AECOM

FCM Continuation Project

FCM Construction, Installation and Commissioning Methodology

14

DRAFT

7.0

Pre-Commissioning Methodology

The following section describes the commissioning procedures that should be carried out prior to putting any new
equipment into operation. Also refer to Newcrest Lihir standard LGL-000-S-P007 Standard Specification P007,
Fabrication, Inspection & Testing of Piping for other commissioning assistance.
No.
7.1.0

Task/Description
Weld Inspection and Testing

7.1.1

All new welds and welding procedures should conform to ASME B31.1

7.1.2

All welds should undergo Non-Destructive Examination (NDE). Full visual examination shall be carried out on each
weld.

7.1.3

Test reports for NDE shall be as per ASME B31.1

7.1.4

Personnel responsible for carrying out and reporting the NDE shall be appropriately qualified as per ASME B31.1

7.2.0

Hydrostatic Testing

7.2.1

Hydrostatic testing is required to be carried out on any new piping as per ASME B31.1 Power Piping, Section 137.4
Hydrostatic Testing

7.2.2

Testing to consist of workshop hydrostatic testing of pipe spools and/or hydro testing of the entire installed system as
a whole

7.2.3

Weld inspection and testing sign offs

7.2.4

Flange tightening checks (including flange tags)

7.2.5

Check against quality plan and check lists, filling line flushing etc

7.2.6

Check against construction drawings

7.2.7

Checking of all pipe supports as per design drawings

7.2.8

Please refer to the Line Schedule 555-1711-PP-LIS-0001 for a list of pipe lines and their required hydrostatic test
pressure.

7.2.9

An in-service leak test shall be also be performed

Suggested Setups

7.2.10

DN80 HFO Header and Feeds Refer to Appendix A for P&ID mark up

7.2.11

Rotate DN40 removable spool piece 90 degrees and blank on feed lines to the FCMs

7.2.12

Bolt DN80 pipework from the Booster side of the flexible hose connection to the downstream DBB isolation valve on
the DN80 feed line to the Booster from the HFO header outside and blank off

7.2.13

Rotate bleed line between DBB isolation valves on the E-steel HFO feed line to the vertical position to act as a high
point vent

7.2.14

Use of high point vent at clayton house by support HFO-S1

7.2.15

Use of high point vent on HFO header on the western end of the pipe bridge

7.2.16

Upstream DBB isolation valve on Feeder 2 (PCA 901) to be used as filling point

7.2.17

Remove DN80 check valve on Feeder 1 (PCA 905) outlet line, connect upstream piping in its place and blank end
before the Feeder. Piping will need to be temporarily supported.

7.2.18

Use of connection to isolation valve on end of header @ Gridline 16 as secondary filling point
P:\603X\60340133\6. Draft Docs\6.1 Reports\Construction, Installation and Commissioning Methodology\555-1711-CO-TRP-0003.docx
Revision A 29-Jun-2015
Prepared for Newcrest Mining Limited ABN: 069 803 998

AECOM

FCM Continuation Project

FCM Construction, Installation and Commissioning Methodology

15

DRAFT

No.

Task/Description

7.2.19

DN50 FO Return Header and Feeds - Refer to Appendix B for P&ID mark up

7.2.20

Open both DN50 DBB isolation valves on all Booster FO return lines
Bolt DN50 pipework from the Booster side of the flexible hose connection to the DN50 check valve on the DN50 FO
return line and blank

7.2.21

Open both DN40 DBB isolation valves on all FCM unit FO return lines

7.2.22

Remove all DN20 spool pieces from FCMs to DN40 flanged check valves and blank upstream side of check valve

7.2.23

Use of high point vent at clayton house by support HFO-S1

7.2.24

Use of high point vent on header at the western end of the pipe bridge

7.2.25

Use of valve on end of header at Gridline 16 for filling point

7.2.26

DN40 Clean Leak Return Header and Feeds - Refer to Appendix B for P&ID mark up

7.2.27

Open both DN25 DBB isolation valves on all FO Return Unit lines

7.2.28

Remove pipework between Fuel Oil Return Units and the DN25 flanged check valve and blank upstream side of
check valve on units 901, 902 and 903

7.2.29

Use of high point vent at clayton house by support HFO-S1

7.2.30

Use of high point vent on header on the western end of the pipe bridge

7.2.31

Use connection to DN25 flanged check valve on unit 904 as filling point

7.2.32

DN80 LFO Header and Feeds - Refer to Appendix C for P&ID mark up

7.2.33

Remove DN80 downstream DBB isolation valve on the LFO header in the seawater trench and blank

7.2.34

Open both DN80 DBB isolation valves on all Booster LFO feed lines

7.2.35

Bolt DN80 pipework from the Booster side of the flexible hose connection to the downstream DBB isolation valve on
the DN80 LFO feed line to the Booster and blank

7.2.36

Open both DN40 DBB isolation valves on all FCM LFO feed lines

7.2.37

Remove spool piece on DN40 feed lines to FCMs and blank off. These lines to be used as high point vents

7.2.38

Use of DN80 isolation valve at the end of the header (Gridline 16) as filling point

7.2.39

D40 FO PCC Feeds and Returns - Refer to Appendix D for P&ID mark up

7.2.40

Remove spool piece on DN40 feed line from FCM to use as filling point

7.2.41

Unbolt DN40 FO return line from the FCM unit and raise pipework enough to enable line to be blanked

7.2.42

Remove PRV valve and blank ends of DN50 feed and return headers

7.2.43

Open all DN40 DBB isolation valves on all lines to and from PCC units

7.2.44

Close all DN25 DBB bleed valves on all lines to and from PCC units

7.2.45

Unbolt DN40 feed and return lines to and from the PCC unit and lift pipework enough to enable connection of
temporary jumper spool/hose between the two lines. Jumper spool should incorporate a high point vent also.

P:\603X\60340133\6. Draft Docs\6.1 Reports\Construction, Installation and Commissioning Methodology\555-1711-CO-TRP-0003.docx

Revision A 29-Jun-2015
Prepared for Newcrest Mining Limited ABN: 069 803 998