Mechanical Completion

PREPARED BY CHECKED BY APPROVED BY CERTIFIED (PTT) REV. DATE NO. D1 18-Feb-08 D2 11-Jun-08

NA

PTT PUBLIC COMPANY LIMITED ONSHORE COMPRESSOR STATION 4 PROJECT

NA REVISED BY

APPROVED BY NA NA

DESCRIPTION ISSUED FOR ITB REVISION ISSUED FOR ITB

SPECIFICATION FOR MECHANICAL COMPLETION COMMISSIONING AND 30 DAY CONTINUOUS OPERATION SPC-0804.02-99.88 REV. D2 TOTAL 49 PAGES

AREA CODE OF SITE LOCATION GENERAL AREA: 010 PTT PLC. CONTRACT NO.

.

PTT PLC. PROJECT NO. 0804.02

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 2 OF 49 REV: D2

CONTENTS SECTION 1.0

SCOPE .................................................................................................... 3

2.0

ACTIVITIES.............................................................................................. 3

3.0

CHECKLISTS, FORMS, AND LOGBOOKS ..................................................... 8

4.0

SCHEDULE............................................................................................... 9

5.0

VENDOR REPRESENTATIVES ..................................................................... 9

6.0

COMPLETION OF WORK...........................................................................10

MECHANICAL COMPLETION FORMS ....................................................................34

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

1.0

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 3 OF 49 REV: D2

SCOPE This Specification describes and clarifies the requirements for mechanical completion, commissioning, 30 day continuous run and provides a format for the Contractor to carry out these activities. It is intended to expand and supplement, but not to supersede the general terms and conditions of the Contract concerning Completion, Commissioning, 30 Day Continuous Operation and Acceptance by PTT.

2.0

ACTIVITIES

2.1

Mechanical Completion and Precommissioning Mechanical Completion and Precommissioning means fabrication, construction, physical installation, testing, inspection, and system verification is complete, such that the Facilities are ready for introduction of product. Activities associated with the term precommissioning are included in mechanical completion activities and shall not be described separately. Mechanical Completion shall also mean that all requirements have been met to begin Commissioning activities, including submittal of commissioning plans and documentation. In general, Mechanical Completion shall include the activities listed below. More detailed activities are included in the attached checklists. •

All civil work shall be complete, including fencing, final grading, and surface preparation.

•

Piping systems shall be checked against designs, cleaned, tested for pressure ratings and tightness, dried, inerted, and restored to tight condition in readiness for operation.

•

All equipment shall be installed, assembled, inspected, calibrated, adjusted, cold-aligned, tested, lubricated, and cleaned as necessary to be ready for operation.

•

Elements such as strainers, temporary strainers, and filters shall be installed, cleaned or replaced so that a clean element is in place for commissioning.

•

All electrical systems shall be installed, energized, and tested for continuity, insulation resistance, ground fault, and operational functions.

•

All instrumentation shall be installed, loop checked, set to proper setpoints, and calibrated.

•

Instrumentation loop checks to the DCS, SIS, UCP, MPC, Load sharing& anti surge controller and other control systems shall be completed.

•

Probes, coupons, samplers, and other consumables shall be installed

•

Utility and safety systems shall be commissioned and demonstrated to be operational

•

All painting, coating, and insulation work shall be completed

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

2.2

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

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•

All changes and modifications shall be incorporated

•

All functional tests and Site Acceptance Test of individual systems shall be performed.

•

All work shall be verified to be in accordance with the related Specifications, Drawings (PTT and vendor), codes, and standards

•

Deficiencies identified during Mechanical Completion activities shall be remedied prior to the commencement of Commissioning

•

Mechanical Completion documentation shall be completed and signed

Commissioning

2.2.1 General The commissioning of the facilities follows Mechanical Completion and encompasses the purging of nitrogen from the system, initial filling with gas, pressurisation, full system function test at the operating condition, start-up of the unit and guarantee run for the machines and equipments The contractor shall be responsible for commissioning all Facilities included in the Scope of Work. Commissioning shall take place in the presence of PTT and Contractor representatives together with PTT approved third party. Operating troubles, defects and reasons, if any, occurring during the Commissioning shall be noted in a log book and signed by the authorised representatives of both parties. All such troubles or defects shall be corrected by Contractor prior to the completion of Commissioning. All utilities required for commissioning shall be provided by contractor. All cost associated with the utilities such as electricity, water, nitrogen, and communication etc. shall be the responsibility of the contractor whether the compressed gas is sent to the customer. 2.2.2 Commissioning Activities Commissioning activities shall include the initial filling with gas, function and performance test of the facilities in sections and related support systems, start up and the Guarantee run. In accordance with applicable specifications and procedures the following commissioning activities shall be performed as minimum. •

Prerequisite for the introduction of gas into the system is that all utilities, safety, and support systems shall be successfully Mechanically Completed and are in operation.

•

Initial gas filling including provision and installation of temporary connections, bypasses, filters/separators and, if required, gas heater and blow down and/or flare facilities.

•

Pressurizing of piping sections and related equipment on a section by section basis including checking for leaks, PTT may request the leak checking to be performed with inert gas where possible.

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

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•

Procedure for jumpering (bypassing) instrumentation, if required.

•

Flowing of gas including functional testing of equipment, instrumentation and controls and performance of the overall station at the designed operating condition.

•

Full functional tests for all control systems under normal operating pressure in the system.

•

Full functional tests for the SIS and other package equipment shutdown systems under normal operating pressure in the system

•

Seat leak test for all ball valves at the designed operating pressure.

•

Performance of Guarantee Run

2.2.3 Guarantee Run The Guarantee Run shall proof A)

the performance of each individual compressor train •

Start of individual compressor train

•

Surge line verification and Anti surge function test

•

Function test for all fall back strategies for anti surge control system

•

Demonstration of performance for varied set points

•

Shut down procedure (normal and ESD)

•

Performance Test in accordance with ASME PTC 10 (compressors) and ASME PTC Check test requirement for the motor

•

Each motor proofing of a) Power under specified operating conditions b) Adequacy of essential protective devices. c) handling characteristics (i.e. starting characteristics, time of loading)

•

Each Gas Compressor proofing of The polytrophic efficiency, the thermodynamic properties of the compressor (power, discharge pressure, etc)

•

Each Motor Driven-Compressor Package proofing of Vibrations Noise level The operation of standby and emergency equipment. Five day continuous reliability test run after the successful of the performance test

•

Gas Coolers proofing of Performance

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 6 OF 49 REV: D2

Noise level B)

the total operability of the Compressor Station •

Sequential start of compressor trains from stand still until full load is achieved

•

Operation under varied load requirements (variation of set points for flow, suction pressure, discharge pressure)

•

Load sharing operation and function test for all fall back strategies.

•

Shutdown, Stand-by (Recycling Mode) and Restart of individual compressor trains

•

Shutdown of total Compressor Station

•

Pressure drop in the piping at the full load condition

•

Performance of the inlet filter separator in term of liquid droplet and solid particle filtering for the entire operation range.

•

Noise level of the station

All noise level and vibration test mentioned in this section shall be performed during the equipment running at the design condition. Details about the tests shall be agreed between PTT and Contractor. Contractor shall submit all test procedures for PTT’s review and approval sixty days prior the test. Before the contractor can proceed with the thirty day continuous operation, the contractor shall submit the check list and the result of each test for PTT to sign off and all major punch list shall be cleared and signed off 2.3

Thirty Day Continuous Operation The Contractor shall demonstrate to the PTT that the OCS 4 station meet the PTT specifications and operating requirements during a 30 day continuous testing period to be performed under normal operating conditions. The testing period shall begin after PTT has accepted the completion of commissioning activities and the scheduled start date for the testing period. The 30 day testing period shall be continuous 24 hours per day at normal operating conditions without major modifications or failures. Should a major error occur, the test shall be stopped, the error corrected, and the thirty day test restarted at day one. Should any abnormal event occur during the thirty day test, the contractor shall immediately investigate the event to determine a cause, correct the fault and submit a report to PTT. The report shall state whether in the opinion of the contractor the event is a major error or not, and the reasons for such a conclusion. During investigation of any abnormal event the Contractor shall continue to operate the station as in the normal operation, if possible. The report shall be submitted to PTT within three calendar days of the event. Failure to submit a

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 7 OF 49 REV: D2

report within the required time shall result in the event being declared a major error. PTT will respond to an abnormal event report within three days; either accepting the report, requesting additional information, or rejecting it. Rejection of a report shall result in the event being declared a major error. The contractor shall not make any major modification to the system during this period. Such modification shall be considered the major error. For the minor error, the 30 day continuous clock shall stop. The contractor shall fix the problem and submit report for PTT to review. Upon the satisfaction of the report, PTT shall allow the contractor to continue with the test and the clock shall be resumed. The Contractor shall prepare and submit test plan(s) for the PTT to review and give permission to proceed at least 30 days prior to the scheduled start date. At a minimum, the test plan(s) shall include. •

The verification for the operation of DCS, SIS, compressor control and other control systems.

•

Alarm and event log verification.

•

The Switching over of the main and stand by equipments.

•

The Switching over of the equipment trains.

•

Testing procedures and schedule

•

Test data to be collected, how the tests will be performed and a comparison of test results to applicable specifications.

The contractor shall submit the daily report which include the activity log, the test data and the result of any verification During this period, the PTT shall have the full access to all systems in the OCS4 and operate the facility under the supervision and responsibility of the contractor. The contractor shall provide the qualify supervisor and field support operator to cover the 24 hour operation PTT will act in good faith not to delay the above mentioned activities; however, interruptions to normal operations caused by PTT or third parties shall halt the 30-day clock. Standby expenses during the interruption shall be to Contractor's account. Once the source of the interruption is removed and Contractor resumes normal operation, the 30-day clock shall also resume such that the Contractor demonstrates a net 30 days of normal operations. In the unlikely event that an interruption beyond the Contractor's control extends for more than 30 days, or multiple such interruptions occur, Contractor shall meet with PTT to determine the best course of action to provide relief to the Contractor and assurance to PTT that the Facilities are operable on a long-term basis. Upon completion of the 30 day continuous test, the Contractor shall notify the PTT in writing stating that the 30 day test period is complete. Upon PTT concurrence, the PTT will issue a “Certificate of Start of Regular Operations” to the Contractor.

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 8 OF 49 REV: D2

PTT will the initial acceptance certificate to the contractor after all major punch lists are cleared and signed off.

3.0

CHECKLISTS, FORMS, AND LOGBOOKS

3.1

General Mechanical Completion, Commissioning and 30 day continuous operation checklists and forms shall be used for all significant items to be erected, installed, and/or modified under the Contract. Contractor shall prepare these checklists and forms following the general format of the attached samples (mechanical completion only - Contractor to generate forms and checklists for commissioning and 30 day continuous operation), modified as necessary for individual equipment and systems. Contractor shall submit these forms for PTT approval at least sixty days prior to initiating the inspection, test, and verification activities covered by the checklists and forms. Checklists and forms required for Commissioning activities shall be submitted with the Commissioning procedure plan at least sixty days prior to Mechanical Completion. Contractor shall prepare and use logbooks for all activities carried out during Commissioning and 30 day continuous operation. At a minimum, Contractor shall maintain a general logbook noting for each shift the personnel onsite, events, activities, process conditions and changes, and results of any tests or inspections. Contractor shall also maintain records of system status (such as valve position and equipment hand-off-auto position) and temporary conditions (such as jumpers installed/removed and valves out of service). To allow accurate reconstruction of events in the case of an upset condition, Contractor shall have available onsite a camera and film and shall record instrument readings, control panel readings, and other relevant information.

3.2

Procedure The checklists and forms prepared by the Contractor and as approved by PTT shall be used as sign-off sheets for the permanent record of inspections, tests, and mechanical completion activities. These shall be signed by Contractor, PTT’s representative, and any Subcontractors or Vendors as applicable. No system or unit shall be considered mechanically complete if any items included in the checklists or forms are not fully signed. Checklists, forms, reports, or other special documentation required by Vendors or PTT shall be completed and considered a part of mechanical completion in the same manner as above. Copies of these documents shall be reproduced by the Contractor in as many copies as required and shall become part of the permanent project records.

3.3

Introduction of Product Contractor shall recognize that the introduction of product to any portion of the Work is a hazardous activity requiring the full knowledge and approval of all parties involved, including Contractor’s staff, PTT and PTT’s

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 9 OF 49 REV: D2

representatives, and the owners of the existing facilities. In addition, the following criteria shall be met for introduction of natural gas: •

The unit shall be mechanically complete, with any exceptions approved by PTT as described above

•

All utility and safety systems, such as firewater, vent and flare, closed drains, instrument air, and electrical, shall be completed and operational

•

The work area around the unit is safe, secure, and clean of all debris, unnecessary equipment, and excess materials

•

A work permit system for hot work, cold work, vessel entry, etc shall be in force

•

Detailed emergency and evacuation procedures shall be approved by PTT for such events as fire, loss of power, loss of instrument air, overpressure, and excessive condensate buildup

•

Procedures for shutdown and standby shall be approved by PTT

In the case of a threat to the safety of personnel or equipment during c commissioning, PTT may require Contractor to halt activities, place the Facilities in a safe condition, and remedy the cause of the threat if within the power of the Contractor. If product has been introduced, such work may include depressurization and/or purging to render the Facilities safe.

4.0

SCHEDULE Contractor shall prepare complete schedules for mechanical completion and commissioning activities.

5.0

VENDOR REPRESENTATIVES

5.1

Installation, Mechanical Completion and Commissioning Contractor shall schedule vendor representatives to be onsite to aid in mechanical completion and commissioning activities as necessary. As minimum, the following vendor representatives shall be on site for the installation, pre commissioning and commissioning activities. Compressor package vendors, this shall include subsystem vendors such as motor driver, gearbox and anti surge valve vendors. DCS, SIS, PIMS and PRM Machine Monitoring System Fire and Gas control panels MPC, load sharing and anti surge controllers Switchgears and MCCs Emergency diesel generator

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 10 OF 49 REV: D2

Instrument air package Communication systems Transformers Inlet filter scrubber Fire water pumps The contractor shall make an arrangement for the local vendor representatives to be on site for the required services such as installation, commissioning and warranty work. The vendor representative outside of Thailand shall be allowed only if the service from the local representative is not available. During the 30 day continuous operation, the contractor shall determine for which systems require the vendor representatives to be on site in order to minimize the downtime for minor or major problems rectification.

6.0

COMPLETION OF WORK Completion of the Work and the sequence of Notice and Acceptance shall be as defined in the Contract. Contractor shall remain fully responsible for the Facilities and all expenses incurred between the Start of Regular Operations and PTT’s issuance of the Certificate of Initial Acceptance. The following conditions for completion shall be met, at a minimum: •

Facilities shall be mechanically and structurally complete, inspected, tested, commissioned, and operable at full design pressure

•

Facilities shall be in a tight and clean condition, and otherwise prepared as described in the Contract

•

All checklists and documentation related to Commissioning and 30 day continuous operation shall be complete and signed

•

Contractor shall have issued the Notice of Start of Regular Operations to PTT

•

All required manuals, accounting records, quality control reports and documents, as-built data, and other documents shall have been prepared and delivered in accordance with the Contract.

•

All deficiencies identified by PTT shall have been remedied

•

Any disturbed land and facilities shall have been appropriately restored and all required landscaping shall be complete

•

All required training shall have been completed

•

All required authorized inspection certification by law such as overhead crane shall be completed and signed.

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

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Mechanical Completion

TO:

DATE : UNITS : SUBJECT: Mechanical Completion and Acceptance

ATTN:

REF NO:

Gentlemen: In accordance with the Contract, the following item(s) is (are) ready for commissioning: ITEMS

EXCEPTIONS

Please sign and return two copies in acknowledgement of your acceptance. Very truly yours,

CONTRACTOR

CERTIFICATE OF ACCEPTANCE (Mechanical Completion) PTT BY DATE

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 12 OF 49 REV: D2

Notice of Completion TO:

DATE : UNITS : SUBJECT: Completion of Construction and

ATTN:

Acceptance REF NO:

Gentlemen: Work has been completed on the item(s), unit(s), facility(ies), or plant(s) listed below. This Work is in accordance with all plans, specifications, and official instructions from PTT and articles of the Contract. ITEMS

EXCEPTIONS

Please sign and return two copies in acknowledgement of your acceptance. Very truly yours,

CONTRACTOR

CERTIFICATE OF ACCEPTANCE PTT BY DATE

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

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MECHANICAL COMPLETION CHECKLIST OUTLINE I.

PIPING Check list against Piping and Instrumentation Diagrams

II.

ELECTRICAL A. Area Classification B. Service Conditions C. Circuit Breakers, Switchgear and Motor Control Center D. Main Power Supply E. Auxiliary Power Supplies F. Wire and Cable G. Conduit Systems H. Electronic Instrument Loops I. Ground System J. Transformer or Generator Neutral Resistance Ground K. Lighting L. Control Stations M. Cathodic Protection

III.

INSTRUMENTATION A. General Check List B. Inspection and Calibration of Instruments 1. Manufacturer's Check Lists 2. Differential Pressure Type Flow Meters 3. Orifice Plates 4. Differential Level Transmitters 5. Level Switches 6. Flow Switches 7. Pressure Switches 8. Temperature Switches 9. Miscellaneous Switches 10. Gage Glasses 11. Pressure Gages 12. Pressure Instruments 13. Temperature Instruments 14. Control Valves 15. Safety and Relief Valves 16. Regulators 17. Instrument Piping and Tubing 18. Analytical Instruments and Specialties 19. Receiver Instruments and Control Panel 20. Annunciators 21. Annubars 22. Detection and Safety Devices 23. Interface to SCADA

IV.

EQUIPMENT A.

Vessels, Tanks and Drums

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

V.

FLUSHING AND CLEANING

VI.

OTHER FACILITIES A. B. C. D. E. F.

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Safety and Fire Protection Concrete Placement and Testing Roads, Fences and Gates Soil Compaction Waste Disposal Documentation

THIS MECHANICAL COMPLETION CHECK LIST IS INTENDED TO ASSIST CONTRACTOR TO DEVELOP THE DOCUMENTATION REQUIRED TO PREPARE THE WORK FOR COMMISSIONING. ITEMS NOT EXPLICITLY LISTED BUT REFLECTED IN SPECIFICATIONS OR ON DRAWINGS SHALL FORM PART OF THE SCOPE OF THIS ACTIVITY. CONTRACTOR SHALL BE RESPONSIBLE TO ENSURE THAT ALL COMPONENTS AND SYSTEMS SHOWN ON THE VARIOUS CONTRACT DOCUMENTS ARE PROPERLY VERIFIED AFTER INCORPORATION INTO THE WORK TO THE ULTIMATE SATISFACTION OF THE OWNER.

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION I.

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

PIPING Prior to hydrostatic test of plant piping, it is necessary to check the plant for complete conformance with the final piping and instrumentation diagrams. The final inspection must include the PTT operations representatives. It may be a combined operations, contractor and engineering effort. This check will help to reveal any errors and prevent retest of the piping in case omissions and errors are found and corrections have to be made. A thorough check must be made of all piping supports, spring hanger settings and spring support settings, anchors and welded attachments. If any welded attachments are found to be incorrect and must be changed, or if some have been omitted and have to be added, this should be done prior to hydrostatic testing if possible. If this is not possible, the welding performed after pressure test must be thoroughly supervised and carefully inspected after completion. A. All piping systems must be checked for proper venting and draining. Check for proper slope where required. B. Is there any configuration not previously observed or corrected likely to result in hydraulic shock (water hammer), slug flow or vapor binding? C. Check accessibility of all operating valves. D. Check all valves for correct body material, trim and packing. E. Check pipe valves and fittings for specification material, correct size, type, pipe schedule, flange rating, and metallurgy. F. Check all bolted joints for proper studding, bolt length and gasket material. G. Check for expansion and vibration. Check for adequate, proper and safe supports, undue stresses and alignment. H. Operate all hand valves. Check for chain wheels where required, platforms and ladders. Grease all stems and handwheels. I.

Check all check direction.

valves for proper flow

J. If internal lining or sleeves are specified, are they in place? Any wear plates left out?

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MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

K. Has stress relief been performed where required? If cold springing specified, has this been checked? L. Check connections and branch piping for proper reinforcement. M. Check to see that unusual or excessive piping loads and temperature strains have not been imposed on pump flanges. N. Check all lubricated valves for proper lubrication as recommended by the manufacturer for the service in which the valve is to function. Verify standardization with depot personnel. O. Check installation and stroke operators and their lubrication settings.

of valve and limit

P. Check motor valve settings for proper support accessibility. Q. Blank off all relief valves prior to testing piping systems. R. Hydraulically or hydrostatically test all pipe in accordance with applicable codes and specifications and complete PTT Form TR-1. Provide hydrostatic test record, such as form TR-2 to supplement PTT form, properly witnessed by PTT. Do not test through instruments or rotating equipment. S. Perform any special tests and special chemical cleaning or pickling required by the Contract specifications or drawings. Complete any required records. T. Has blowing and/or flushing been performed? Most debris and dirt should have been routinely removed during construction. Avoid flushing dirt and debris from one section to another where it may become lodged. Do not flush into instrument take-offs. (See Flushing and Cleaning, Section V). U. After flushing is complete and piping reassembled, check for installation of start-up strainers on pumps as specified by the drawings and specifications. Strainers must be in place before equipment has final alignment check. Check and remove any blinds used during construction and test.

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MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

V. Check to see that proper orifice plates, pressure gauges, sample valves, thermowells and other such accessories are installed as per drawings and specifications. Orifice plates should be installed after prestart flush. W. Check to see that all insulation, whether for process, noise, or personnel protection required at start-up, is installed. X. Is all sentinel drilling (tell-tale holes) complete? Y.

Special procedures are required when air or moisture must be removed or excluded. Has this work been performed?

Z.

Check if Stamp and data reports that are required for API 5L Piping Standards are in place. Check if ASTM data reports that are required are in place.

AA. Make the necessary tie-ins at the unit limits as required by the drawings and specifications. BB. Prepare operating (live) systems for safe tieins. CC. Install car seals or locks on valves designated as car sealed or locked valves. Check and record position of all car sealed or locked valves. II. ELECTRICAL Contractor shall prepare a comprehensive Mechanical Completion form for each set of electrical connections and electrical loops to supplement: instrument data sheets, including electrical wiring and electrical connections to equipment furnished for the Work. Contractor shall follow the requirements in the Electrical Installation Specification, Vendor supplied instructions, instruction provided in this section and directions received from PTT. A.

Area Classification Check that all equipment is suitable for the relevant area classification.

B.

Service Conditions Check that all material meets the conditions specified in the plan drawings.

C.

Circuit

Breakers,

Switchgear

and

Motor

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MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

Control Centers 1.

Equipment shall be visually inspected for damage and missing parts, and thoroughly cleaned of any dirt, debris or foreign material accumulated during construction.

2.

All field wiring shall be checked for connection to proper terminals.

3.

All components shall be megger tested (600-volt megger) minimum reading to be one (1) megohm, before being energized.

4.

Make continuity checks of all circuits simulating actual operating conditions as far as possible without energizing equipment.

5.

Verify that instruments, instrument transformers, relays, fuses and other devices are of proper type, size and rating, in accordance with relay and fuse coordination information provided.

6.

With breaker in test position, test operation with local, remote and manual operation.

7.

Secure approval of PTT to energize equipment.

8.

Induction type relays and other protective devices shall be set and tested per manufacturer's recommendation.

9.

All seals in conduit shall be checked to determine if installed correctly and properly filled with approved sealing compound.

10. Fences and other enclosures for high voltage apparatus must be complete and locks installed on gates. D.

E.

Main Power Supply 1.

Before closing main breaker, check phase rotation and voltage.

2.

Energize feeders.

Auxiliary Power Supplies

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MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

F.

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

1.

Check battery and charger for damage and check electrolyte for level and specified gravity. Follow manufacturer's precommissioning instructions.

2.

Check emergency generator and automatic transfer equipment for automatic starting, generation and transfer with simulated loss of normal power.

3.

Check UPS static "no-break" power system for AC and DC input voltage and check that output is "no-break" by simulating loss of AC supply and loss of battery.

Wire and Cable 1.

600-volt wiring and cable shall be inspected for mechanical defects at time of installation. Wire with damaged or non-concentric insulation shall not be used. All 600-volt wire shall be tested with a megger and shall show minimum reading as indicated in (2) to ground or between each wire and all others in a common conduit or raceway.

2. The insulation resistance will vary with conditions; the following should serve as a guide: Insulation Resistance Wire Size 1 megohm #12 & smaller (4mm2) 500,000 ohms #10 to #8 (6/10mm2) 400,000 ohms #6 to #2 (16/35 mm2) 300,000 ohms #1 to #4/10 (50/95 mm2) 250thru 750 MCM (120/300 mm2) 200,000 ohms 3. All high voltage cables (above 600 volts) shall be given a high potential test according to manufacturer's instructions. This test shall be at a voltage not less than IPCEA or AEIC standard voltage test. Cable shall be tested on reel as soon as possible after delivery and again after installation (DC Volt to be applied 10 min.). 4. Cable runs shall be tested with a megger prior to high-potential test. 5. All potheads or cable terminations installed on the site shall be given the same high potential test as the cable to which it is attached.

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MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION 6. Complete Form applicable.

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION EE-2

(typical)

where

G. Conduit Systems 1. Underground – Check for compliance with construction drawings. 2. Above Ground - Check for compliance with detailed design drawings and the construction specification. H. Electronic Instrument Loops 1. Check all terminations for proper and tight connections, check loops for continuity and accidental ground. 2. Inspect all terminal boxes for drains, cable seals and moisture. 3. Check for proper type RTD wire. Form EE-2 (typical) if necessary.

Use

4. Check power supply and fuses at control board, control loops and field instruments. Use Form TR-4 (typical). I.

Ground System 1. The ground system should be inspected for defective or incomplete connections. 2. Measure actual resistance to ground at the ground loop or grid with a ground resistance megger. 3. Check resistance to ground of all equipment and tanks that connect to individual ground rods. Each ground should test 5 ohms or less. 4. Verify integrity of separate "instrument ground" needs. 5. Complete Form TR-3 (typical).

J. Transformer or Generator Neutral Ground 1. For resistance grounding: Check grounding transformer, resistor, current transformer, and relay for size and rating. 2. Set relay in accordance coordination settings.

with

relay

K. Lighting 1. All light fixtures and convenience outlets shall be checked for proper voltage and operation.

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2. Floodlights shall be checked at night and directed to obtain correct lighting design illumination levels. 3. Verify all illumination levels. L. Control Stations 1. Check out manual control stations. M. Cathodic Protection 1. Check continuity of system. 2. Turn on and adjust current as appropriate before piping is placed in service. 3. Balance CP circuits after piping is put in service with pipeline CP. III.

INSTRUMENTATION Contractor shall prepare a comprehensive Mechanical Completion form to supplement each instrument data sheet furnished for the Work Contractor shall follow the requirements in the applicable Specifications, Vendor supplied instructions, instructions provided in this section and directions received from PTT. A. General Check List 1. Check to see that specification materials have been used in the installation of instrument distribution piping, connecting tubing, and fittings. 2. Check all instrument loops for proper installation in accordance with the latest approved drawings. 3. Check to see that all parts are accessible. 4. Check to see that control lines are not in contact with hot lines or equipment. 5. Check to see that instrument air dryers and filters are working properly. 6. Check to see that all parts, including instrument piping and tubing, are properly supported and protected from possible damage due to operating or maintenance activities in the area. 7. Check to see that the power to valves and gas to instruments supplied with air by lateral lines or tubing is ready to be filled with air.

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MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION 8. Warning hydrotest.

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

Isolate

instruments

during

9. All piping and tubing is to be cleaned by disconnecting at both ends and blowing out. All instrument air distribution piping shall require a pneumatic test with air. Tubing shall be tested for leaks with an air bubbler in accordance with ISA standards. 10. After lines are cleaned and tested, they should be immediately capped or connected to the instrument to prevent any contamination or water from entering. The loop drawings should be used to record this test and cleaning. Complete Form TR-6 (typical). 11. Check to see that lighting is adequate for operations and maintenance. Check at night. B. Inspection and Calibration of Instruments 1. Manufacturer's Check List a. Calibrate instrument and control system in accordance with manufacturer's information and instrument data sheets. b. All instrument elements should be checked against design data for correctness of location, connection, labelling, and range of measurement. c. Check to see that all measuring elements, control valves, or other instruments removed for the flushing and cleaning operation are replaced and connected. d. Operate all hand valves including instrument air supply valves. e. Check to see that all electrical circuits are tested. Grounding for safety and shielding is to be checked. f.

Control valves should be tested for proper response to their control devices and for proper action on signal failure.

g. Alarm devices and automatic safety switches are tested. Shutdown systems are to be checked. Set all

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switches in accordance instrument data sheets. h. Maintain a calibrations.

log

of

with

instrument

i.

The calibration of transmitters, controllers, etc., shall be checked to comply and meet manufacturer's guaranteed accuracy’s.

j.

Each control valve shall be checked by local pressure reduction to comply with and meet manufacturer's guaranteed accuracy’s.

k. Set all controllers with preliminary modes per Vendor's documentation. l.

Complete required.

Form

IE-1

(typical)

as

m. All thermocouples and RTDs are to be checked in a single operation from the thermocouple to the indicator at the panel board. After disconnecting the wires from the element, the calibration of the indicator is to be checked at three points or more by the use of a potentiometer. n. Install seal fluids where Properly seal instruments.

required.

2.. Differential Pressure Type Flowmeter a. Bench calibrate against a standard water column manometer at three points (zero, line 5 and line 9). b. Use a precision output meter or gage to monitor output on transmitters. c. Complete manufacturer's check list. 3.. Orifice Plates a. Check nameplate data. b. Check for an upstream sharp edge. c. Measure and record bore with inside micrometer to ensure compliance with specifications. d. Check material. 4. Differential Transmitter

Pressure

Type

Level

a. Bench calibrate against a standard

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water column manometer at three points. b. Use a precision output meter or gage to monitor output. c. Fill seal legs. d. Complete manufacturer's check list. 5. Level Switches Check mechanical movement against output on float or displace types. No calibration required. 6. Flow Switches a. Check and set differential pressure types using standard water column manometer. b. Mechanically check only - through-flow types. 7. Pressure Switches a. Check using a hydraulic or deadweight test and set to the required alarm and/or trip point. b. Set receiver types to the required trip point using a precision pressure gage. 8. Temperature Switches a. Bench check using temperature bath.

a

controlled

b. Set to required alarm and/or trip point. 9.

Miscellaneous Switches - Solenoid valves, electrical relays, timers, pushbuttons, etc. shall be checked for proper operation.

10. Gage Glasses a. Install as received. b. Clean and check illuminators and check protectors and other accessories. c. Do not replace any broken glasses without proper instruction and torque wrenches. Clean broken glass from piping. 11. Pressure Gages a. Gages are subject to construction damage and should not be installed

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until immediately commissioning.

prior

to

b. Do not calibrate direct connected, bourbon-tube type gages, but where required zero instrument prior to installation. c. Receiver-type pressure gages shall be three-point calibrated using a precision pressure gage and precision air regulator. d. Draft gages, diaphragm type shall be three-point calibrated using a water column manometer. e. Glass tube manometers and draft gages shall be filled with the proper fluid and properly zeroed. 12. Pressure Instruments a. Pressure and pressure differential transmitters and transducers shall be three-point bench calibrated using a hydraulic or dead weight tester prior to installation. A precision output meter or gage shall be used to monitor the output. b. Complete manufacturer's check list. 13. Temperature Instruments a. Gages are subject to construction damage and should not be installed until immediately prior to commissioning. b. Prior to installation, filled system instruments shall be three-point bench calibrated using a controlled temperature bath. c. Thermocouple transducers shall be calibrated using a portable precision potentiometer in place in the racks. d. The multi-point temperature indicator calibration shall be checked using a portable precision potentiometer. e. Temperature recorder calibration shall be checked using a portable precision potentiometer. f.

Complete Form IE-2 (typical) and manufacturer's check list as needed.

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g. Bi-metallic dial thermometers shall not be calibrated but the dial or the pointer reset shall be set to the known ambient temperature before installing. h. Thermocouples shall be checked for type, polarity, double reversals, shielding, and proper point identification. 14. Control Valves a. All diaphragm and piston-operated control valves shall be pneumatically stroked using a pressure regulator and pressure gage against the spring range shown on the nameplate. Mechanical seating and travel shall be checked against the nameplate. It is desirable that this check be made in the shop prior to installation. b. Valve positioners shall be calibrated on the control valve in accordance with the instrument specifications. Split range positioners shall not have bypasses and shall be carefully checked. c. Prior to installation, electropneumatic valve transducers shall be bench calibrated with a portable or bench power supply and meter and output gage. If transducers are received mounted on valves, calibration should be done in place. d. Control valve accessories, such as handwheels, booster relays, etc., shall be operationally checked. e. All control valves shall be carefully checked by nameplate data and specifications and lubricated as required. f.

Butterfly valves shall be carefully checked to see that the vane moves freely into the upstream and downstream piping. Throttling butterfly valves shall be set for maximum travel in accordance with the vendor's data.

15. Safety and Relief Valves a. Check all safety valves for proper

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nameplate setting as per the valve and instrument specifications. b. Test all relief and safety valves for proper relieving pressure and possible leakage before installation. This test shall be performed by a qualified person. Qualified person is one who as attended a school of instruction or received training pertinent to the equipment involved. c. Where seals are found broken on relief valves, the relief valve is to be retested and resealed in accordance with plant safety practice. d. Where block valves are permitted under the relief valve, they shall be full line size and locked in the open position. e. Where rupture discs are used to isolate the safety valve from process fluid, their pressure rating is to be checked. f.

Conduct all operating tests required by code, law and insurance.

g. Complete Form TR-5. 16. Regulators a. Install self-contained pressure and temperature regulators as received. b. Check inlet and outlet ports and nameplate data. 17. Instrument Piping and Tubing a. Check against specifications. b. Verify correct installation. 18. Analytical Instruments and Specialties a. Calibrate analyzers and sampling systems, using product samples where furnished. b. Check recording, peak-picking, alarm interrupt circuitry. (Manufacturer to calibrate after installation.) c. Package instrument systems shall be carefully checked and calibrated to vendor's specifications. 19. Receiver Instruments and Control Panels

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a. Check all instrument nameplates, both front and rear, and all panelboard nameplates for tag number, service, location, and proper spelling. b. Install and check all charts and scales for range in accordance with specification. c. Calibrate all principal front-of-panel, rear-of-panel, and rack mounted instruments in accordance with manufacturer's instructions. d. Panel instrument calibration test instruments shall be precision devices and shall be the standard for loop matching. e. Check loop matching, such as zeroing transmitter to receiver. f.

Pressure test all signal air lines to ensure leak tightness.

g. Check all wiring for continuity. h. Perform megger tests for proper grounding and no shorts. Use Form TR-3 (typical). 20. Annunciators a. Check nameplates for engraving, spelling, and proper location. b. Check operation and point continuity by mechanically actuating all trouble contacts for low-high-deviation alarm operation, auxiliary contact operation and sequence. Use Form EE-3. 21. Check operation and calibration of all annubars 22. Check all detection and safety devices. Are they property calibrated? Do they initiate the proper alarms and shutdowns upon activation? 23. Interface to SCADA a.

Check transfer of digital inputs from field to SCADA display screen.

b.

Check 0, 25, 50, 75, and 100% rising and falling levels for each analog input to SCADA display screen.

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c. Check frequency inputs at 10 Hz and maximum frequency to SCADA display screen. d. Check control outputs from SCADA command to end device in field. e. Check analog setpoints from SCADA output to end device. Verify that feedback of setpoint is correctly shown on SCADA display with controller in local and remote. IV. EQUIPMENT Contractor shall prepare a comprehensive Mechanical Completion form for each unit shown in the Equipment List as furnished for the Work. Contractor shall pre-plan and notify PTT in advance when manufacturer's representatives or service engineers are to be present at the job site to implement the Mechanical Completion program. Contractor shall follow the requirements in the applicable Specifications, Vendor supplied instruction, instructions provided in this section, and directions received from PTT. A

Vessels, Tanks and Drums Contractor shall verify under this section: Completeness of gas dehydrators, dryers, filters, flame arrestors and silencers. 1.

Internal Inspection Before the final bolting of cover plates on manways, the interiors of the vessels must be inspected for cleanliness, completeness, and proper installation of internal components. Metallurgy of internals and interior cladding must be checked. Measurements and locations of internals must be verified as to drawings and specifications. This check shall be a joint inspection with PTT. A more detailed check list is given below. a.

Are all nozzles. Pipes. And internals installed at proper location with correct orientation and clearances as shown on the drawings and called for in the vessel specification ?

b.

Are all internals fabricated of proper materials as per the vessel specifications? Are cladding. lining. And wear plates installed as specified and of proper metallurgy ?

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c. Check tightness of all bolting, fitting, and positioning of vessel internals. d. Are all thermowells in correct position and of correct alloy and length? Are level control or indicator floats of proper size and free to move, with stilling wells were specified? 2. External Inspection a. Are all specified nozzles and other connections installed at proper location? b. Are all valve connections for sampling or pressure installed and at correct locations? c. Are all thermowells installed? d. Are all ladders and platforms installed? Are there any safety hazards such as piping, valves, conduits too close to ladder rungs and rails? e. connected piping, has this been done? Complete From TR-2 (typical). f.

Are all required pressure relief valves installed? Do nameplate pressure settings agree with specifications? If the assignment includes testing, has this been done?

g. Is all lifting gear, such as davits, etc., in place? (As per drawings) h. Are adequate vents and drains provided? Plugs or valves installed? Make check for plastic shipping plugs that must be removed and replaced with specification steel plugs for vessel rating and service. i.

Are plugs removed from “tell-tale” holes in reinforcing pads? Pipe vent outside insulation using ¼” open end pipe.

j.

Is electrical grounding system complete?

k. Is painting complete? l.

required

before

start-up

is

Special procedures are required when air or moisture must be removed or excluded. Has this work been done?

m. Check adequacy of lighting. This should be done at night with cooperation of PTT. 3. Complete typical Forms ME-1

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V. FLUSHING AND CLEANING A. All piping and vessels should be thoroughly cleaned of loose scale and internal debris that accumulates during construction. Flush or blow lines to remove the bulk of this loose material. A large part of this flushing can be accomplished by removing water from lines and equipment after hydrotesting or during the run-in of pumps. During test and flushing operations all lines and systems must be checked for proper drainage and venting. Most of the process and auxiliary lines may be flushed through established circuits from vessels, which are filled with water for that purpose. A single filling of a vessel may not provide adequate water for flushing all lines for which it is a reservoir, in which case a continuous or intermittent flow of water into the vessel should be maintained. Water may be admitted to most vessels via temporary connection to a nozzle on the bottom outlet line. If washing of the vessel itself is a primary object, introduce water into the top of the vessel by hose connection or by other means. Overhead lines may be flushed by overflowing the related vessel. When washing lines from a vessel always be certain that the vessel is adequately vented to prevent a vacuum condition. Verified? B. In any system to the greatest extent possible, flush downward or horizontally, and out at low points. The low point discharge openings will usually be temporary openings made by disconnecting flanges or fittings; normal drains may be used for flush outlets provided they are equal to line size or nearly so. For best results, there should be no restriction at the outlet or any other point in a line undergoing cleaning; where it is necessary to throttle the flushing flow, do so at the supply end. The higher the velocity of flushing, the more thoroughly a line will be cleaned. With a limited supply of flushing medium, do not flush through too many circuits or openings simultaneously. Flush through all vents, drains and other side connections. Flush by-passes alternately with their main channels. Try to avoid flushing line debris into equipment where it may become lodged or trapped. This is particularly important when washing towers

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containing perforated trays. So far as it can be done conveniently and economically, divert the initial flow ahead of, or around such equipment until lines upstream are clean, and then flush into or through the item concerned. Verified? C. When flushing of the lines is finished, drain water from the system as completely as possible. Provide ample top venting of all lines and vessels during the draining operation and drains must be provided in all low spots of the system to ensure removal of all flushing water or media. Blow lines with air to effect further water removal. Done? D. At the conclusion of flushing any system, check carefully to see that normal alignments are restored, temporary connections broken, temporary breaks reconnected, check valve flappers and/or cover plates replaced, orifices installed, etc. Start-up strainers are to be installed for pump and alignment of equipment checked after piping has been bolted in place. Completed and checked? E. Special instructions shall be issued outlining cleaning procedures for units or sections where moisture cannot be tolerated due to process considerations. Done? VI. OTHER FACILITIES Contractor shall prepare a comprehensive Mechanical Completion form for each facility installed as shown on drawings. Contractor shall follow the requirements in the applicable Specifications, Vendor supplied instructions, instructions provided in this section and directions received from PTT. A. Safety and Fire Protection 1. Are all systems operable? All components tested "end-to-end," verified and working? 2. Ladders and platforms are installed for safe operation and access. 3. Any safety hazards? Identify and describe. B. Concrete Placement and Testing 1. Were all concrete tests completed? laboratory and field reports on file?

Are

2. Verify that minimum strength has been

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achieved for all pours. 3. Has all concrete work been inspected for cracks? Make necessary repairs. C. Roads, Fences and Gates 1. Verify all new road surfaces suffered no damage and all damages have been repaired. The repairs have been accepted? 2. Verify all new and/or relocated gates operate properly. 3. Verify all fencing materials suffered no damage and all damages have been repaired to PTT satisfaction. 4. Verify all new road culverts and headwalls suffered no damage and all damages have been repaired to PTT satisfaction. 5. Have security fences, gates, and guard houses been completed? 6. Has construction equipment such as cranes, welding machines, etc., no long being used, been removed from operation areas? D. Soil Compaction 1. Has test been conducted, results documented and degree of compaction accepted? 2. If treatments to accelerate process were used, describe and verify acceptance. E. Waste Disposal 1. Have required been obtained?

governmental

approvals

2. Do all underground drains flow freely? Have seals been established where required? 3. Are outfall lines, ditches, etc., ready for use? F. Documentation 1. Complete all work shown on drawings and verify all check lists are complete. 2. Have required identifying markers and signs been installed?

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MECHANICAL COMPLETION FORMS The sample forms on the following pages may be used for recording field inspection results and tests. The list is not necessarily complete and the specific requirements for each facility or system must be a matter of agreement between Contractor and PTT. FORM NO. Test and Record Forms: TR-1, TR-1, TR-2 TR-3 TR-4 TR-5 TR-6, TR-6,

p. 1 p. 2

p. 1 p. 2

Piping Strength Test Pressure Report (Page 1) Piping Strength Test Pressure Report (Page 2) Hydrostatic Test Record Megger Readings - Ground Resistance Record Electrical Test Record Safety and Relief Valve Record Instrument Test Record (Page 1) Instrument Test Record (Page 2) Mechanical Equipment Check List

ME-1

Vessels Electrical Equipment Check List

EE-1 EE-2 EE-3

Circuit Breakers Lighting Panels, Insulation Resistance, and Remote Terminal Display (RTD) Alarm Circuit Operation Test

Instrument Check List IE-1 IE-2 IE-3

Controllers Direct Connected Recorders and Recorder Controllers Electronic Controllers, Recorders & Indicators

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

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FORM TR-1 PIPING LEAK AND STRENGTH PROOF TEST REPORT (Page 1) LEAK AND STRENGTH PROOF TEST REPORT (Page 1 of 2)

Onshore Compressor Station 4 Project FORM TR-1 DEPARTMENT CONDUCTING TEST

REPORT DATE

REASON FOR TEST: ‰ NEW CONSTRUCTION 1.

‰ EXISTING FACILITY

‰ STOCK PIPE

LOCATION:

‰ Facilities in GSP

‰ Metering Station

(Name.________________)

‰ Pipeline

‰ “A” ‰ “B”

Milepost Station

to to

(Name.________________)

‰ Natural Gas Piping ‰ LPG Piping ‰ NGL Piping ‰ Oil/Water/Other Piping

____ ____

DRAWING REFERENCES: 2. PIPE DATA AND TEST PRESSURE REQUIREMENTS a. Size

b. Wall

c. Spec

d. Material

e. Min. Test Pressure

f. Min. Test Time

g. Footage Tested

Columns a. through f. need to be completed and approved prior to test. 3. TEST MEDIUM INFORMATION

‰ Water

‰ Natural Gas ‰ Nitrogen

‰ Other:____________________________________

If water is to be used, the following must be completed: Source____________________________ Sample Analysis______________________________________ Agency How to be Consulted_________________________ Disposed____________________________________________ ENGINEERING APPROVAL BY:__________________________________________________________DATE: _________________ 4. TEST INSTRUMENTS AND EQUIPMENT: Type Pressure Recorder Temperature Recorder Dead Weight Tester Others:

Make

Range

Serial No.

Date Last Calibrated

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

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FORM TR-1 PIPING LEAK AND STRENGTH PROOF TEST REPORT (Page 2) LEAK AND STRENGTH PROOF TEST REPORT Page 2 of 2

Onshore Compressor Station 4 Project FORM TR-1 5. PROFILE DATA: ELEVATION

PRESSURING POINT

LOCATION OF DEAD WEIGHT TESTER

Survey Station Elevation 6. FIELD TEST PRESSURE DATA: Date of Test

$ $ $ $

Time Test Began

Date & Time Test Ended

Weather:

1.

2.

3.

4.

5.

6.

1.

2.

3.

4.

5.

6.

Clock Time

Press. Point (psig)

Min. Press. @ Max. Elev. (psig)

Max. Press. @ Min. Elev. (psig)

Amb. Temp. (EF)

Test Medium Temp. (EF)

Clock Time

Press. Point (psig)

Min. Press. @ Max. Elev. (psig)

Max. Press. @ Min. Elev. (psig)

Amb. Temp. (EF)

Test Medium Temp. (EF)

Enter in column 2, the pressure reading from the dead weight tester. Columns 3 and 4 data may be calculated if accurate elevation information is available. For piping in the GSP facility, furnish a field sketch if test layout differs from reference drawings. Temperature and pressure recorder charts and gage calibration charts are to be attached to the original of this report together with the water analysis if such a test was necessary. For mainline piping, furnish field profile sketch recording the pipeline length tested and the elevations and pressure as at high and low elevations. Existing bench marks & survey monuments shall be referenced in the test section.

TEST PERFORMED BY:

‰ PTT

By: _____________________________

‰ Contractor (Firm)

By: _____________________________

‰ Subcontractor (Firm)

By: _____________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

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FORM TR-2 HYDROSTATIC TEST RECORD Onshore Compressor Station 4 Project

HYDROSTATIC TEST RECORD

FORM TR-2 TEST SECTION NO. ______________________________ (1) PIPING SERVICE SYSTEM_________________________________ DATE OF TEST ________________________ METHOD OF TEST ___________________ TEST MEDIUM SOURCE ________________ COMPOSITION_________ AMBIENT TEMPERATURE __________________________ TEST MEDIUM TEMPERATURE ___________________ DESIGN PRESSURE ______________________________ TEST PRESSURE _______________________________ (2) Line Numbers

1

Drawing No.

2

3

1

2

3

ISO No.

REMARKS

LEAKS 1 2

3

FILL PUMP GPM MAX PRESSURE PUMP GPM GPM AT MAX MAXIMUM PRESSURE DEADWEIGHT TESTER TEST HEADERS AND BLINDS ________________________________________________________

EQUIPMENT INCLUDED IN TEST TAG NO. DESCRIPTION REMARKS

NOTES: (1)

Destination

TEST INSTRUMENTATION AND TEST RECORDS CALIBRATION READINGS THROUGH TEST PERIOD DATE TIME PRESS. TEMP.

TEST INSTRUMENT DESCRIPTION AND RANGE

DESCRIBE:

Origin

EQUIPMENT EXCLUDED - SHOP TESTED TAG NO. DESCRIPTION REMARKS

Prepare documentation for each Test Section – include schematics, layout and periodic notes during test period. (2) Use data from Project issued sheets

Accepted: Subcontractor

PTT Date LOCATION

Accepted: Contractor

DATE Date

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 38 OF 49 REV: D2

FORM TR-3 MEGGER READINGS - GROUND RESISTANCE RECORD Onshore Compressor Station 4 Project

MEGGER READINGS GROUND RESISTANCE RECORD

FORM TR-3 GROUND SYSTEM TEST LOCATION

SYSTEM NUMBER

RESIST. (OHMS)

AMB. TEMP.

WEATHER

DATE

TESTER'S INITIALS

EQUIPMENT

ACCEPTED __________________________________ SUBCONTRACTOR DATE _______________________________________

ACCEPTED______________________________________ PTT DATE __________________________________________

ACCEPTED __________________________________ CONTRACTOR DATE _______________________________________

ACCEPTED _____________________________________ PTT DATE___________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

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SPC-0804.02-99.88 PAGE: 39 OF 49 REV: D2

FORM TR-4 ELECTRICAL TEST RECORD Onshore Compressor Station 4 Project

ELECTRICAL TEST RECORD

FORM TR-4 SYSTEM METHOD OF TEST DESIGN VOLTAGE CIRCUIT NUMBERS

ITEM NO.

DATE OF TEST TEST VOLTAGE VOLTAGE

ORIGIN

DESTINATION

EQUIPMENT INCLUDED IN TEST DESCRIPTION ITEM NO.

RUN IN

DRAWING NO.

DESCRIPTION

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 40 OF 49 REV: D2

FORM TR-5 SAFETY AND RELIEF VALVE RECORD Onshore Compressor Station 4 Project

SAFETY & RELIEF VALVE RECORD

FORM TR-5 SAFETY VALVES ITEM NUMBER

EQUIPMENT

SIZE

PRESSURE

SETTING TESTED

DATE TESTED

INSTALLED OK

RELIEF VALVES

SYSTEM TEST

REMARKS:

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

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FORM TR-6 INSTRUMENT TEST RECORD (Page 1) Onshore Compressor Station 4 Project

INSTRUMENT BANK TEST AND CALIBRATION RECORD Sheet 1 of 2

FORM TR-6 TYPICAL FORM:

TITLE FROM INSTRUMENT INPUT/OUTPUT LIST TAG NO.

NAME

(T) (1)

(C) (2)

VERIFY (4)

INSTALLED LOCATION OK? (3) M

NOTES: (1) (2) (3) (4)

I

E

W

REMARKS AND OTHER R

S

Show date of bank test completed and accepted. Describe below test method used. Verify calibration of instrument and describe procedure followed. Include separately approved calibration certificate. Indicate compliance with drawings. M = mounting with all brackets and identifiers finished I = installation complete ready for use E = piping ends connected after piping test and cleaning W = electrical wiring tested, passed and connections finished R = recorders with printing media verified (inks, pens, paper, etc.); verify with data collected during precommissioning S = remote receipt of data

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 42 OF 49 REV: D2

FORM TR-6 INSTRUMENT TEST RECORD (Page 2) Onshore Compressor Station 4 Project

INSTRUMENT BANK TEST AND CALIBRATION RECORD Sheet 2 of 2

FORM TR-6 SYSTEM METHOD OF TEST DESIGN CRITERIA LOOP NUMBERS

ITEM NO.

DATE OF TEST TEST CRITERIA INSTRUMENT NO.

RANGE

EQUIPMENT INCLUDED IN TESTS DESCRIPTION ITEM NO.

DRAWING NO.

DESCRIPTION

NOTES:

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 43 OF 49 REV: D2

FORM ME-1 VESSELS Onshore Compressor Station 4 Project

FIELD INSTALLATION CHECK LIST

FORM ME-1 VESSELS EQUIPMENT NO. FABRICATOR TYPE MATERIAL THICKNESS ITEM TO CHECK CONDITION WHEN RECEIVED? ERECTION ALIGNMENT, ELEVATION & PLUMB GROUNDING STRAP INSTALLED? INTERNALS INSULATION & FIREPROOFING GROUTED CLEANED TESTED LADDERS, PLATFORMS, DAVITS CLOSED

SERVICE P.O. NUMBER CODE DATE RECEIVED REMARKS/OK

DATE TESTED

REMARKS:

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 44 OF 49 REV: D2

FORM EE-1 CIRCUIT BREAKERS Onshore Compressor Station 4 Project

FIELD INSTALLATION CHECK LIST

FORM EE-1 CIRCUIT BREAKERS EQUIPMENT NO. MANUFACTURER ITEM TO CHECK CONTACT PARTS CLEAN? VISUALLY CLEAN? (NOT CORRODED) NO MOISTURE PRESENT? ENCLOSURE HAS BREATHER & DRAIN? COVERS ON TIGHT? SEALS FILLED? INSTANTANEOUS TRIP SETTING: PHASE A PHASE B PHASE C

SERVICE INSTALLED BY REMARKS/OK

DATE TESTED

REMARKS:

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 45 OF 49 REV: D2

FORM EE-2 LIGHTING PANELS, INSULATION RESISTANCE, REMOTE TERMINAL DISPLAY (RTD) Onshore Compressor Station 4 Project

ELECTRICAL TEST RECORD

FORM EE-2 TYPICAL FORM FOR:

CIRCUIT NUMBER

WIRE NUMBER

LIGHTING PANELS INSULATION RESISTANCE REMOTE TERMINAL DISPLAY (RTD) WIRE SIZE

FROM

TO

MEGGER READING (MEG OHM) @ 1 2 3

DATE

AMB. TEMP.

WEATHER

NOTE: @ MEGGER READINGS TO BE WITH WIRES COMPLETELY INSTALLED, CONDUIT FITTINGS CLOSED, SEALS FILLED, AND WITH THE CIRCUIT BREAKER OPEN INSTALLED BY _________________________________________ DATE___________________________________

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 46 OF 49 REV: D2

FORM EE-3 ALARM CIRCUIT OPERATION TEST Onshore Compressor Station 4 Project

FIELD INSTALLATION CHECK LIST

FORM EE-3 ALARM CIRCUIT OPERATION TEST ALARM UNIT NUMBER

EQUIPMENT LOCATION

TESTER'S INITIALS

DATE

REMARKS

NOTE: EACH DEVICE SHOULD BE ACTUATED BY ACTUAL PRESSURE, TEMPERATURE, LEVEL, SPEED, FLOW, ETC. ALL ITEMS MUST BE SIGNED AS BEING IN SATISFACTORY CONDITION BEFORE OPERATION IS PERMITTED.

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 47 OF 49 REV: D2

FORM IE-1 CONTROLLERS Onshore Compressor Station 4 Project

INSTRUMENT CHECK LIST

FORM IE-1 CONTROLLERS INSTRUMENT NO.

SERVICE

MANUFACTURER

SERIAL NO.

ITEM TO CHECK 1. Blow air supply line at filter. Adjust air supply to specified pressure. 2. Align or synchronize controller so that when both process and set point are together near mid-range, the output air pressure does not drift. Observe for at least 2 minutes. The proportional bank adjustment should be able to be moved through its full range (2 to 300%) without change in output pressure. 3. Check the tubing from output to valve or pneumatic set unit of another instrument. There should be no restriction or leaks. Check stack for leaks - tighten bolts if necessary. (Bubble test should be used on all pneumatic controller systems.) 4. Controller is connected to proper valve and to proper connections. 5. Check manual control position. Put instrument on manual, adjust output to about 9 psig, move set point above and below process pen. No change in output air pressure should result. 6. Check that controller output air action is correct for valve or instrument to which it is connected. Control action is set "as process measurement increases" output air. (INCREASES for direct action and DECREASES for reverse action.) 7. Affix calibration sticker.

DATE CHECKED

REMARKS:

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 48 OF 49 REV: D2

FORM IE-2 DIRECT CONNECTED RECORDERS AND RECORDER CONTROLLERS Onshore Compressor Station 4 Project

INSTRUMENT CHECK LIST

FORM IE-2 DIRECT CONNECTED RECORDERS AND RECORDER CONTROLLERS INSTRUMENT NO.

SERVICE

MANUFACTURER

SERIAL NO.

ITEM TO CHECK 1. Remove all paper tags, strings, shipping stops, and install chart. 2. Check pen linkages for proper connection and freedom of movement. 3. Check calibration of recording pens at three points: 0, 50%, 100% of span; if not within 0.5% of span, recalibrate and report results on attached sheet. 4. If instrument is a controller, synchronize and align controller. Blow air supply line and adjust regulator to 20 psig before connecting controller to air supply. 5. Check output air tubing for leaks and connection to proper valve. Check that control action is correct. 6. Fill pens with ink and see the ink flows freely. 7. Check that chart drive operates. 8. Check nameplates for correct identification. 9. Affix calibration sticker. Shut off chart drive. Leave instrument clean and neat, ready for operation.

DATE CHECKED

REMARKS:

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

MECHANICAL COMPLETION AND COMMISSIONING AND 30 DAY CONTINUOUS OPERATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-99.88 PAGE: 49 OF 49 REV: D2

FORM IE-3 ELECTRONIC CONTROLLERS, RECORDERS AND INDICATORS ELECTRONIC CONTROLLERS, RECORDERS AND INDICATORS

INSTRUMENT CHECK LIST

Onshore Compressor Station 4 Project FORM IE-3 ELECTRONIC CONTROLLERS, RECORDERS AND INDICATORS INSTRUMENT NO.

SERVICE

MANUFACTURER

SERIAL NO.

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

ITEM TO CHECK Check continuity of wiring, location and value of dropping resistors, and verify service manual feature (if provided) is disengaged. Turn on power supply and check voltage level and polarity. Check and adjust input span and zero. Set output signal limits. (High = 100%; Low = 0%) Place controller in Automatic Mode and check alignment. Transfer controller to the Manual Mode and check both up and down scale ramp rates. Verify output signal action is correct for receiver. "Output is to _______________ with input signal increase." Check correct chart and scale ranges. Install recorder ink capsules Affix calibration sticker.

DATE CHECKED

REMARKS:

ACCEPTED ________________________________ SUBCONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________

ACCEPTED ________________________________ CONTRACTOR DATE _____________________________________

ACCEPTED _______________________________________ PTT DATE ____________________________________________