PTT Public Company Limited Ratchaburi World Cogeneration Company Limited

PTT PUBLIC COMPANY LIMITED
RATCHABURI WORLD
COGENERATION COMPANY LIMITED
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
02/04/13
Issued for Construction
WS
JR
NP
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:
DOCUMENT CHANGE RECORD
Rev
Date
Prepared/
Revised
By
Reviewed
By
Approved
By
Description
13/02/13
WS
JR
NP
Issued for Approval
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
NOTICE OF COMPLETION
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
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, Owners 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
Contractors staff, Owner and Owners 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 Owners 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 Contractors requirements for training, the scheduling for vendor
representatives shall also include ample time to provide specialized training to Owner on the
vendors equipment. The vendors 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 Owners 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
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
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
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
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
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
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.
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?
________
________
________
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.
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.
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
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
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
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
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
applicable
Specifications,
Vendor
supplied
instructions, instructions provided in this section and
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
________
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 accuracys.
________
________
________
11. Each control valve shall be checked by

local pressure reduction to comply with
and meet manufacturer's guaranteed
accuracys.
________
________
________
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
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
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.
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
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
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
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
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.
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.
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
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
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 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
WITNESSED:
PTT
OTHER
ITEM
5.3858 EQUIPMENT
Contractor
shall
prepare
a
comprehensive
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
________
ITEM
PERFORMED:
CONTR.
WITNESSED:
PTT
OTHER
5.3858 EQUIPMENT
Contractor
shall
prepare
a
comprehensive
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?
________
________
________
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.
applicable
Specifications,
Vendor
supplied
instructions, instructions provided in this section and
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
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
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
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:
Serial No.
Date Last
Calibrated
FORM TR-1:
PIPING LEAK AND STRENGTH PROOF TEST REPORT (Page 2/2)

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.
(C)
6.
Test
Mediu
m
Temp.
(C)
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.
(C)
6.
Test
Medium
Temp.
(C)
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: _______________________________________
FORM TR-2:
HYDROSTATIC TEST RECORD

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
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)
TEMP.
2
3
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
FORM TR-5:
MEGGER READINGS - GROUND RESISTANCE RECORD

FORM TR-5
GROUND
SYSTEM
TEST
LOCATION
SYSTEM
NUMBER
RESIST.
(OHMS)
AMB.
TEMP.
C
SUMMITTED
MEGGER READINGS GROUND RESISTANCE RECORD

WEATHER
DATE
OWNER/CONSULTANT
SUBCONTRACTOR
LOCATION
DATE
DATE
ACCEPTED
DATE
CONTRACTOR
TESTER'S
INITIALS
EQUIPMENT
FORM TR-6:
ELECTRICAL TEST RECORD

FORM TR-6
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.
SUMMITTED
OWNER /CONSULTANT
SUBCONTRACTOR
DATE
LOCATION
DATE
ACCEPTED
CONTRACTOR
DATE
RUN IN
DRAWING NO.
DESCRIPTION
FORM TR-7:
SAFETY AND RELIEF VALVE RECORD

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
DATE
TESTED
INSTALLED
OK
FORM TR-8:
INSTRUMENT TEST RECORD (Page 1/2)

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)
REMARKS
AND
OTHER
R
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
FORM TR-8:
INSTRUMENT TEST RECORD (Page 2/2)

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)
REMARKS
AND
OTHER
R
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
FORM ME-2:
VESSELS

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
DATE TESTED
FORM EE-5:
CIRCUIT BREAKERS

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
DATE TESTED
FORM EE-8:
LIGHTING PANELS, INSULATION RESISTANCE, REMOTE TERMINAL DISPLAY (RTD)

FORM EE-8
TYPICAL FORM FOR:
CIRCUIT
NUMBER
WIRE
NUMBE
R
LIGHTING PANELS
INSULATION RESISTANCE
REMOTE TERMINAL DISPLAY (RTD)
WIRE
SIZE
FROM
TO
MEGGER READING
(MEG OHM) @
1
DATE
AMB.
TEMP.
C
WEATHER
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
FORM EE-9:
ALARM CIRCUIT OPERATION TEST

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
FORM IE-1:
CONTROLLERS

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
DATE CHECKED
FORM IE-2:
DIRECT CONNECTED RECORDERS AND RECORDER CONTROLLERS

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.
REMARKS:
SUBMITTED
OWNER /CONSULTANT
SUBCONTRACTOR
DATE
LOCATION
ACCEPTED
DATE
CONTRACTOR
DATE
DATE CHECKED
FORM IE-3:
ELECTRONIC CONTROLLERS, RECORDERS AND INDICATORS

FORM IE-3
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
DATE CHECKED

PTT Public Company Limited Ratchaburi World Cogeneration Company Limited

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PTT PUBLIC COMPANY LIMITED

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT

Issued for Construction

Issued for Approval

SIAM RAJATHANEE JOINT VENTURE

UNITY ENGINEERING AND CONSULTANCY

MECHANICAL COMPLETION PROCEDURE

DOCUMENT CHANGE RECORD

Issued for Approval

Issued for Construction

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

MECHANICAL COMPLETION CHECKLIST OUTLINE

MECHANICAL COMPLETION CHECK LIST

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

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

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

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

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

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

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

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

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

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

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

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

Ratchaburi World Cogeneration Company Limited.