PKOP Shymkent Refinery Modernization &

Revamping project

Requirements for Completion Data

Prepared by Liu Gui

Checked by Han Haichao
Approved by Zhou Ziyu

Kazakhstan branch of CPECD

0

PKOP refinery project

Date2014-5-8

Chapter I General...................................................................................................... 2

Provide equipment data scope for completion data.............................................2

Content of completion data............................................................................. 2

Cover of Completion Data...............................................................................4

Submission number, text & translation for Completion Data.................................4

Generating, binding & publishing requirement for Completion Data.......................4

Chapter II Completion data requirements for classified equipment....................................5

Pressure containers....................................................................................... 5

Boilers......................................................................................................... 6

Mechanical pumps, generators, fans, turbines...................................................7

Cranes............................................................................................................ 9

Electrical equipment, materials........................................................................9

Meters on pressure, temperature & flow rate, security meter, materials...............10

Skid-type system such as DCS system, communications, stored program control

phone exchange, security system..............................................................................11

PSAsewage treatment system, fuel loading system (skid system)....................12

Steel materials, accessories, fasteners and etc................................................12

Valve and pipe fittings............................................................................... 13

Steel structure & light board house..............................................................13

Attachments........................................................................................................ 14

Requirements for Completion Data

In order to ensure the completion data consistent with Kazakhstan national
standards, and meet the document requirements by owner, successfully pass the
inspection and acceptance of the Owners committee & the country and to avoid data
rectification for improvement of document management efficiency, the standardized
requirements for the completion data by Vendors are as follows:

Chapter I General

1 Provide equipment data scope for completion data

1 Equipent: including rotating & static equipment, boilers and furnace, among
which static equipment includes reactors, columns, filters, cyclone separators,
pressure containers, tanks, heat exchangers, fire extinguisher equipment, skidtype equipment of PSA, etc.; Rotaing equipment includes main blower sets, gas
turbine generator sets, compressor sets, air coolers, kinds of pumps, watersupplying equipment, sewage treatment equipment, cranes,etc,; Boilers include
waste heat boiler, gas boiler and heat furnace, etc.
2 Pipeline including steel pipes and pipe fittings, valves, pipe filters, seal
coushions, fasteners, PPR pipes and fittings, PVC pipes & fittings.
3 Electrical including generators, motors, control cabinets, switch cabinets,
distribution box, UPS power source, cables, air-conditioners, cathodic protection
devices, explosion-proof lamps, explosion-proof materials and electrical
appliance materials, etc.
4 Instrument kinds of instruments, DCS & SIS system, instrument cables,
instrument tube fittings and explosion-proof materials for intruments, etc.
5 Communications video monitoring system, explosion-proof intercom
system entrance guard systempublic broadcasting system equipmentphone
system equipment materials, etc.
6 Steel & steel structure steel structure frame & pipe rack, ladders & platform,
bradge, etc., kinds of shape steel, structural pipe, protecting tubes, etc.
7 Non-metallic materials coatings, anticorrosive adhesive tapes, fire-proof
2

coating, insulation materials, lining materials, etc.

8 Spare partsall kinds of consumable materials and maintenance accessories for
all kinds of equipment.
9 others
2 Content of completion data
1 Requirements for content of completion data
The completion data refers the binded data handbook containing design
document, specification, manual of installation, operation & maintenance, certificate,
ex-factory inspection data and process data made by vendor according to supply
contract, mainly including the following:
A
B

Catalogue
Design documents including specifications, data table, calculations and
drawings, etc.
C Descriptions, manual of installation, operation & maintenance
D Ex-factory qualified certificate, inspection reports, release paper for
supervision inspection
E Materials list for equipment purchased from foreign country, certificate
F Welder qualification, welding records, heat treatment records, NDT inspection
reports, repair reports
G Pressure test report, performance test report
H National verification certificates for cranes, boilers, pressure containers
I Lists of spare accessories
If each part has sub-catalog, the sub-catalog is marked by A.1, A.2., then the
order like A.1.1, A.1.2 to mark the third level, and so on.
For the completion data of some equipment inapplicable to above requirements,
manufacturers may make adjustments according to the specific content and submit
them to professionals of CPECC Kazakhstan branch for review. After approval,
official publication can be made to ensure the integrity of the content of completion
data.
The content of completion data shall conform to the contract requirements. Each
file shall be clearly labelled for tracking and check. If the content of data book alters,
revised files should be brought in and indicated with revision reasons.
2 For such equipment as crane, pressure container and boiler, etc., the completion
data shuld be prepared as to attachment requirements.(refer to attachment 4, 5,
6)
3 Certificates, quality certification and test report of equipment materials shall be

original and stamped clearly.

4 Except for the detailed vendors address, postal code, contacts and contact way
in the completion data, the address, postal code, contacts form production or
service department and its contact way of the subsuppliers or manufacturers
should be also added for the buyers/end users to purchase spare parts or
contact the manufacturer in case of quality problems.

3 Cover of Completion Data

Cover
shall
be
Chinese(attachment
1),
English(attachment
2),
Russian(attachment 3). The content of cover contains project title, vendor name,
equipment materials name, order NO.,tag NO., etc.
4 Submission number, text & translation for Completion Data
1 Submission numbers. The version of completion data should be Chinese, English
& Russian in separate volume. The last submission of completion data for every
set of equipment: 3 sets of Chinese version( 1 original & 2 copies)+ 7 sets
of English Version (1 original & 6 copies) +7 sets of Russian Version (1original & 6
copies), 4 CD (Chinese, English & Russian in one CD) materials and common
equipment may be submitted by unit of orders. The contents and pages of the
originals & copies shall be the same throughly. Seal should be done on the top
right of the cover of the originals & copies submitted by Vendors to distinguish.
2 CD requirements.
1) CD text shoule be Office 2003, drawngs shall be made by Auto cad 2004 or
higher version.when submitting PDF, editable version must attached.
2) Electronic version of Chinese, English & Russian documents is required to be
named in Chinese, English & Russian separately.
3) Catalog bookmarks should be made for electronic PDF version according to the
each part of completion data handbook.
4) The names of vendors, materials names & orders NO. Etc. Must be printed on
the front side of data disk provided with CD printer.
3 Text requirements for completion data. Small 4 font should be adopted, single
spaced. Chinese should be in Song sytle, English & Russian in Arial body.
4 Transplation for completion data. Translation must be correct, complete and teh
content in Chinese, English & Russian versions is consistent.

5 Generating, binding & publishing requirement for Completion Data

1 Generating for completion data.
1 Generating should be in the order of A BK according to teh comver +
comtent of completion sata. Each part should be separated with eared partition
papers marked with A BIf Not Applicable applies to some portions of the
content, Not Applicable pages should be inserted in the corresponging parts.
2 Each handbook should be less 60MM thick.
3 The pages of the whoel book should be continuous and the corresponding pages
of each portion should be marked in catalog (from the first page of content)
4 Completion data may be devided into several sections as required.
2 Binding requirement for completion data.
1
2

Folder back requirements. The height of side back is 180MM. The names of
equipment and information of volumes should be shown on the back.
Folder requirements. 80mm thick black loose leaf folders with 2 drilling holes.
For the documents less than 100 pages, simple edge clip folders are
allowable. Two holes must be drilled with punch evenly.
Papers requirements. White A4 printing papers for word form, standard double
holes are drilled on left side for binding. A4 Loose leafs with vertical double
holes on left side are used for drawings to bind, which is foldable and the
pages, drawing names and NO should be obvious.

3 Publish requirement for completion data

1 Data submission approval After vendors finish the completion data, electronic
version will be submitted to project department for review via purchaser. After
successful approval by the project, vendors may publish and submit as to the
above requirements.
2 Submittal of completion data Copies of shipment documents in Chinese,
English & Russsian should be prepared separately. Separate sealing packageing
forms are required. The location of completion data is indicated on the box
outside and box list. The remaining documents shall be posted or transferred to
the receiver designated by Buyer within 15 days after delivery of goods.
3 Documents requirements in contract Copletion data which is not submitted as
scheduled shall be considered that works are not delivered on time; Completion
data which does not meet the rules herein shall be deemed as products of
defects.
4 Waterproof measures should be taken inside completion data. Protecting
measures such as foam bags are used in data box to prevent the data damage
during long way transportation, loading and unloading.

Chapter II Completion data requirements for classified

equipment
1 Pressure containers
1

Completion data

Ex-factory data for pressure containers should be prepared and submitted

inaccordance with the specified provisions, including the following:
1)
Equipment drawing(blueprint), shows: specs, data & size.
2)
Assembly drawing for internals (if any)
3)
Inspection certificate by Thirs party, such as regulatory burear(subject to
government regulations under China)
4)
Completion inspection report/record.
5)
X ray distribution drawing/sketch.
6)
X ray report/record.
7)
NDT report/record, such as P.T, MT, UT, etc. And specific locatioon.
8)
Heat treatment record & hardness test.(if applicable for equipmment)
9)
Pressure test report.
10)
Type/grade & quality certificate of main pressure elements including
chemical composition & mechanical properties.
11)
Acceptance report by factory
12)
All the quality certificatess & kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.
2

Except for the above requirements, pressure containers certificates shall be

supplied by Vendors according to attachment format (attachment 4: sample for
pressure container certificate in Chinese, English & Russian version) in order to
register in local government departments for pressure containers.

Specially noted: all the instruments used are the brand and specifications
registered in Kazakhstan, which is veried by CPECC branch.
2 Boilers
1

Completion data

Ex-factory data for boilers should be prepared and submitted inaccordance with
the specified provisions, including the following:
1) Installation manual for equipment body
6

2)
3)
4)
5)
6)
7)
8)
9)
10)

Operation manual for equipment body

Installation manual for auxiliary equipment
Operation manual for auxiliary equipment
Quality certificate for equipent body
Quality certificate for auxiliary equipment
Quality certificate for pipe fittings
Quality certificate for instrument equipment
Thermal calculation sheet for hot water boiler
Calculating summary sheet for boiler strength & emmission summary sheet
for safety valve

Quality certificates including but not limited to the following:

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)

Product certificate
Product technical characteristic table
Materials list for main pressure elements
Test report of mechnics & bending property for welded test coupon
Insptection report for appearance & physical size of pressure container
RT report for welding joint
UT report for welding joint
PT report
Magnetic particle test report
Welding quality certificate for main pressure elements
Test report of heat treatment
Pressure test report
Test certificate for mechnical pumps
Substitution record for pressure elements materials
Modification report for product manufacture
UT report for steel plates, forging pieces
Evaluation table of radiographic film for welding joint
Anti-corrossion data
Rubbing of product nameplate
Spare parts list: including spare parts to be installed and spare parts lists for
2-year preparation (spare parts to be installed and single completion data for
2-year preparation).
21) Other quality provement documents by vendors
22) All the quality certificatess & kinds of reports supplied by vendors in original
completion data shall be original, and stamped clearly.
2

Except for the above requirements, boilers certificates shall be supplied by

Vendors according to attachment format (attachment 5: sample for boilers
certificate in Chinese, English & Russian version) in order to register in local
government departments for boilers.

Specially noted: all the instruments used are the brand and specifications
registered in Kazakhstan, which is veried by CPECC branch.

3 Mechanical pumps, generators, fans, turbines

Ex-factory data for such equimpent as mechanical pumps, generators and fans
should be prepared and submitted inaccordance with the specified provisions,
including the following:
1

Completion data
1) Intallation, operation & maintenance manuals.
2) Outline drawing, installation diagram & assembly drawing of equipment &
fittings (including lisf of main parts)
3) Characteristic curve of equipment(if applicable).
4) Recommended spare parts (completion data of spare parts supplied alone).
5) Mechanical seal map & descriptions.
6) Shaft coupling diagram & descriptions.
7) Technical instruction for driving device.
8) Model & material quality certificate for main components & parts, as shell,
blade whell & main shaft, etc.
9) The rotor static balance.
10) The rotor rotating balance.
11) Pressure test report for shell.
12) Acceptance report of factory (also motors) & running test report prior to exfactory.
13) All the acceptance reports, certificatess, static & rotating balance reports,
pressure test report for shell, acceptance report of factory, etc. supplied by
vendors in original completion data shall be original, and stamped clearly.
Specially noted: all the instruments used are the brand and specifications
registered in Kazakhstan, which is veried by CPECC branch.

4 Compressors
1) Intallation, operation & maintenance manuals.
2) Outline drawing, installation diagram & assembly drawing of equipment &
fittings (including lisf of main parts).
3) Characteristic curve of equipment(if applicable).
4) Recommended spare parts (completion data of spare parts supplied alone).
5) Mechanical seal map & descriptions.
6) Shaft coupling diagram & descriptions.
8

7) Technical instruction for driving device.

8) Model & material quality certificate for main components & parts, as shell,
blade whell & main shaft, etc.
9) Acceptance certificate of calculated capacity through safety vavle.
10) The rotor static balance.
11) The rotor rotating balance.
12) Pressure test report for shell.
13) Acceptance report of factory (also motors) & running test report prior to exfactory.
14) All the acceptance reports, certificatess, static & rotating balance reports,
pressure test report for shell, acceptance report of factory, etc. supplied by
vendors in original completion data shall be original, and stamped clearly.
15) Drawings further include
a)Overall plan of compressors(diagrams of auxiliary compressor & piping,
auxiliary tube & devices)
b)Compressor assembly drawing with installation descriptions
c)Drawing of all parts indicating the manufacturing size and deviations.
d)Drawings of pressure containers
e) Atlas for parts with specified parameters
Specially noted: all the instruments used are the brand and specifications
registered in Kazakhstan, which is veried by CPECC branch.

5.

Cranes

Ex-factory data for cranes should be prepared and submitted inaccordance with
the specified provisions, including the following:
1 Completion data
1)
2)
3)
4)
5)
6)
7)

Installation manual for equipment body

Operation manual for equipment body
Installation manual for auxiliary equipment
Operation manual for auxiliary equipment
Rubbing of product nameplate
Lists of spare parts (completion data of spare parts supplied alone)
Other quality proven documents by vendors

8) Related drawings
9) All the quality proven documents and kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.

Except for the above requirements, information shall be supplied by Vendors

according to attachment format (attachment 6: sample for crane certificate in
Chinese, English & Russian version) in order to register in local government
departments for cranes.

6 Electrical equipment, materials

Ex-factory data for electrical equipment, materials should be prepared and
submitted inaccordance with the specified provisions, including the following:

1 Completion data

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)

Installation manual for equipment

Operation manual for equipment
Installation manual for auxiliary equipment
Operation manual for auxiliary equipment
Certificates
Test report of quality documentation, equipment grade certificate, material
quality certification papers
Quality documentation for electrical equipment componnets(eg. Main switch
for cabinet)
Rubbing of product nameplate
Lists of spare parts (completion data of spare parts supplied alone)
Lists of spare parts for 2-year operation(completion data for 2-year operation
spare parts supplied by vendors)
Arrange diagram of switch cabinet
Battery connection diagram for UPS battery cabinet
Electrical single-line dragram, electrical principle control diagram, wiring
diagram
Bus NO., bus connection diagram
Insllation location list for accesssories
Acceptance report of manufacturer
All the quality proven documents and kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.
10

18) Electrical materials or electrical meter fittings attached to equipment should

be the brand and models registered in Kazakhstan, and relevant written
documents should be supplied.

7 Meters on pressure, temperature & flow rate, security meter, materials

Ex-factory data for these meters & materials should be prepared and submitted
inaccordance with the specified provisions, including the following:

Completion data

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)

Installation manual for equipment

Operation & maintenance manual for equipment
Installation manual for auxiliary equipment
Operation & maintenance manual for auxiliary equipment
Quality documentation includig materials quality documentation, test report,
grade certificate and verification report
Proved papers for main equipment components
Product certificates
Meter data sheet by factory(if applicable)
Technical documents and drawing for meter-skid system by vendors
Acceptance report by factory
All the quality proven documents and kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.
Meters or meter attached to equipment should be the brand and models
registered in Kazakhstan, and relevant written documents in Russian should
be supplied.

Specially noted: all the meters used are the brand and specifications registered
in Kazakhstan, which is veried by CPECC branch.
8 Skid-type system such as DCS system, communications, stored program
control phone exchange, security system
Ex-factory data for these type equipment should be prepared and submitted
inaccordance with the specified provisions, including the following:

Completion data

11

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)

Installation manual for equipment

Operation & maintenance manual for auxiliary equipment
Installation manual for auxiliary equipment
Operation & maintenance manual for auxiliary equipment
Design files
Quality documentation includig materials quality documentation, test report,
grade certificate and verification report
Proved papers for main equipment components
Product certificates
Meter data sheet by factory(if applicable)
Technical documents and drawing for meter-skid system by vendors
Acceptance report by factory & ex-factory test report
Layout plan, control schematics, wiring diagram, etc.
All the quality proven documents and kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.

Specially noted: all the meters used are the brand and specifications registered
in Kazakhstan, which is veried by CPECC branch.

9 PSAsewage treatment system, fuel loading system (skid system)

Ex-factory data for these type equipment should be prepared and submitted
inaccordance with the specified provisions, including the following:

Completion data
1) Including but not limited to: installation, operation & maintenance manual for
the whole set of equipmnet
2) Design files
3) Inspection & test report, test report for performance, overall test report
4) Meanwhile, quality documentation of main equipment: mechanical
equipment, pressure vessels, relevant data for electrics & instrument.
(machinery, pressure vessels, electrical equipment and instrument equipment
shoud be prepared and generated separately.)
5) Other materials shall be executed as to the ex-factory data requirement of
the same kind.
6) All the quality proven documents and kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.
7) Metors or meter attached to equipment should be the brand and models
registered in Kazakhstan, and relevant written documents in Russian should
12

be supplied.
Specially noted: All the meters used are the brand and specifications registered
in Kazakhstan, which is veried by CPECC branch.
10

Steel materials, accessories, fasteners and etc.

Ex-factory data for steel materials, pipe fittings, fasteners, etc. should be
prepared and submitted inaccordance with the ASME or specified provisions in
design documents, including the following:
Completion data

1) Manufacturing certificates including: material models, size and quantity

2) Chemical composition and mechanical performance of raw materials
3) Pre-fabrication detailed drawing for steel structure( noted if already
submitted)
4) Site re-inspection report for special materials (if needed)
5) All the quality proven documents and kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.
11

Valve and pipe fittings

Ex-factory data for valves etc. should be prepared and submitted inaccordance
with the ASME or specified provisions in design documents, including the following:

Completion data

1) Manufacturing certificates including: material models, chemical composition

& mechanical performance of main parts
2) Indicating the section view of main parts
3) Pressure test report
4) Acceptance report by factory
5) Provide the list of size, models, quantity bills of vavles actually
checked(supplied by Contractor)
6) All the quality proven documents and kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.

13

12

Steel structure & light board house

Ex-factory data for these items should be prepared and submitted inaccordance
with the specified provisions in design documents, including the following:

Completion data

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)

Installation descriptions
Certificates
Quality documentatioon (provide test records for crane beam, rail)
Materials quality documentations
NDT report for key welding joints & skid resistance test report for highstrength bolts
Welding records
Construction/acceptance records for anti-corrossion, fire-proof
Fabrication & installation drawing for steel structure
Layout diagram for wall boards and roof panel of light board house
All the quality proven documents and kinds of reports supplied by vendors in
original completion data shall be original, and stamped clearly.

Attachments
Attachment 1: Cover of Completion Data (Chinese version)
Attachment 2: Cover of Completion Data (English version)
Attachment 3: Cover of Completion Data (Russian version)
Attachment 4: Samples of pressure containers certificate (Chinese, English &
Russian)
Attachment 5: Samples of boiler certificate (Chinese, English & Russian)
Attachment 6: Samples of crane certificate (Chinese, English & Russian)

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