South Island

Central Island

North Island

Valve Testing, Preservation & Installation

UZ750 PROJECT ISLANDS SURFACE FACILITIES EPC2
PROJECT No. : P7512
CONTRACT No. : CT750 UZ11 01 10

West Island

Valve Testing Sequence at

valve shop

Hydro
(Body/
Seat)

Pneuma
tic
(Seat)

FET, LT
& FAT

19-Feb-15

Draining
, drying
& plugs
seal
weld

Valve Testing & Preservation at

Vendor shops

Evolution of valve
process

Responsible party

Records Generated

Valve Shops:
Assembled, Tested,
drained, dried, seal
welded, preserved &
Packed

Supplier performed the activity as

per approved procedures & ITP.

Following records
generated & endorsed by
Inspectors
1. Pressure/
performance test
reports
2. Preservation log
sheet,
3. MTC & cert pack
4. IRN/ SRN
5. Packing list
6. Shipping docs
7. Vendor Preservation
Procedure

PED Inspectors;
100% Witnessed assembly check
& applicable tests as per approved
ITP & procedures. Also
preservation check & Packing
verification.
COMPANY inspectors verified on
random
PED QEs / Lead QE visits vendor
shops for additional surveillance

19-Feb-15

Valve Preservation during Storage at

Marshalling Yard Records Generated
Evolution of
Responsible party
process
Storage at Marshaling
yard:
Receiving inspection
& generate reports

PED Material Management &

Preservation Engineer to ensure:
a) Verified packing condition &
ensure no damage.
b) Stored in dry place with original
packing & preservationundisturbed.
c) Ensure end caps are protected
from dust ingression.
d) Periodical monitoring (weekly) by
preservation engineer
e) Vendor preservation
recommendations are strictly
followed by yard preservation
team.
f) Preservation procedure from
vendors issued to the yards.
g) PED Quality/ Materials
management to perform selective
audits at yards for preservation
compliance
19-Feb-15

1. Material receiving
inspection report
2. Monthly preservation
check sheet and Log
Sheet completed by
yard preservation team.
3. Weekly monitoring by
home office
preservation team.
4. The equipment check
sheet for preservation is
modified by
preservation team to
suit vendors
recommendation, if
necessary where
applicable.
5. KPIs to be developed
to monitor compliance
with preservation
procedures
4

Valve Preservation during Storage

at FAB Yard

Evolution of valve
process

Responsible party

Records Generated

Storage at Fab
yard:
Receiving inspection
by FAB subcontractor and
reports issued

FAB Sub-contractor is
responsible to ensure vendor
recommendation be followed;
Yard preservation engineers to
monitor preservation be carried
out by sub-contractor and check
sheets are being verified;

Check sheets
generated by the
sub-contractor
verified by PED
preservation
engineers.
Preservation records
are part of load out
dossiers for each
modules.

19-Feb-15

Evolution of valve
process

Valve Preservation during

Storage at Site

Site Construction:
Receiving inspection &
generate reports

Responsible party

Records Generated

Construction Sub- contractor is

responsible to carry out the
preservation activities as per vendor
recommendation.

1. Material receiving
inspection report
2. Preservation check
sheet and Log
completed by subcontractor and
verified by PED
preservation
Engineer.
3. The equipment check
sheet for preservation
is modified by
preservation team to
suit vendors
recommendation, if
necessary where
applicable.

PED Preservation engineer to monitor

the following;
a) valves to be issued from marshaling
yard upon request from site based
on construction & installation
schedule
b) Periodical audits by preservation
engineer at site

19-Feb-15

Valve Installation at FAB shop

Evolution of valve
process

Responsible party

Valve Installation at
Fabrication Shop:

Fabrication Sub-contractor is
1. Flange management
responsible to ensure vendor
records.
recommendation be followed for
2. Mechanical
handling & installation methodology.
completion dossier
a) Monitor by PED Fabrication
for the sub system.
supervisor.
b) During Installation the correct
flange management is
completed.
c) On the final walk down when
piping sub system is completed
then the verification is being
carried out by mechanical
completion.

19-Feb-14

Records Generated

Valve Installation at Site (Stick

Built)

Evolution of valve
process

Responsible party

Records Generated

Valve Installation at
Site:

Construction sub-contractor is
responsible to ensure vendor
recommendation be followed for
handling & installation methodology.
a) Monitor by PED construction
supervisor.
b) During Installation the correct
flange management is
completed.
c) On the final walk down when
piping sub system is completed
then the verification is being
carried out by mechanical
completion.

1. Flange
management
records.
2. Mechanical
completion dossier
for the sub system.

19-Feb-15

Valve Installation sequence

Reference to COMPANY Corporate Engineering Spec for
Piping Fabrication Erection & Testing of metallic pipework
(Doc. No. Z0-TS-P-04010 Rev-1)
Ensure the lines is clean (no foreign particles, debris)
by blowing with air.
Identify the valves to be installed and issue request to
material group
Preservation engineer to ensure valve is in good
condition and ensure vendor recommendation is
followed.
Handle the valve as per vendor recommendations.
Install valves to ensure dimensional control

19-Feb-15

Valve Installation sequence

Soft seated valves, particularly ball valves shall be
installed in fully open position.
Drop Instrument valves, control valves, safety relief
valves and check valves prior to line flushing and
replaced with pup pieces. Dropped valves shall be
protected with end caps and preserved as per vendor
recommendation (responsibility with sub-contractor
and monitored by Preservation engineers)
Flush piping system with clean water (PED to develop
procedures for flushing and system hydro test)
Test the loop with clean fresh water having min. pH8
and 30ppm of chloride content.
Drain test water followed by drying with air blowing (6
to 7 bar)
Post installation preservation to be followed.
19-Feb-15
10

Post Meeting Notes

Topic

Discussions

Action

Vendor
Inspection

Vendors performing valve testing Sankar requested PED

prior to offering up for PED / ZADCO
team to relook at testing
inspection and testing
as concerned with 100%
No failures of valves to date during
success rate.
inspection. Only issue raised was PED
Quality
(home
weld overlay thickness which was
office) to add additional
previously addressed
surveillance
(random
check)

Preservationvendor shop
to installation

PED preservation team updates ZADCO Quality /

valve specific preservation check
Materials Management
sheets to ensure compliance with
to perform selective
manufacturer
specifications.
audit of valves at ME
Currently, manual system until
yards for preservation
PetroPCS is fully operational. At that
compliance
point, the system will generate
KPIs to be developed to
action reports and
When valves arrive at Fab Yards /
monitor compliance with
Marshalling yard, will be in Care and
preservation
Custody of that location including
procedures.
preservation
12-Feb-14

11

Post Meeting Notes

Topic

Discussions

Action

Fabricatio
n Yard
Scope:

Prior to installation of valves, lines will ZADCO / PED to look

be blown with air
at spec and discuss
Soft seated valves (particularly ball
with ZADCO corporate
valves) shall be installed in fully option
PED to confirm that no
position
Instrument valves, control valves, safety
risk exists for this type
relief valves and check valves shall be
of occurrence
dropped for flushing and cleaning
ZADCO concerned about risk to ball
PED to develop
valves being left in and potential scoring
procedures for
if debris caught in cavity.
flushing and hydro
PED stated that if ball valves are kept in
testing
full open position for flushing and
testing, then no accumulation can
develop that would not be able to be
drained due to welded plugs
Flushing and hydro test plans discussed
at high level as specifics have not been
developed yet
12-Feb-14

12

Post Meeting Notes

Topic

Discussions

Action

Preservation for
modules between
fabrication yard
and island:

Fabrication yards responsible Detailed plans

for preserving systems
and procedures
to be
developed by
PED

Commissioning /
Valve testing on
Island

Commissioning plans yet to PED to propose

be developed
critical valve
PED to hire subcontractor to
list for review
define test loops
by ZADCO
PED plans to conduct Helium /
within March15
Nitrogen seat leak test on PED to prepare
critical valves tested in-line
leak test
Close
downstream
valve,
procedure and
open
vent and use mass
submit to
spectrometer to (sonic as
COMPANY for
alternate)
approval
12-Feb-14

13

Post Meeting Notes

Topic

Discussions

Action

Spare
Philosophy

Spare Philosophy was discussed

but details not provided.

PED to share sparing

philosophy; ZADCO to consider
operational spares

Others

PED to develop valve

rectification plans if fail
during commissioning leak
test

PED to propose recovery

plan to ZADCO

PED to review with DSME

DSME process not discussed
for consistency and input
as Petrofac not aware of
DSME plans

12-Feb-14

14

Thank You

19-Feb-14

15