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Mechanical Completion
Certificate (MCC)
A certificate issued by the Executor to document that his MC scope
has been carrie...
Some examples include the running and entire testing of the power generation systems, testing of
emergency shutdown and co...
proprietary databases and work-order progress management tools. These tools blend well with systems
turnover and follow on...
documented by the ready for commissioning certificate (RFCC).
5.4 Carry Over Work Register (COWR)
The COWR lists all punch...
• Calibration and testing of instruments prior to installation.
• Visual inspection for complete and correct installation....
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Mechanical completion

  1. 1. Mechanical Completion Certificate (MCC) A certificate issued by the Executor to document that his MC scope has been carried out. The MC certificates shall be used per MC package. Mechanical Completion Check Record (MCCR) A discipline Check record for the various equipment. These records form the basis of the MC documentation. MCCRs are prepared for one or more items for recording of the results from checking and testing performed during Mechanical completion.Mechanical completion and commissioning Z-007 Rev. 2, Dec. 1999 NORSOK standard Page 4 of 54 Mechanical Completion (MC) The checking and testing of equipment and construction to confirm that the installation is in accordance with drawings and specifications and ready for commissioning in a safe manner and in compliance with project requirements. Mechanical Completions, Preservation, Pre- Commissioning & Commissioning Mechanical Completion (CMS) Mechanical Completion is an integral process of management verification of approved design installation. It represents the interface between construction and commissioning group activities and includes all interface checks between all systems and subsystems whether modular or plant wide. Mechanical Completion verification confirms that construction and installation of equipment, piping, instrumentation, cabling, electrical, telecoms and mechanical components are physically complete and all inspections, testing and documentation requirements have been completed. Preservation Preservation covers the method of protection and preventative maintenance carried out on equipment and systems before and after they are taken into use. The process begins with the application of preservatives and protection fittings by suppliers/vendors, prior to delivery permitting the equipment/system to arrive at GPS fabrication yard undamaged. Pre-Commissioning Pre-Commissioning (PC) is the stage that involves the verification of functional operability of elements within the system, by subjecting them to a set of simulated operational conditions, to achieve a state of readiness for commissioning. Pre-commissioning requires energisation of equipment and the introduction of the Permit to Work / LOTO systems.
  2. 2. Some examples include the running and entire testing of the power generation systems, testing of emergency shutdown and control systems and dynamic trials on oil and gas export systems prior to load out to minimize the offshore or site scope. Commissioning GPS’s commissioning capability consists of checking and testing all functions according to their design parameters in conditions as close as possible to the design conditions, and in bringing them to the status “Ready for Start-Up / Operations Readiness”. Start-Up & Commissioning Late facility design details, accelerated construction schedules, just- in-time manufacturing of equipment and managed low-levels of materials inventory at the distributor are the New Normal. As such, improper attention to systems completion, systems turnover, pre- commissioning, commissioning and start-up can lead a project further toward failed economics. Useful Definitions: System – A section of the facility or process which is mechanically continuous, but which can be isolated from other sections of the plant or process in a way which allows independent turnover, inspection or confirmation of process function. Pre-Commissioning – Checking for design conformance, piping mechanical completion, electrical code compliance and instrumentation installation and process tubing adequacy. Pre-Commissioning includes equipment run-in, PLC and DCS action checks, and a rotation check of process equipment which can be isolated from the overall process. Pre-Commissioning activities overlap with construction activities. The two are isolated from one-another by system boundaries and a robust system package turnover protocol. LOTO compliance, always a must, takes on even greater meaning as electrical equipment and circuits become energized and equipment rotation inspections commence. Commissioning – The phase of a project where actual process fluids are introduced to process equipment. Commissioning includes multiple function and process performance checks but precedes actual Start-Up. Start-Up – When stable process conditions are established and intentional product making or manufacturing for sale commences. As one of the last contractors to have access to the work, Ardent inherits the lost schedule float of all construction predecessors in the form of construction acceleration. To help manage ourselves toward timely and efficient completion we have developed a number of
  3. 3. proprietary databases and work-order progress management tools. These tools blend well with systems turnover and follow on well into systems pre-commissioning and start-up. Pre-Commissioning starts when facility systems achieve Mechanical Completion. In today's fast track world of building while some detailed designs are still in review, the Pre-Commissioning efforts must be tasked and managed in conjunction with the project's integrated Critical Path schedule. Construction is often progressed by area, and by the time erection progress exceeds 70% and/or I&E progress exceeds 50%, it is time to begin turning over systems from construction to the Pre-Commissioning team. Ardent's system turnover database and protocol helps to define,punchlist and manage inspection and pre- commissioning efforts. Our experienced instrument technicians and field process techs can inspect, track and assure systems completion progress is monitored, measured, achieved and reported. Commissioning and Start-up are a key part of project execution and are the natural outflow of quality systems completion, turnover and pre-commissioning. Introducing and stabilizing process fluids and conditions and commencing product export are WHY facilities get built. Ardent's Pre-Commissioning, Commissioning and Start-up Techs can help lead the way to the ultimate finish line, successful project completion. 5 MECHANICAL COMPLETION 5.1 Introduction This chapter forms the basis for the execution and documentation of mechanical completion activities. Mechanical completion takes place through all phases of a project, up to the commissioning phase. • Mechanical completion encompasses all disciplines. • The detailed responsibilities are described in the contract. • Executor of MC activities is responsible for establishing and compiling the MC dossiers and report status into PCS. 5.2 Documentation for a MC Package The MC package shall consist of an MCC, an MCSI, MCCRs and a PLR printout as described below. A Mechanical Completion Certificate (MCC) is a form completed by the Executor after all MC is carried out. The MCC is the cover sheet for each MC package. An MC package shall when signed, be ready for handover to commissioning. The Check Records (MCCR) are the forms on which the Executors record the results of all checks, inspections and tests carried out for each individual item. A Punch List (PL) shall be prepared by the Executor along with the package a PL shall be included to document incomplete work. A Mechanical Completion Status Index (MCSI) listing the status of all MCCRs for the MC package shall be included. 5.3 Handover at Mechanical completion Handover from Mechanical completion to commissioning shall be at commissioning package level,
  4. 4. documented by the ready for commissioning certificate (RFCC). 5.4 Carry Over Work Register (COWR) The COWR lists all punch items that the Project accepts as cannot be completed during present phase. The register is used for the release of the work from the Executor and will as such be an input to the scheduling and planning of outstanding work to be performed during later phases. The COWR Item number and cross reference to the Punch list/MCCR shall be given. COWR work shall be marked up on drawings or sketches and be included in the records. Material Status List (MSL) and marked up drawings/instruction shall contain sufficient information for job setting in a later phase. 5.5 Typical Mechanical completion activities Mechanical completion activities includes checking of fabrication and installation work. Executor shall complete packages related to listed disciplines and as required by the MCSI. Executor shall complete the check list items as per the MCCRs. (See Annex A for typicals). The activities shall include but not be limited to: 5.5.1 Mechanical • Visual inspection for complete and correct installation. • Internal inspection of tanks and vessels. • Alignment. • Load testing of lifting equipment. • Hot oil flushing. • Bolt tensioning. • Dimension control. • Preservation. 5.5.2 Electrical • Visual inspection for complete and correct installation. • Insulation and continuity testing of cables. • Insulation testing of generator, transformers and motors, panels, distribution board etc. • Earthing checks. • Static check of switches and control devices. • Battery preparations. • Lighting and socket outlet checks. • Area completion. • Heat tracing. • Preservation. 5.5.3 Instrument/Telecommunication
  5. 5. • Calibration and testing of instruments prior to installation. • Visual inspection for complete and correct installation. • Insulation and continuity testing of cables. • Cleaning, flushing, pressure and leak testing of pneumatic and hydraulic tubing. • Adjustment of control, alarm and shutdown settings. • Loop testing. • Function testing of control systems. • Function testing of field instruments. • Hot oil flushing of instrument tubing. • Area completion. • Preservation. 5.5.4 Piping • NDE carried out. • Welding procedures. • Removal of all items subject to damage during flushing, cleaning and pressure testing. • Flushing of pipework. • Chemical cleaning and testing of pipework. • Drying of tested pipework. • Preservation of tested pipework. • Reinstatement of all items after testing. • Final inspection of pipework. • Test ISO's and P&ID's showing the extent of each pressure test. • Pneumatic and hydraulic tubing. • Hot oil flushing of pipework. • Bolt tensioning. • Pipe supports completed. • Insulation. • Flow coding.
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