244606874-PR-P-1102-21-4012-004-Rev-0-MECHANICAL-COMPLETION-PROCEDURE-SW-docx.docx

PTT PUBLIC COMPANY LIMITED

RATCHABURI WORLD COGENERATION COMPANY LIMITED

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT

0

02/04/13

Issued for Construction

WS

JR

NP

A

13/02/13

Issued for Approval

WS

JR

NP

Rev.

Date

Description

Prepared By

Checked By

Approved By

CONTRACTOR:

CONSULTANT:

SIAM RAJATHANEE JOINT VENTURE

UNITY ENGINEERING AND CONSULTANCY SERVICES CO.,LTD.

DOCUMENT TITLE:

MECHANICAL COMPLETION PROCEDURE

DOCUMENT NO.:

PR-P-1102.21-4012-004

REVISION:

0

DOCUMENT CHANGE RECORD

Rev

Date

Prepared/ Revised By

Reviewed By

Approved By

Description

A

13/02/13

WS

JR

NP

Issued for Approval

0

02/04/13

WS

JR

NP

Issued for Construction

REVIEW STAMP E. Work may proceed. F. Work may proceed. Submit “for Construction” Documents. G. Revise and Resubmit. Work may proceed Subject to incorporation of changes indicated. H. Revise and Resubmit. Work may not proceed. I. Review not required. Work may proceed. Acceptance in any of these categories shall be in no way relieve the Contractor/Supplier of its responsibility for the due and proper performance of the Work in accordance with the Contract/Purchase Order. Name: Sign: Date:

COMMENTS

TABLE OF CONTENT ARTICLE

PAGE

1.

SCOPE.......................................................................................................................................... 4

2.

DEFINITIONS................................................................................................................................ 4

3.

ACTIVITIES................................................................................................................................... 4

4.

CHECKLISTS, FORMS, AND LOGBOOKS..................................................................................5

5.

SCHEDULE................................................................................................................................... 6

6.

VENDOR REPRESENTATIVES.................................................................................................... 6

7.

COMPLETION OF WORK............................................................................................................ 7 MECHANICAL COMPLETION

8

NOTICE OF COMPLETION

9

MECHANICAL COMPLETION CHECKLIST OUTLINE

10

MECHANICAL COMPLETION CHECK LIST

12

FORM TR-1:

PIPING LEAK AND STRENGTH PROOF TEST REPORT (Page 1/2)...............36

FORM TR-1:

PIPING LEAK AND STRENGTH PROOF TEST REPORT (Page 2/2).............37

FORM TR-2:

HYDROSTATIC TEST RECORD.......................................................................38

FORM TR-5:

MEGGER READINGS - GROUND RESISTANCE RECORD............................39

FORM TR-6:

ELECTRICAL TEST RECORD...........................................................................40

FORM TR-7:

SAFETY AND RELIEF VALVE RECORD...........................................................41

FORM TR-8:

INSTRUMENT TEST RECORD (Page 1/2).......................................................42

FORM TR-8:

INSTRUMENT TEST RECORD (Page 2/2).......................................................43

FORM ME-2:

VESSELS........................................................................................................... 44

FORM EE-5:

CIRCUIT BREAKERS........................................................................................45

FORM EE-8: LIGHTING PANELS, INSULATION RESISTANCE, REMOTE TERMINAL DISPLAY (RTD) ........................................................................................................................... 46 FORM EE-9:

ALARM CIRCUIT OPERATION TEST...............................................................47

FORM IE-1:

CONTROLLERS................................................................................................48

FORM IE-2:

DIRECT CONNECTED RECORDERS AND RECORDER CONTROLLERS.....49

FORM IE-3:

ELECTRONIC CONTROLLERS, RECORDERS AND INDICATORS................50

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

1.

SCOPE This Specification describes and clarifies the requirements for mechanical completion 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, and Acceptance.

2.

DEFINITIONS For the purposes of this specification, the following definitions shall apply: Owner

means

Ratchaburi World Cogeneration Company Limited.

Advisor

means

PTT Public Company Limited.

Project

means

Gas Pipeline and Gas Metering and Regulating Station Project.

Consultant

means

Unity Engineering and Consultancy Services Co., Ltd.

Contractor

means

Siam Rajathanee Joint Venture

Vendor

means

The party which supplies materials, equipment, technical Documents/drawings and services to perform the duties specified by Contractor.

3.

ASME

means

The American Society of Mechanical Engineers.

ANSI

means

American National Standards Institute

ACTIVITIES 3.1

Mechanical Completion 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 pre-commissioning are included in mechanical completion activities and will 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, coldaligned, 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 mechanical operation

•

All instrumentation shall be installed, loop checked, set to proper set-points, and calibrated

•

Instrumentation loop checks to the SCADA master shall be completed

•

All modifications and upgrades to the SCADA system shall be completed

•

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

•

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

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

3.2

•

All painting, coating, and insulation work shall be completed

•

All changes and modifications shall be incorporated

•

All functional tests of individual systems shall be performed.

•

All work shall be verified to be in accordance with the proper Specifications, Drawings (Owner 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

Partial Activities and Exceptions With the approval of Owner, Contractor may subdivide the overall facilities into units and perform mechanical completion activities on these units separately. The units so selected shall be logical, well defined, and beneficial to project scheduling. No special consideration shall ensue as a result of the division of the Facilities into units and Contractual conditions and guarantees for Mechanical Completion of the overall Facilities shall remain in force regardless of the state of activities on the individual units. Contractor may give notice of mechanical completion of a unit with a detailed list of exceptions for items, which are incomplete, defective, or otherwise not in accordance with the Contract. This list shall include all outstanding mechanical completion items and shall show a schedule for completing each exception.

4.

CHECKLISTS, FORMS, AND LOGBOOKS 4.1

General Mechanical Completion checklists and forms will 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), modified as necessary for individual equipment and systems. Contractor shall submit these forms for Owner approval at least thirty days prior to initiating the inspection, test, and verification activities covered by the checklists and forms. Contractor shall prepare and use logbooks for all activities carried out during Commissioning. 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 shall record instrument readings, control panel readings, and other relevant information.

4.2

Procedure The checklists and forms prepared by the Contractor and as approved by Owner shall be used as sign-off sheets for the permanent record of inspections, tests, and mechanical completion activities. These shall be signed by Contractor, Owner’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 Owner 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.

4.3

Introduction of Natural Gas Contractor shall recognize that the introduction of natural gas to any portion of the Work is a hazardous activity requiring the full knowledge and approval of all parties involved, including

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

Contractor’s staff, Owner and Owner’s 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 Owner 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 Owner 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 Owner

In the case of a threat to the safety of personnel or equipment during commissioning, Owner 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. 5.

SCHEDULE As required by the Contract, Contractor shall prepare complete schedules for mechanical completion activities. Schedules for such units shall allow the contractually defined dates to be met.

6.

VENDOR REPRESENTATIVES 6.1

Mechanical Completion Contractor shall schedule vendor representatives to be onsite to aid in mechanical completion activities as necessary. At least 60 days prior to Mechanical Completion, Contractor shall submit for Owner’s review a list of vendor representatives to be brought to the site and a schedule showing their planned arrival and departure dates. Owner may request additions to this list. Notwithstanding the planned departures shown on this schedule, each vendor representative shall remain onsite until his equipment is fully commissioned.

6.2

Training As required to meet the Contractor’s requirements for training, the scheduling for vendor representatives shall also include ample time to provide specialized training to Owner on the vendor’s equipment. The vendor’s representative shall bring sufficient training materials, aids, and documentation as needed to complete the training requirements.

7.

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 Owner’s issuance of the Certificate of Acceptance. The following conditions for completion shall be met, at a minimum: •

Facilities shall be mechanically and structurally complete, inspected, tested, 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 shall be complete and signed

•

Contractor shall have issued the Notice of Start of Regular Operations to Owner.

•

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

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

•

All deficiencies identified by Owner shall have been remedied

•

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

•

All Contractually required training shall have been completed

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

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) Owner BY DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

NOTICE OF COMPLETION TO:

DATE :

UNITS : ___ SUBJECT: Completion of Construction and Acceptance ATTN:

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 Owner 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

Owner BY DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

MECHANICAL COMPLETION CHECKLIST OUTLINE I.

PIPING Check list against Piping and Instrumentation Diagrams (P&IDs) Check list against Piping Arrangement and Isometric Drawings

II.

III.

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

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

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

IV.

19.

Receiver Instruments and Control Panel

20.

Annunciators

21.

Annubars

22.

Detection and Safety Devices

23.

Interface to SCADA

EQUIPMENT Vessels, Tanks and Drums

V.

FLUSHING AND CLEANING

VI.

OTHER FACILITIES A.

Safety and Fire Protection

B.

Concrete Placement and Testing

C.

Roads, Fences and Gates

D.

Soil Compaction

E.

Waste Disposal

F.

Documentation

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

MECHANICAL COMPLETION CHECK LIST 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 from 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.

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM 111111112.2

PERFORMED: CONTR.

WITNESSED: PTT OTHER

PIPING

Prior to hydrostatic test of station piping, it is necessary to check the station for complete conformance with the final piping and instrumentation diagrams. The final inspection must include the Owner 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. 3. All piping systems must be checked for proper venting and draining. Check for proper slope where required.

_______

________

________

4. Is there any configuration not previously observed or corrected likely to result in hydraulic shock (water hammer), slug flow or vapor binding?

________

________

________

5. Check accessibility of all operating valves.

________

________

________

6. Check all valves for correct body material, trim and packing.

________

________

________

7. Check pipe valves and fittings for specification material, correct size, type, pipe schedule, flange rating, and metallurgy.

________

________

________

8. Check all bolted joints for proper studding, bolt length and gasket material.

________

________

________

9. Check for expansion and vibration. Check for adequate, proper and safe supports, undue stresses and alignment.

________

________

________

10. Operate all hand valves. Check for chain wheels where required, platforms and ladders. Grease all stems and hand wheels.

________

________

________

11. Check all check valves for proper flow direction.

________

________

________

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

________

________

________

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

13. Has stress relief been performed where required? If cold springing specified, has this been checked?

________

________

________

14. Check connections and branch piping for proper reinforcement.

________

________

________

15. Check to see that unusual or excessive piping loads and temperature strains have not been imposed on pump flanges.

________

________

________

16. 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.

________

________

________

17. Check installation and stroke of valve operators and their lubrication and limit settings.

________

________

________

18. Check motor valve settings for proper support accessibility.

________

________

________

19. Blank off all relief valves prior to testing piping systems.

________

________

________

20. Hydraulically or hydrostatically test all pipe in accordance with applicable codes and specifications and complete Owner Form TR-1. Provide hydrostatic test record, such as form TR-2 to supplement Owner form, properly witnessed by Owner. Do not test through instruments or rotating equipment.

________

________

________

21. Perform any special tests required by the Contract specifications or drawings. Complete any required records.

________

________

________

________

________

________

________

________

________

________

________

________

22. 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). 23. 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. 24. 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.

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

25. Check to see that all insulation, whether for process, noise, or personnel protection required at start-up, is installed.

________

________

________

26. Is all sentinel drilling (tell-tale holes) complete?

________

________

________

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

________

________

________

28. Checks 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.

________

________

________

29. Make the necessary tie-ins at the unit limits as required by the drawings and specifications.

________

________

________

30. Prepare operating (live) systems for safe tie-ins.

________

________

________

________

________

________

31. 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.

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

PTT

WITNESSED: OTHER

3.32 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 Owner. 33.

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

________

________

________

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

________

________

________

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.

________

________

________

________

________

________

________

________

________

________

________

________

34.

C.2 Circuit Breakers, Switchgear and Motor Control Centers

7. Secure approval equipment.

of

Owner

to

energize

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

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR. apparatus must be complete and locks installed on gates.

PTT

WITNESSED: OTHER

________

________

________

4. Before closing main breaker, check phase rotation and voltage.

________

________

________

5.

________

________

________

7. Check battery and charger for damage and check electrolyte for level and specified gravity. Follow manufacturer's pre-commissioning instructions.

________

________

________

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

________

________

________

9. 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.

________

________

________

________

________

________

________

________

________

13. 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.).

________

________

________

14. Cable runs shall be tested with a megger prior to high-potential test.

________

________

________

D.3 Main Power Supply

Energize feeders.

E. 6Auxiliary Power Supplies

F.10

Wire and Cable

11. 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. 12. The insulation resistance will vary with conditions; the following should serve as a guide: Wire Size Insulation Resistance #12 & smaller (4mm2) 1 megohm #10 to #8 (6/10mm2) 500,000 ohms #6 to #2(16/35 mm2) 400,000 ohms #1 to #4/10 (50/95 mm2) 300,000 ohms 250 thru 750 MCM (120/300 mm2) 200,000 ohms

15. All potheads or cable terminations installed on the site shall be given the same high potential test as

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM the cable to which it is attached. 16. Complete Form EE-8 (typical) where applicable.

PERFORMED: WITNESSED: CONTR. PTT OTHER ________ ________ ________ ________

________

________

18. Underground – Check for compliance with construction drawings.

________

________

________

19. Above Ground - Check for compliance with detailed design drawings and the construction specification.

________

________

________

21. Check all terminations for proper and tight connections, check loops for continuity and accidental ground.

________

________

________

22. Inspect all terminal boxes for drains, cable seals and moisture.

________

________

________

23. Check for proper type RTD wire. Use Form EE-8 (typical) if necessary.

________

________

________

24. Check power supply and fuses at control board, control loops and field instruments. Use Form TR-6 (typical).

________

________

________

26. The ground system should be inspected for defective or incomplete connections.

________

________

________

27. Measure actual resistance to ground at the ground loop or grid with a ground resistance megger.

________

________

________

28. Check resistance to ground of all equipment and tanks that connect to individual ground rods. Each ground should test 5 ohms or less.

_______

________

________

29. Verify integrity of separate "instrument ground" needs.

________

________

________

30. Complete Form TR-5 (typical).

________

________

________

32. For resistance grounding: Check grounding transformer, resistor, current transformer, and relay for size and rating.

________

________

________

33. Set relay in accordance with relay coordination settings.

________

________

________

G.17

Conduit Systems

H. 20Electronic Instrument Loops

I.25 Ground System

J.31 Transformer or Generator Neutral Ground

K.34 Lighting

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

PTT

WITNESSED: OTHER

35. All light fixtures and convenience outlets shall be checked for proper voltage and operation.

________

________

________

36. Floodlights shall be checked at night and directed to obtain correct lighting design illumination levels.

________

________

________

37. Verify all illumination levels.

________

________

________

________

________

________

41. Check continuity of system.

________

________

________

42. Turn on and adjust current as appropriate before piping is placed in service.

________

________

________

43. Balance CP circuits after piping is put in service with pipeline CP.

________

________

________

L.38 Control Stations 39. Check out manual control stations. M.40 Cathodic Protection

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

4.3544 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 Owner. 36. General Check List 45. Check to see that specification materials have been used in the installation of instrument distribution piping, connecting tubing, and fittings.

________

________

________

46. Check all instrument loops for proper installation in accordance with the latest approved drawings.

________

________

________

47. Check to see that all parts are accessible.

________

________

________

48. Check to see that control lines are not in contact with hot lines or equipment.

________

________

________

49. Check to see that instrument air dryers and filters are working properly.

________

________

________

50. 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.

________

________

________

51. 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.

________

________

________

52. Warning hydrotest.

________

________

________

53. 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.

________

________

________

54. 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-8 (typical).

________

Isolate

instruments

during

________

55. Check to see that lighting is adequate for

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

________

ITEM operations and maintenance. Check at night. 37.56

PERFORMED: WITNESSED: CONTR. PTT OTHER ________ ________ ________

Inspection and Calibration of Instruments

57. Manufacturer's Check List 2. Calibrate instrument and control system in accordance with manufacturer's information and instrument data sheets.

________

________

________

3. All instrument elements should be checked against design data for correctness of location, connection, labeling, and range of measurement.

________

________

________

4. Check to see that all measuring elements, control valves, or other instruments removed for the flushing and cleaning operation are replaced and connected.

________

________

________

5. Operate all hand valves instrument air supply valves.

________

________

________

6. Check to see that all electrical circuits are tested. Grounding for safety and shielding is to be checked.

________

________

________

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

________

________

________

8. Alarm devices and automatic safety switches are tested. Shutdown systems are to be checked. Set all switches in accordance with instrument data sheets.

________

________

________

9. Maintain a log of instrument calibrations.

________

________

________

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

________

________

________

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

________

________

________

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

________

________

________

13.Complete Form IE-1 (typical) as required.

________

________

________

including

14. 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 PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR. the indicator is to be checked at three points or more by the use of a potentiometer.

WITNESSED: PTT OTHER

________

________

________

________

________

________

a. Bench calibrate against a standard water column manometer at three points (zero, line 5 and line 9).

________

________

________

b. Complete manufacturer's check list.

________

________

________

a. Check nameplate data.

________

________

________

b. Check for an upstream sharp edge.

________

________

________

Measure and record bore with inside micrometer to ensure compliance with specifications.

________

________

________

Check material.

________

________

________

17. Bench calibrate against a standard water column manometer at three points

________

________

________

18. Use a precision output meter or gage to monitor output

________

________

________

19. Fill seal legs.

________

________

________

20. Complete manufacturer's check list.

________

________

________

________

________

________

22. Check and set differential pressure types using standard water column manometer.

________

________

________

23. Mechanically check only - through-flow types.

________

________

________

15. Install seal fluids where Properly seal instruments.

required.

2. Differential Pressure Type Flowmeter

3. Orifice Plates

c.

d.

4.16 Differential Transmitter

Pressure

Type

Level

5.21 Level Switches Check mechanical movement against output on float or displace types. No calibration required.] 6. Flow Switches

7.24

Pressure Switches

25. Check using a hydraulic or dead-weight

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

test and set to the required alarm and/or trip point.

________

________

________

26. Set receiver types to the required trip point using a precision pressure gage.

________

________

________

________

________

________

________

________

________

________

________

________

31. Install as received.

________

________

________

32. Clean and check illuminators and check protectors and other accessories.

________

________

________

33. Do not replace any broken glasses without proper instruction and torque wrenches. Clean broken glass from piping.

________

________

________

11.34 Pressure Gages 35. Gages are subject to construction damage and should not be installed until immediately prior to commissioning.

________

________

________

36. Do not calibrate direct connected, bourbon-tube type gages, but where required zero instrument prior to installation.

________

________

________

37. Receiver-type pressure gages shall be three-point calibrated using a precision pressure gage and precision air regulator.

________

________

________

38. Draft gages, diaphragm type shall be three-point calibrated using a water column manometer.

________

________

________

39. Glass tube manometers and draft gages shall be filled with the proper fluid and properly zeroed.

________

________

________

8.27

Temperature Switches

28. Bench check using temperature bath.

a

controlled

29. Set to required alarm and/or trip point. 9.30

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

10. Gage Glasses

12.40

Pressure Instruments

41. Pressure and pressure differential transmitters and transducers shall be three-point bench calibrated using a

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR. hydraulic or dead weight tester prior to installation. A precision output meter or gage shall be used to monitor the output.

WITNESSED: PTT OTHER

________

________

________

________

________

________

44. Gages are subject to construction damage and should not be installed until immediately prior to commissioning.

________

________

________

45. Prior to installation, filled system instruments shall be three-point bench calibrated using a controlled temperature bath.

________

________

________

46. Thermocouple transducers shall be calibrated using a portable precision potentiometer in place in the racks.

________

________

________

47. The multi-point temperature indicator calibration shall be checked using a portable precision potentiometer.

________

________

________

48. Temperature recorder calibration shall be checked using a portable precision potentiometer.

________

________

________

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

________

________

________

50. 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.

________

________

________

51. Thermocouples shall be checked for type, polarity, double reversals, shielding, and proper point identification.

________

________

________

53. 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.

________

________

________

54. 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.

________

________

________

42. Complete manufacturer's check list. 13.43

14.52

Temperature Instruments

Control Valves

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

55. 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.

________

________

________

56. Control valve accessories, such as handwheels, booster relays, etc., shall be operationally checked.

________

________

________

57. All control valves shall be carefully checked by nameplate data and specifications and lubricated as required.

________

________

________

58. 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.

________

________

________

60. Check all safety valves for proper nameplate setting as per the valve and instrument specifications.

________

________

________

61. 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.

________

________

________

62. Where seals are found broken on relief valves, the relief valve is to be retested and resealed in accordance with plant safety practice.

________

________

________

63. Where block valves are permitted under the relief valve, they shall be full line size and locked in the open position.

________

________

________

64. Where rupture discs are used to isolate the safety valve from process fluid, their pressure rating is to be checked.

________

________

________

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

________

________

________

15.59

Safety and Relief Valves

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: WITNESSED: CONTR. PTT OTHER ________ ________ ________

66. Complete Form TR-7. 16.67

Regulators

68. Install self-contained pressure and temperature regulators as received.

________

________

________

69. Check inlet and nameplate data.

________

________

________

71. Check against specifications.

________

________

________

72. Verify correct installation.

________

________

________

74. Calibrate analyzers and sampling systems, using product samples where furnished.

________

________

________

75. Check recording, peak-picking, alarm interrupt circuitry. (Manufacturer to calibrate after installation.)

________

________

________

76. Package instrument systems shall be carefully checked and calibrated to vendor's specifications.

________

________

________

78. Check all instrument nameplates, both front and rear, and all panelboard nameplates for tag number, service, location, and proper spelling.

________

________

________

79. Install and check all charts and scales for range in accordance with specification.

________

________

________

80. Calibrate all principal front-of-panel, rearof-panel, and rack mounted instruments in accordance with manufacturer's instructions.

________

________

________

81. Panel instrument calibration test instruments shall be precision devices and shall be the standard for loop matching.

________

________

________

82. Check loop matching, such as zeroing transmitter to receiver.

________

________

________

83. Pressure test all signal air lines to ensure leak tightness.

________

________

________

84. Check all wiring for continuity.

________

________

________

17.70

18.73

19.77

outlet

ports

and

Instrument Piping and Tubing

Analytical Instruments and Specialties

Receiver Instruments and Control Panels

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR. 85. Perform megger tests for proper grounding and no shorts. Use Form TR-5 (typical).

WITNESSED: PTT OTHER

________

________

________

87. Check nameplates for engraving, spelling, and proper location.

________

________

________

88. 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-9.

________

________

________

________

________

________

________

________

________

20.86

Annunciators

21.89 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.

b.

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

__________

_________

________

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

___________

_________

________

__________

_________

________

__________

_________

________

__________

__________

_______

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.

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

5.3858 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 Owner 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 Owner. 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 Owner. 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 ? 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. b.

Are all specified nozzles and other connections installed at proper location? Are all valve connections for sampling or

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

__________

__________

_______

__________

__________

_______

Are all ladders and platforms installed? Are there any safety hazards such as piping, valves, conduits too close to ladder rails?

__________

________

________

If vessel requires pressure test separately connected piping, has this been done? Complete From TR-2 (typical).

__________

__________

________

__________

__________

________

___________

__________

_______

5.3858 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 Owner in advance when manufacturer's representatives or service engineers are to be present at the job site to implement the Mechanical Completion program. pressure installed and at correct locations? c. Are all thermowells installed? d. rungs and e. form 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) i.

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.

_________

__________

________

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

_________

___________

________

Is electrical grounding system complete?

_________

___________

________

_________

_________

________

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

_________

_________

________

n. Check adequacy of lighting. This should be done at night with cooperation of Owner.

_________

_________

________

_________

_________

________

j. insulation k.

o. Is painting complete?

Has

3.

required

before

start-up

is

Complete typical Form ME-2.

ITEM

PERFORMED: CONTR.

6.3959 FLUSHING AND CLEANING 40. All piping and vessels should be thoroughly cleaned of loose scale and internal debris that

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

WITNESSED: PTT OTHER

ITEM 5.3858 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 Owner in advance when manufacturer's representatives or service engineers are to be present at the job site to implement the Mechanical Completion program. 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?

PERFORMED: CONTR.

________

WITNESSED: PTT OTHER

________

41. 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 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

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

________

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

5.3858 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 Owner in advance when manufacturer's representatives or service engineers are to be present at the job site to implement the Mechanical Completion program. concerned. Verified?

________

________

________

42. 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?

________

________

________

43. 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?

________

________

________

44. Special instructions shall be issued outlining cleaning procedures for units or sections where moisture cannot be tolerated due to process considerations. Done?

________

________

________

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

7.45 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 Owner. 46. Safety and Fire Protection 60. Are all systems operable? All components tested "end-to-end," verified and working?

________

________

________

61. Ladders and platforms are installed for safe operation and access.

________

________

________

62. Any safety hazards? Identify and describe.

________

________

________

________

________

________

65. Verify that minimum strength has been achieved for all pours.

________

________

________

66. Has all concrete work been inspected for cracks? Make necessary repairs.

________

________

________

68. Verify all new road surfaces suffered no damage and all damages have been repaired. The repairs have been accepted?

________

________

________

69. Verify all new and/or relocated gates operate properly.

________

________

________

70. Verify all fencing materials suffered no damage and all damages have been repaired to Owner satisfaction.

________

________

________

71. Verify all new road culverts and headwalls suffered no damage and all damages have been repaired to PTT satisfaction.

________

________

________

72. Have security fences, gates, and guard houses been completed?

________

________

________

73. Has construction equipment such as cranes, welding machines, etc., no long being used, been removed from operation areas?

________

________

________

47.63

Concrete Placement and Testing

64. Were all concrete tests completed? laboratory and field reports on file?

C.67

D.74

Are

Roads, Fences and Gates

Soil Compaction

75. Has

test

been

conducted,

results

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

ITEM

PERFORMED: CONTR.

WITNESSED: PTT OTHER

documented and degree of compaction accepted?

________

________

________

76. If treatments to accelerate process were used, describe and verify acceptance.

________

________

________

78. Have required governmental approvals been obtained?

________

________

________

79. Do all underground drains flow freely? Have seals been established where required?

________

________

________

80. Are outfall lines, ditches, etc., ready for use?

________

________

________

82. Complete all work shown on drawings and verify all check lists are complete.

________

________

________

2. Have required identifying signs been installed?

________

________

________

E.77

F.81

Waste Disposal

Documentation

markers

and

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

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 Owner. FORM NO. Test and Record Forms: TR-1, p. 1

Piping Strength Test Pressure Report (Page 1/2)

TR-1, p. 2

Piping Strength Test Pressure Report (Page 2/2)

TR-2

Hydrostatic Test Record

TR-5

Megger Readings - Ground Resistance Record

TR-6

Electrical Test Record

TR-7

Safety and Relief Valve Record

TR-8, p. 1

Instrument Test Record (Page 1/2)

TR-8, p. 2

Instrument Test Record (Page 2/2) Mechanical Equipment Check List

ME-2

Vessels Electrical Equipment Check List

EE-5

Circuit Breakers

EE-8

Lighting Panels, Insulation Resistance, and Remote Terminal Display (RTD)

EE-9

Alarm Circuit Operation Test Instrument Check List

IE-1

Controllers

IE-2

Direct Connected Recorders and Recorder Controllers

IE-3

Electronic Controllers, Recorders & Indicators

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

FORM TR-1:

PIPING LEAK AND STRENGTH PROOF TEST REPORT (Page 1/2)

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM TR-1 DEPARTMENT CONDUCTING TEST

LEAK AND STRENGTH PROOF TEST REPORT (Page 1 of 2) REPORT DATE

REASON FOR TEST:  NEW CONSTRUCTION EXISTING FACILITY 1.

 STOCK PIPE

LOCATION:

 Compressor Station (Name.________________)

 Metering Station (Name.________________)

 Pipeline Milepost Station

 Gas Piping

 “A”  “B” to to

 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

Make

Range

Pressure Recorder Temperature Recorder Dead Weight Tester Others:

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

Serial No.

Date Last Calibrated

FORM TR-1:

PIPING LEAK AND STRENGTH PROOF TEST REPORT (Page 2/2)

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM TR-1

LEAK AND STRENGTH PROOF TEST REPORT Page 2 of 2

5. PROFILE DATA: ELEVATION

PRESSURING POINT

LOCATION OF DEAD WEIGHT TESTER

Survey Station Elevation 6. FIELD TEST PRESSURE DATA: Date of Test 1. Clock Time

2. Press. Point (psig)

Time Test Began 3. Min. Press. @ Max. Elev. (psig)

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

5. Amb. Temp. (ºC)

6. Test Mediu m Temp. (ºC)

Date & Time Test Ended

Weather:

1. Clock Time

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

2. Press. Point (psig)

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

5. Amb. Temp. (ºC)

6. Test Medium Temp. (ºC)

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 compressor station piping, 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: Signature of Representatives  OWNER/CONSULTANT  Contractor (Firm) ______________________  Subcontractor (Firm)____________________

By: _______________________________________ By: _______________________________________ By: _______________________________________

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

FORM TR-2:

HYDROSTATIC TEST RECORD

GAS PIPELINE AND GAS METERING HYDROSTATIC TEST RECORD AND REGULATING STATION PROJECT 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

Origin

Destination

TEST INSTRUMENTATION AND TEST RECORDS CALIBRATION READINGS THROUGH TEST PERIOD DATE

TEST INSTRUMENT DESCRIPTION AND RANGE

TIME 1

DESCRIBE:

PRESS. 2 3

FILL PUMP PRESSURE PUMP MAXIMUM PRESSURE DEADWEIGHT TESTER TEST HEADERS AND BLINDS

EQUIPMENT INCLUDED IN TEST TAG NO. DESCRIPTION REMARKS

NOTES:

Drawing No.

(1) (2)

1

TEMP. 2 3

1

ISO No.

REMARKS

LEAKS 2 3

GPM MAX GPM GPM AT MAX

EQUIPMENT EXCLUDED - SHOP TESTED TAG NO. DESCRIPTION REMARKS

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

SUMMITTED: SUBCONTRACTOR

DATE

ACCEPTED: CONTRACTOR

DATE

OWNER /CONSULTANT LOCATION DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

FORM TR-5:

MEGGER READINGS - GROUND RESISTANCE RECORD

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM TR-5 GROUND SYSTEM TEST LOCATION

SYSTEM NUMBER

RESIST. (OHMS)

AMB. TEMP. ºC

SUMMITTED

MEGGER READINGS GROUND RESISTANCE RECORD WEATHER

DATE

OWNER/CONSULTANT SUBCONTRACTOR LOCATION

DATE

DATE ACCEPTED DATE

CONTRACTOR

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

TESTER'S INITIALS

EQUIPMENT

FORM TR-6:

ELECTRICAL TEST RECORD

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM TR-6 SYSTEM METHOD OF TEST DESIGN VOLTAGE CIRCUIT NUMBERS

ITEM NO.

ELECTRICAL TEST RECORD

DATE OF TEST TEST VOLTAGE VOLTAGE

ORIGIN

DESTINATION

EQUIPMENT INCLUDED IN TEST DESCRIPTION ITEM NO.

SUMMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION DATE

ACCEPTED CONTRACTOR DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

RUN IN

DRAWING NO.

DESCRIPTION

FORM TR-7:

SAFETY AND RELIEF VALVE RECORD

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM TR-7

SAFETY & RELIEF VALVE RECORD

SAFETY VALVES ITEM NUMBER

EQUIPMENT

SIZE

PRESSURE

SETTING TESTED

RELIEF VALVES

SYSTEM TEST

REMARKS:

SUMMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION DATE

ACCEPTED CONTRACTOR DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

DATE TESTED

INSTALLED OK

FORM TR-8:

INSTRUMENT TEST RECORD (Page 1/2)

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM TR-8

INSTRUMENT BANK TEST AND CALIBRATION RECORD Sheet 1 of 2

TYPICAL FORM: TITLE FROM INSTRUMENT INPUT/OUTPUT LIST TAG NO.

NAME

(T) (1)

(C) (2)

INSTALLED LOCATION OK? (3)

VERIFY (4)

M

I

E

W

REMARKS AND OTHER R

S

NOTES: (1) Show date of bank test completed and accepted. Describe below test method used. (2) Verify calibration of instrument and describe procedure followed. Include separately approved calibration certificate. (3) Indicate compliance with drawings. (4) 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

SUMMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION DATE

ACCEPTED CONTRACTOR DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

FORM TR-8:

INSTRUMENT TEST RECORD (Page 2/2)

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM TR-8

INSTRUMENT BANK TEST AND CALIBRATION RECORD Sheet 2 of 2

TYPICAL FORM: TITLE FROM INSTRUMENT INPUT/OUTPUT LIST TAG NO.

NAME

(T) (1)

(C) (2)

INSTALLED LOCATION OK? (3)

VERIFY (4)

M

I

E

W

REMARKS AND OTHER R

S

NOTES: (1) Show date of bank test completed and accepted. Describe below test method used. (2) Verify calibration of instrument and describe procedure followed. Include separately approved calibration certificate. (3) Indicate compliance with drawings. (4) 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 pre-commissioning S = remote receipt of data

SUMMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION DATE

ACCEPTED CONTRACTOR DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

FORM ME-2:

VESSELS

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM ME-2

FIELD INSTALLATION CHECK LIST

VESSELS EQUIPMENT NO. FABRICATOR TYPE MATERIAL THICKNESS

SERVICE P.O. NUMBER CODE DATE RECEIVED

ITEM TO CHECK CONDITION WHEN RECEIVED?

REMARKS/OK

ERECTION ALIGNMENT, ELEVATION & PLUMB GROUNDING STRAP INSTALLED? INTERNALS INSULATION & FIREPROOFING GROUTED CLEANED TESTED LADDERS, PLATFORMS, DAVITS CLOSED REMARKS:

SUMMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION DATE

ACCEPTED CONTRACTOR DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

DATE TESTED

FORM EE-5:

CIRCUIT BREAKERS

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM EE-5

FIELD INSTALLATION CHECK LIST

CIRCUIT BREAKERS EQUIPMENT NO. MANUFACTURER

SERVICE INSTALLED BY

ITEM TO CHECK CONTACT PARTS CLEAN?

REMARKS/OK

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

REMARKS:

SUBMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION DATE

ACCEPTED CONTRACTOR DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

DATE TESTED

FORM EE-8:

LIGHTING PANELS, INSULATION RESISTANCE, REMOTE TERMINAL DISPLAY (RTD)

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM EE-8 TYPICAL FORM FOR:

CIRCUIT NUMBER

WIRE NUMBE R

ELECTRICAL TEST RECORD

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

FROM

TO

MEGGER READING (MEG OHM) @ 1

2

DATE

AMB. TEMP. ºC

WEATHER

3

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

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION DATE

ACCEPTED CONTRACTOR DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

FORM EE-9:

ALARM CIRCUIT OPERATION TEST

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM EE-9

FIELD INSTALLATION CHECK LIST

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.

SUBMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION DATE

ACCEPTED CONTRACTOR DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

FORM IE-1:

CONTROLLERS

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM IE-1

INSTRUMENT CHECK LIST

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. REMARKS:

SUBMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION

ACCEPTED

DATE CONTRACTOR

DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

DATE CHECKED

FORM IE-2:

DIRECT CONNECTED RECORDERS AND RECORDER CONTROLLERS

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM IE-2

INSTRUMENT CHECK LIST

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. REMARKS:

SUBMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION

ACCEPTED

DATE CONTRACTOR

DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

DATE CHECKED

FORM IE-3:

ELECTRONIC CONTROLLERS, RECORDERS AND INDICATORS

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT FORM IE-3

INSTRUMENT CHECK LIST

ELECTRONIC CONTROLLERS, RECORDERS AND INDICATORS INSTRUMENT NO.

SERVICE

MANUFACTURER

SERIAL NO.

ITEM TO CHECK 1. Check continuity of wiring, location and value of dropping resistors, and verify service manual feature (if provided) is disengaged. 2. Turn on power supply and check voltage level and polarity. 3. Check and adjust input span and zero. 4. Set output signal limits. (High = 100%; Low = 0%) 5. Place controller in Automatic Mode and check alignment. 6. Transfer controller to the Manual Mode and check both up and down scale ramp rates. 7. Verify output signal action is correct for receiver. "Output is to _______________ with input signal increase." 8. Check correct chart and scale ranges. 9. Install recorder ink capsules 10. Affix calibration sticker. REMARKS:

SUBMITTED

OWNER /CONSULTANT SUBCONTRACTOR

DATE

LOCATION

ACCEPTED

DATE CONTRACTOR

DATE

PR-P-1102.21-4012-004 Rev.0 (MECHANICAL COMPLETION PROCEDURE)

DATE CHECKED