Professional Documents
Culture Documents
Number:
EP-08-030-37
Version Number:
8.0
Date Revised:
16 March 2015
Owner:
Harish Chopra
Authoriser:
Manoj Thakur
TABLE OF CONTENTS
1.
INTRODUCTION ................................................................................................................................................. 3
2.
PURPOSE .............................................................................................................................................................. 3
3.
4.
5.
6.
MDR CONTENTS................................................................................................................................................. 6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
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1.
INTRODUCTION
The Manufacturers Data Report (MDR) is the compilation of all the technical details and records of
activities performed by a contractor as part of an engineering construction or modification project. This may
include any of the following activities.
a.
Design
b.
c.
d.
e.
The MDR is provided by a Contractor to the Superintendent on completion of the Work under the Contract,
usually as a precondition to the issue of the Certificate of Practical Completion.
The primary purpose of the MDR is to provide CSBP with the information required to safely operate the
plant and equipment provided under the contract and to service and maintain the equipment to achieve
reliable operation over its expected life.
The MDR also serves as a historical record and can be useful in helping to identify the cause of problems
with quality, performance or reliability of the plant and equipment later in its life.
2.
PURPOSE
The purpose of this procedure is to define the requirements for preparation and submission of a MDR, and to
provide a contents checklist for typical engineering projects.
This document is focussed primarily to mechanical engineering contracts which include design, supply of
equipment, off site fabrication, site installation and commissioning of mechanical equipment and piping. It is
also relevant to civil, structural, electrical and instrumentation works, and should be used as a guide to
format the MDR for these works.
Note:
It is usual for special equipment items such as pumps, control valves, and relief valves to be
purchased by CSBP's Project Responsible Officer and free-issued to the contractor for installation.
The technical data for these free-issued items will be assembled by the CSBP Responsible Officer
and passed on to Reliability Support and to the CSBP Customer in the form of an MDR as
described in this document.
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3.
The following CSBP documents shall form the basis of MDR requirements.
a.
b.
c.
Technical Data Sheets - Mechanical, Electrical and Instrumentation (ES-14-101-12). (These sheets
should be provided to the Contractor early in the project to ensure standardisation of presentation of
information)
d.
e.
f.
CSBP Stage 1 Commissioning Inspection Report and Stage 2 Commissioning Test Report forms.
Note: These forms are available in Dom.doc in Business Support - Engineering - Engineering
Forms - Commissioning Reports
g.
Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks (DP-05-095-06)
h.
Major Alterations and Replacement to Existing Pressure Equipment, Piping and Tanks (DP-05-09508)
i.
j.
4.
The Contractor shall compile an MDR for the contract work in the format detailed in 5. below. For large
complex projects, the MDR may be submitted in several parts, for example, MDR for off-site manufacture
and supplied equipment, MDR for on-site installation, erection and pre-commissioning; MDR for
commissioning. In addition, operational information shall be filed separately to QA/QC information.
For larger, multi discipline projects, separate MDRs shall be produced for each discipline eg MDR for Civil
Works, MDR for equipment supply/fabrication/assembly, MDR for mechanical installation, MDR for
Electrical Installation.
The Contractor and the Superintendent will review the check list provided in Appendix 1 at an early stage of
the contract to agree the content of the MDR.
The MDR shall be progressively compiled during the course of the work and kept up to date as the work
progresses so that delivery of the MDR is not delayed at the completion of the work. Presentation of the
required number of copies of a full and comprehensive MDR at the conclusion of construction is a
contractual requirement under all CSBP engineering contracts and, unless specifically stated otherwise in the
contract, is a precondition for the issue of the Certificate of Practical Completion to the Contractor and
payment of a certain percentage of the contract sum.
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5.
CSBP Project Electronic Filing System and/or Electronic Document Management System
MDR FORMAT
The electronic MDR shall have a detailed table of contents as per Appendix 1 and separate folders for each
section.
The front cover shall be identified with:
All documents for inclusion in MDR shall be written in the English language, in SI units, shall be complete
and shall be clearly legible.
The electronic MDR shall be in a similar folder structure as the approved hard copy but with additional subfolders for grouping of associated documents. Individual electronic files shall be provided for all documents
and grouped by equipment number and discipline. Large single PDF MDR files, containing all documents,
will not be accepted.
Documents pertaining to quality assurance are to clearly legible scanned copies of original documents
(material certificates and material test reports, etc.).
Documents that may need to be maintained and updated post construction/commissioning shall be supplied
in an editable electronic format (Word, Excel, etc).
All drawings shall be in fully functional AutoCAD compatible format.
3D CAD models and where applicable model databases, shall be supplied in native format. Where the native
format is not AutoCAD dwg or dxf a separated web-friendly reduced file size format such as Navisworks or
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6.
MDR CONTENTS
The MDR shall be divided into the sections described below, as appropriate to the scope of the contract.
The check list attached as Appendix 1 should be reviewed to check that all relevant documents for each
aspect of the work have been included in the relevant section of the MDR as detailed below and in Appendix
1.
If not already covered in this procedure, MDRs shall also contain those documents identified in the approved
Inspection and Test Plan / Inspection and Test Program for the subject work as well as those identified in
Contract/Order and in the applicable codes, Standards and legislation.
6.1
SCOPE OF WORK
Insert as the front of MDR a brief description of the contract Scope of Work applicable to the MDR.
6.2
SECTION 1 - DESIGN
This section shall include all design calculations required to be submitted under the contract including design
criteria, assumptions made and any references for design method selected. Calculations shall be sufficiently
detailed to enable independent verification. Copies of all technical queries and their replies shall be included.
Details of any authorised deviations from the contract specifications and the reasons for the deviations shall
be included.
Lists of all equipment, valves, pipelines and vessels provided by the contractor shall be included for
reference.
6.3
This section shall contain records of all activities associated with off site fabrication and assembly of
materials and equipment to be incorporated into the works. The extent of the information to be included in
the MDR will depend on the requirements of the contract.
6.3.1
Where material traceability is required under the contract, this section shall contain an indexed list
identifying material certificates and material test reports referenced to the locations of the materials used by
their part, piece or item number and the applicable drawing(s). The material certificates and traceability
shall include welding consumables.
A copy of the certificates and reports shall be included in this section of the MDR indicating the certificate
or report number, Heat, lot, plate number, etc, and the name of Mill.
For clarity, the section shall also contain a drawing of the equipment or piping marked up to show the
certificate number and heat number for the materials used at each location.
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Weld Records
Details of all welding procedures and qualifications relevant to the subject work, including evidence of
CSBP's approval, shall be included in this section.
If more than one welder is used, then traceability sheets and / or marked up drawings, sketches or maps shall
be included to identify the welder responsible for each weld, and what WPS was used.
6.3.3
This section shall include a list of all NDE carried out on the subject works. The listing shall include for each
test location, the type of NDE, the NDE procedure, the NDE report number and the result of the
examination. The listing may be incorporated into the welding control and record sheets. The section shall
include a marked up drawing, sketch or map to identify the NDE report numbers relevant to each test
location together with a copy of all NDE certificates/reports in the order in which they are included in the
above list.
The section shall also include a list of all non-destructive testing personnel employed on the subject work
and evidence of their qualifications.
6.3.4
Heat Treatment
If applicable, certificates and properly scaled furnace charts for all heat treatment performed shall be
included. Charts shall include the complete heat treatment cycle including heating, soak period and cooling.
The charts shall clearly show the calibrated temperature and time scales and provide a reference to the heat
treatment procedure and to the specific item or weld that was heat treated.
The charts shall be dated and signed by the person responsible for verifying the correctness of the heating
cycle.
Traceability sheets and / or marked up drawings, sketches or maps shall be included to identify the heat
treatment charts relevant to each weld or item being heat treated.
6.3.5
Hydrostatic Testing
Where required by the contract, records of hydrostatic testing performed offsite, along with supporting
documentation such as NATA test certificates for test gauges, shall be included in this section of the MDR.
Stage 1 Commissioning inspection report forms should be completed prior to the commencement of such
tests, and be included in this section of the MDR, whether included in the ITP or not.
6.3.6
The traceability sheets and drawings, sketches or maps for material certificates, welder identification, NDT
and heat treatment may be combined partially, or fully, in a format to be approved by the Superintendent.
6.4
This section shall contain records of all activities associated with site fabrication, assembly, installation and
construction and Stage 1 commissioning of materials, plant and equipment incorporated into the works.
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6.5
SECTION 4 - COMMISSIONING
This section shall contain records of all activities associated with Stage 2 and Stage 3 commissioning.
Where a standard CSBP Stage 2 Commissioning Test Report form is available for a particular item of
equipment, the form shall be completed and included in this section of the MDR, whether indicated in the
ITP or not.
The records shall be filed in this section of the MDR in the order in which they are identified on the ITP, or
in some other logical order, clearly referenced to the particular inspection or test stage identified on the ITP.
6.6
This section shall contain technical information for all items of equipment supplied under the contract to
allow ongoing operation, servicing and maintenance to be carried out.
6.6.1
Individual Technical Data Sheets shall be provided for each maintainable equipment item in an editable
electronic format. Technical data in this section should address service conditions and operating parameters,
e.g. temperatures, pressures, etc.
This information should contain sufficient detail to enable purchase of a replacement equipment assemblies
and items able to perform the same function even if from another manufacturer. Name plate details for tanks,
vessels, heat exchangers, etc., should also be included in this section of the MDR.
Supplier Technical Data Sheet can be used or blank CSBP Technical Data Sheets can be sourced from
Technical Data Sheets - Mechanical, Electrical and Instrument (ES-14-101-12)
The file naming convention shall be in accordance with APPENDIX 1 - File naming convention of technical
data sheets & equipment maintenance manuals
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Equipment Parts
A complete parts list shall be supplied for each maintainable equipment assembly together with a drawing
showing a complete breakdown of all parts. The parts list is indicate the quantity of each part required and
the manufacturers part number. Any specific overhaul / repair kit must also have a part number and identify
the items comprising the kit.
Detail of each part shall contain sufficient information to uniquely identify, catalogue and purchase the parts.
The equipment parts list for each maintainable equipment item should detail, but not be limited to the
following:
An example of an Equipment Parts List form and information required is contained in Technical Data
Requirements for Plant and Equipment (GM-05-043-01), Appendix 3
Dimensional details of all non-proprietary parts shall be provided by the Contractor, to allow CSBP to source
replacements at a competitive price e.g. bearings, gaskets, oil-seals, packing materials, etc.
Detailed drawings for all purpose-built parts, unavailable off-the-shelf, shall be included in this section,
specifying materials and all dimensions required to manufacture a replacement. E.g. gaskets for heat
exchanger end covers, non-standard pipework components, etc.
Nozzle drawings, showing flange details, should also be included in this section, to assist in linking gaskets
to items of equipment.
6.6.3
Commissioning, Operating and Maintenance Manuals shall be included for all items provided under the
contract in sufficient detail to enable CSBP to safely and reliably commission, start up, operate, service,
maintain and overhaul the items supplied by the contractor.
The file naming convention shall be in accordance with APPENDIX 1 - File naming convention of technical
data sheets & equipment maintenance manuals
6.7
SECTION 6 - DRAWINGS
6.7.1
Drawing List
A complete list of all drawings including revision numbers produced by the Contractor for construction
purposes, and which have been passed to CSBPs drawing office for electronic storage, shall be included in
this section of the MDR.
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Vendor Drawings
Vendor drawings including assembly and sectional drawings showing details of overall width, height, baseto-shaft centres, base plate holes, etc, shall be provided with the MDR.
6.7.3
As-built Drawings
As-built drawings shall be provided with the MDR. All drawings including original and all As Built
revisions are to be supplied in fully functional (native) AutoCAD dwg format unless otherwise approved by
the Superintendent. As-built details shall be marked up with a red pen onto a paper copy of the contract
drawing to clearly show changes that were made during manufacture or construction and to record any
particular details not included in the original drawings. In particular, the exact location of buried pipework or
buried other services shall be accurately recorded.
All As Built drawings shall conform to Drawing Preparation (ES-14-101-03)
6.7.4
3D Model
3D CAD models and/or model databases shall be supplied as detailed in section 5.0 above.
6.8
This section shall list the various parts, equipment, materials and activities which require statutory approval
and registration. Evidence of the required approval and compliance for each item shall be included in this
Section.
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SECTION 1 - DESIGN
a.
Design calculations
b.
Technical Queries
c.
Authorised Deviations
d.
Equipment lists
e.
Valve List
f.
Pipeline lists
g.
h.
Instrument List
i.
Motor List
b.
Material Certificates, including all items directly welded to piping or pressure vessels
c.
d.
Consumables Certificates
e.
f.
g.
h.
i.
j.
k.
Weld maps identifying welders and WPS used for each weld
l.
m.
n.
Map for identifying heat treatment records against welds and/or location
o.
p.
q.
r.
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Test Certificates
b.
Material Certificates
b.
Civil Works
a.
b.
c.
Earthworks
1.
2.
Backfill Checklist
3.
Compaction Checklist
Concrete Works
1.
2.
3.
4.
Reinforcing Schedule
5.
Concrete Testing
1.
b.
a.
Approved repair procedure as per DP-05-095-06 for welded tie-ins to existing piping and
equipment
b.
c.
d.
e.
Material Certificates
f.
Piping
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h.
i.
j.
k.
l.
m.
Pressure Testing Records and test packs, including NATA calibration certificates for test
instruments
n.
Completed Punch-lists
o.
p.
b.
c.
d.
e.
f.
Miscellaneous Records
a.
SECTION 4 - COMMISSIONING
a.
b.
c.
d.
b.
c.
Vendor contact details (address, telephone number, fax number, email address, contact
name)
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b.
c.
d.
Test certificates
e.
Calibration certificates
General Information
b.
Safety Precautions
c.
d.
Start-up Procedures
e.
f.
g.
h.
i.
Storage instructions
j.
Test Certificates
k.
l.
Calibration procedures
SECTION 6 - DRAWINGS
a.
b.
c.
Layout drawings
d.
Marking plans
e.
Vendor drawings
f.
Assembly drawings
g.
As-Built Drawings
h.
1.
2.
3.
3D model(s)
b.
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d.
e.
f.
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Note:
1162P1012-TDS
1100TX0006-TDS
1166LT0507-TDS
1162P1012-EMM
1100TX0006-EMM
1166LT0507-EMM
If there are multi technical data sheets or equipment maintenance manuals for a specific item of
equipment, each data sheet or manual should be given a unique identifier as per the following
examples:
1124X0821-TDS-01 (tech data sheet 1)
1124X0821-TDS-02 (tech data sheet 2) etc
1124X0821-EMM-01 (manual 1)
1124X0821-EMM-02 (manual 2) etc
(space dash space is required between equipment number & equipment type / duty description).
EXAMPLES:
For manuals that are specific for and reference the CSBP Equipment Number, the title is to comprise the
CSBP Equipment Number; Manufacturers Name; Equipment Type and Model Number.
EXAMPLE:
Note:
space dash space is required between CSBPs equipment number and the Manufacturers name.
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Ln#
CSBP Equipment
Number
Lvl
Original Manufacturers
Part Number
Manufacturer
Quantity
UOM
Recom
mended
stock
levels
Lead time
(Days)
Unit Cost
($AUD)
1150PIT2201
EJA110A-EMS4B 94EB/SU2/X1
TRANSMITTER; DP;
ACME
EA
90
$3,500.00
1150PIT2201
F9270AM
ACME
Per SET
2 Sets
14
$60.00
1150PIT2201
D0114RB
ACME
Per SET
4 Sets
14
$25.00
1150TIT2202
YTA110-EA4DB/X1
TRANSMITTER TEMPEARTURE
ACME
EA
60
$2,000.00
1150TIT2202
AF-KNE-BE-3B-S-2-06-HT-R115
K TYPE THERMOCOUPLE
CITEZEN
EA
$120.00
6
7
8
9
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Document last modified: 16 March 2015. Date printed: 22 June 2015.