides interfaces with

export pipelines and subsea flowlines. Each of these areas needs to

be thoroughly confirmed as complete, tested to the applicable

codes and turned over with documentation to the Pre-Commission/

Commissioning team as mechanically complete. During this phase

of the work, depending on the regulatory agencies involved and

the area of installation, the authority having jurisdiction (USCG,

BOEMER, NRC, ABS, EPA, etc), will be involved in many

aspects of the testing and approvals to allow the project to proceed

further.

One Mustang project consisted of large modules assembled in a

fabrication yard and then shipped to a remote location where they

were installed followed by joining interconnecting pieces for the

piping, instrumentation and electrical. During Mechanical

Completion, all systems and components were inspected by

Mustang and verified. Any incorrect component was identified,tagged and later corrected prior to shipment of any modules from

the fabrication yard. When the modules were finally shipped,

limited personnel were only needed briefly at the remote site.

These actions minimized the overall project schedule resulting in

a significant savings and allowed production to commence earlier

than originally planned.

Structural, Mechanical and Piping Mechanical Completion

of the structural, mechanical and piping portion of the project


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includes, but is not limited to,

verification that the piping systems,

mechanical equipment and their

supporting structure are installed,

non-destructively examined,

hydrostatically tested and flushed

clean. Equipment and piping

which required stress analysis and

the resulting line stops, piping

spring hangers, anchors, guides,

etc, should be verified that

installation is in accordance

with the design data. Rotating

equipment, including specialized

larger pumps, compressors,

generators and engine driven

equipment, are handled differently.

The equipments complex nature,

and typically the limited knowl-

edge of this type equipment by

the fabricator, necessitates relying

upon contracting vendors for field

support of their equipment. These representatives assist and

confirm the installation of such equipment, verifying alignment,

completeness of preservation and operating fluids during this

phase of the work. This assistance ensures warranties for such

equipment are maintained and the equipment is ready for service

when required. When the facility is installed offshore, the required

work to assist start-up is largely completed in a few days and has

no impact to the schedule.

Electrical Verification of the electrical installation / construction

is more complicated, as much of it is field routed for best fit. In

addition to normal inspection of each of the cables and wiring,

all terminations should be validated for the quality and accuracy

of the installation. Some areas of inspection during this phase

include, but are not limited to, cable and tray support, tray f ill,

grounding, integrity, stress cone installation for medium and high

voltage cable, terminations, continuity and megger testing, as well

as checking the bend radius of the f inal installation and tiedown.

Instrumentation Mechanical Completion for instrumentation

systems includes validation of the instruments, valves and valve

operators compared to the original design data to assure that

process flow conditions will be met. As with the electrical MC,

all wiring will need to be verified, inspected for continuity and

insulation as well as loop checks for confirmation to the automation

system. Both hydraulic and pneumatic tubing will be cleaned,

flushed and pressure tested to assure that there are no leaks and

that cleanliness meets required quality for the system it controls.

Surface Protection The best possible coating application can

minimize work in later stages of the project. Inspections will reveal

whether or not painting or coatings on specified surfaces has been

completed and insulation has been finished and is as specified in

the drawings. Fireproofing application or special coatings provide

a challenge on all projects and need to be closely examined.

New Build or BrownfieldAlthough the MC activities are very similar for both a new build

facility and a brownfield project, each has its own challenges.

With the new build not being operational, there is more latitude

for making construction decisions regarding hotwork and

pressurized systems. With an operating facility, however, planning,

scheduling and logistics in verifying tie-ins and equipment

operation can be more complex and critical to avoiding any

shutdown or disruptions to operations. Construction limitations

due to hydrocarbons restrict the types of work that can beperformed and the equipment utilized to perform the work.

Many brownfield projects on an operating facility will require

restricted hot work permits and utilize welding habitats that enable

hot work to be performed without shutting down the facility.

This minimizes production shutdowns but adds another layer of

complexity and interfaces among disciplines. An additional problem

on many operating facilities is the limited bed space availability

required for both operations and MC personnel.

A thorough Mechanical Completion phase can reduce the overallproject schedule.


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Equipment Preservation

Preservation of the equipment after it arrives on site is an activity

most often overlooked yet potentially quite costly to any project.

This activity plays a critical role in the efficiency and cost

effectiveness of not only Mechanical Completion, but the overall

success of achieving a planned startup date. Preservation defines

the preventive maintenance tasks that are necessary to ensure that

equipment and systems are appropriately cared for from the time

they leave the manufacturing facility to when they are put into

normal operation. The more complex a project or the longer it

takes to complete, the more susceptible equipment and components

are to be damaged or neglected, thus voiding manufacturers

warranties.

Materials procured for a project are usually stored on-site at the

fabrication facility awaiting their installation. If the equipment is a

component on the lower level of a multi-tiered deck, for instance,

it might be installed at an early fabrication stage and subjected

to weather for an extended period while the rest of the facility is

being fabricated and assembled. The cost of repairing or replacing

equipment due to inadequate preservation can be significant.

It is an area where experienced Mustang inspectors can assist

third-party specialists, often contracted to supervise equipment

preservation during the project and can be a worthwhile investment

to limit equipment damage on site and delays in Mechanical

Completion and Pre-Commissioning.

Handover

Ideally, with good planning, inspection and engineering interface,

the projects construction phase will conclude with a successful

mechanical completion. Upon conclusion of Mechanical

Completion activities, a certificate should be issued stating that the

relevant inspections and tests have been carried out according to

the contract. All of the support documentation and redline drawings

and documents should be attached. The certificate will be accom-

panied by the punch list if the sail dates dont allow completion of

all MC activities prior to moving to the next location.

The exercise of Mechanical Completion is a critical link between

the engineering/design and construction of

the facility and its ultimate installation and

operation. Mustang has the expertise to fill

many roles during this phase. Mustangs

planning during early project stages, execution

with experienced construction management

and inspector oversight, proper equipment

preservation supervision , and interface

management make the pre-commissioning

and commissioning phases more efficient

and economical.

For more information concerning Mustangscapabilities in Mechanical Completion and

Pre-Commissioning/Commissioning, contact

Richard Shirley or Dan Vela at

[email protected] or

[email protected].

Mustang inspectors are critical to successful MechanicalCompletion.

Equipment installed on the lower level of a multi-tiered deck can be subjected to weatherfor long periods.

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MM Mechanical FINAL