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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), PreCommissioning 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.
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.
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 knowledge 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 fill, 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 final 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.
A thorough Mechanical Completion phase can reduce the overall project schedule. 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.
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. Mustang inspectors are critical to successful Mechanical Completion.
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 accompanied 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 Mustangs capabilities in Mechanical Completion and Pre-Commissioning/Commissioning, contact Richard Shirley or Dan Vela at richard.shirley@mustangeng.com or dan.vela@mustangeng.com.
Equipment installed on the lower level of a multi-tiered deck can be subjected to weather for long periods.