Gems g-2p1 Procedures For The Completion of Work

DEC 97 PROCEDURES FOR THE COMPLETION OF WORK GEMS G-2P1
TABLE OF CONTENTS
PAGE
1. SCOPE .............................................................. 2
2. REFERENCES ......................................................... 2
2.1 Company Specifications ....................................... 2
2.2 Company Drawings ............................................. 2
2.3 Codes and Standards .......................................... 2
3. GENERAL ............................................................ 3
4. PHASE I ............................................................ 3
4.1 General ...................................................... 3
4.2 Buildings .................................................... 5
4.3 Exchangers and Coolers ....................................... 5
4.4 Vessels and Trays ............................................ 6
4.5 Heaters and Boilers .......................................... 8
4.6 Insulation and Painting ...................................... 9
4.7 Piping ....................................................... 9
4.8 Instruments .................................................. 12
4.9 Electrical ................................................... 15
4.10 Safety and Fire Facilities ................................... 16
4.11 Pumps and Fans ............................................... 17
4.12 Mechanical Drive Single Stage General Purpose Turbines ....... 18
4.13 Compressors and Multi-Stage Steam Turbines ................... 19
4.14 Lube Oil System for Special Purpose Rotating Equipment ....... 24
4.15 Packaged Equipment and Units ................................. 30
4.16 Flares and Incinerators ...................................... 30
4.17 Cooling Towers ............................................... 30
4.18 Tanks ........................................................ 31
4.19 Clean-up ..................................................... 32
4.20 Lubrication .................................................. 33
4.21 Completion of Phase I ........................................ 33
5. PHASE II ........................................................... 34
6. PHASE III .......................................................... 34

6.1 Acceptance Test .............................................. 34
6.2 Completion of Phase III ...................................... 37
PAGE 1 OF 37
©TEXACO GENERAL ENGINEERING DEPARTMENT
1. SCOPE
This specification defines minimum technical requirements for the start-

up, completion, and acceptance phases of construction projects.
2. REFERENCES
2.1 Company Specifications
This specification contains references to the following Company

specifications:
1. GEMS I-2M, “Thermal Insulation”.

2. GEMS J-1P, “Field Pressure Testing of Piping, Sewers, Fired Heater
Tube Assemblies, and Exchangers”.
3. GEMS K-20D, “Instrument Storage, Checkout, and Calibration”.
4. GEMS L-1P, “Installation of Electrical Systems”.
5. GEMS M-4D, “Design of Water Spray and Deluge Systems for Fire
Protection”.
6. GEMS U-1M, “Induced Draft Cooling Towers”.
2.2 Company Drawings
This specification contains references to the following Company
drawings:
None.
2.3 Codes and Standards

This specification contains references to the following codes and
standards:
2.3.1 American Society for Testing and Materials (ASTM)

1. D 877, “Test Method for Dielectric Breakdown Voltage of
Insulating Liquids Using Disk Electrodes”.
2. D 923, “Test Method for Sampling Electrical Insulating
Liquids”.
3. D 971, “Test Method for Interfacial Tension of Oil Against
Water by the Ring Method”.
4. D 974, “Test Method for Neutralization Number by Color-
Indicator Titration”.
5. D 1500, “Test Method for ASTM Color of Petroleum Products
(ASTM Color Scale)”.
6. D 1816, “Test Method for Dielectric Breakdown Voltage of
Insulating Oils of Petroleum Origin Using VDE Electrodes”.
7. D 2285, “Test Method for Interfacial Tension of Electrical
Insulating Oils of Petroleum Origin Against Water by the
Drop-Weight Method”.
2.3.2 American Society of Mechanical Engineers (ASME)
Boiler and Pressure Vessel Code, Section I, “Power Boilers”.
PAGE 2 OF 37
2.3.3 National Fire Protection Association (NFPA)

15, “Standard for Water Spray Fixed Systems for Fire
Protection”.
2.3.4 Occupational Safety and Health Administration (OSHA)

1. 1910.36C, “Protection of Employees Exposed by Construction
and Repair Operations”.
2. 1910.119, “Pre-Startup Safety Review”.
3. GENERAL
1. Constructor shall be responsible for complete construction of the

project. This includes procurement, installation, and completion of
all items within Constructor's Scope of Work. This also includes
all activities of subcontractors under Constructor's jurisdiction.
2. Constructor shall turn the completed project over to Company in an
orderly manner.
3. The completed project shall be clean, safe, and operable.
4. Each site (single and multiple site projects) will normally be
completed in the following three phases:
a. Phase I-Complete to the extent that operations can be started
safely.
b. Phase II-All portions of the site complete to the extent that
Constructor's equipment and temporary facilities can be removed.
c. Phase III-Complete acceptance. All tests complete and
corrections made to meet licenser’s process/operating
conditions.
5. Company shall reserve the right to use portions of completed
facilities, provided this does not interfere with Constructor or
prevent efficient completion of the project. To accomplish this,
Company may defer portions of work from Phase I to Phase II.
6. Plant's safety review/approval procedures shall be applied to
completion of the work.
7. A “Notice of Completion” shall be prepared by Constructor for each
phase of construction. Notice shall be signed by appropriate
Constructor and Company representatives.
8. When required, Constructor shall prepare test procedures which
shall be signed off by Company representative before testing is
performed.
9. A “Notice of Acceptance” shall be prepared by Constructor for each
required test. Notice shall be signed by appropriate Constructor
and Company representatives.
4. PHASE I
4.1 General
4.1.1 Exclusions and Omissions
1. Portions of the completion and operations sections of this
specification may refer to facilities or equipment that
are excluded from the scope of the contract. If notified
by Company, Constructor shall be relieved of
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responsibility for performing work associated with such

items.
2. Portions of the completion and operations sections of this
specification may omit requirements for facilities or
equipment that are included within the scope of the
contract. If notified by Company, Constructor shall
develop procedures for Company approval and perform all
work associated with completing and preparing such items
for sustained operation.
4.1.2 By Constructor
Constructor shall prepare unit for initial operation in
accordance with the following procedures:
1. Provide, install, and conduct tests where required in the

presence of a designated Company representative.
2. Clean up and inspect all required facilities to provide a
complete operating unit in accordance with all project
requirements.
3. Prepare a group listing of all equipment and lines to be
included in a system test and/or individual line test.
4. Advise Company's construction manager well in advance of
any field tests to be witnessed or inspected by a Company
representative.
5. Follow manufacturer's and Company's requirements in
installing, aligning, and checking out equipment. Obtain
their approvals that equipment is satisfactorily
installed, particularly on large equipment.
6. Provide to Company's construction manager a timely
schedule of the planned arrival and departure from the
jobsite of equipment supplier's servicemen.
7. Obtain approval from Company's construction manager prior
to releasing supplier's servicemen from the job.
8. Review with Company the requirements set forth by
engineering contractor, licenser, or supplier for handling
and loading catalyst, inert fills, chemicals, inert gas,
and start-up gas.
9. Unless instructed otherwise by Company, Contractor shall
provide flushing oils, degreasing chemicals, lubrication
oils and greases, oil filtering media, etc., in accordance
with equipment manufacturer's requirements. Contractor
shall dispose of these materials in accordance with
methods approved by Company.
10. Provide as built drawings and documentation required for
safe operation, maintenance, and mechanical integrity,
such as, but not limited to, all underground
installations, process, instrument, and electrical
drawings.
4.1.3 By Company
Preparation of the unit for initial operation shall include,
but not be limited to, the following work by Company.
1. Audit Constructor's performance with regard to inspecting

materials, equipment, and field work. Any material,
PAGE 4 OF 37
equipment, or work which does not comply with project

requirements shall be rejected. Such field inspection
audits by Company do not relieve Constructor of the
responsibility for faulty workmanship, material, or
equipment or compliance with all project requirements in
accordance with the contract.
2. Witness and approve individual field tests as they are
successfully completed. Sign off on test reports.
3. Unless otherwise specified, provide feed stocks, catalyst,
chemicals, gas, and inert fills as required for operation
of unit.
4. Arrange for installation of catalyst and inert fills. Care
shall be taken to ensure that breakage of these materials
does not occur and that minimum sizes are maintained.
4.2 Buildings
Completion of Phase I for buildings shall comply with the following:
The responsibility of Constructor is to complete all work shown
on drawings, provide signs and labels as specified, and install
all equipment, including installation and applicable testing,
as follows:
1. Test mechanical facilities.

2. Test fire safety systems.
3. Test ventilating, heating, and utility systems.
4. Clean building thoroughly, wash windows, polish floors,
etc., prior to occupancy by Company.
5. Arrange and participate in inspections by governmental
agencies as required by local regulations and codes.
4.2.2 By Company
1. Provide and install furniture, unless included in
Constructor's Scope of Work.
2. Assume building and equipment maintenance upon completion
and written acceptance.
4.3 Exchangers and Coolers
Completion of Phase I for exchangers and coolers shall comply with the
following:
1. Constructor shall prepare shell and tube exchangers and
spiral exchangers as follows:
a. Field test exchangers as required by project
specifications.
b. Check for proper thread lubricant use.
2. Constructor shall prepare air cooled heat exchangers as
follows:
a. Field test exchangers as required by project
specifications.
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b. Check fins for damage and repair if required. Clean

debris from fins.
c. Check airfan motors. Rectify any problems found.
d. Check and set airfan blade pitch in accordance with
allowable horsepower of drives and manufacturer's
recommendations.
e. Check automatic controls, variable pitch fans, and
variable speed drives. Rectify any problems found.
f. Check fan rotation. Rectify any problems found.
g. Run fans, lubricate as required, and check vibration
and balance. Rectify any problems found.
h. Provide Company with airfan motor ampere readings.
i. Install, fill, and test automatic lubrication systems.
4.3.2 By Company
Completion of Phase I for exchangers and coolers requires
Company to:
1. Witness and approve all required tests.

2. Sign off on test reports.
4.4 Vessels and Trays
Phase I preparation of vessels and trays requires the following
procedures by Constructor:
1. Field Installed Vessel Internals

a. Install all required vessel internals, including, but
not limited to, trays, baffles, supports, linings, and
other materials.
b. Perform tray leakage, alignment (horizontal and
vertical), and other tests necessary to confirm proper
installation of vessel internals.
(1) Tray leakage shall be kept to the minimum
consistent with the tray specifications.
(2) Constructor's outline of proposed tray leakage
testing for each vessel shall be submitted to
Company for approval.
c. Clean all vessels internally of all foreign material to
Company's satisfaction. Vessels that are
hydrostatically field tested shall be drained at
Company approved rates following testing to facilitate
cleaning.
2. Shop Installed Vessel Internals
a. Blind and open up vessels for internal inspection by
Constructor and Company representatives prior to
hydrotest to ensure cleanliness and conformance with
project requirements. Provide adequate ventilation for
entry.
b. Internal inspection of vessels and towers requires
unheading all tray manways, or sections, for complete
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internal inspection, unless specifically waived by

Company. Scaffolding and ladders shall be provided as
required by Company.
c. Inspection shall also be made to ensure proper
installation of thermowells, trays, downcomers, and
gaskets specified on the tray supplier's drawings and
internal flow distributors at top, feed, and bottom
trays.
3. Conduct field pressure tests where required using test
gaskets.
a. Hydrostatic tests shall not be required on shop tested
vessels, unless:
(1) An alteration has been made.
(2) Vessels have sustained damage that may affect
vessel strength.
b. Vessels may be subject to hydrostatic tests as parts of
piping systems.
4. Dry out all vessel linings in strict accordance with
specifications and manufacturer's requirements prior to
loading catalyst or other moisture sensitive materials.
5. Set up piping and vessels for chemical cleaning and
passivations when required.
6. Load catalyst, unless relieved of responsibility by
Company.
7. Head-up vessels after Company inspection and written
authorization.
a. Constructor shall install new service gaskets. Test
gaskets may be used as service gaskets, if they meet
specifications, with prior approval.
b. Inspections should be combined to minimize the number
of unheadings required.
4.4.2 By Company
Completion of Phase I for vessels and trays requires the
following procedures by Company.
1. Visually inspect trays and internals in the area of the

vessel manholes, and advise of any tray manways not
required to be removed for further inspection.
2. Verify that vent gaps have been provided in welds that
attach internals to vessel wall in hydrogen service.
3. Witness tray leakage and other internal tests.
4. Witness field hydrostatic tests.
5. Inspect vessels after final cleaning by Constructor.
6. Monitor and approve catalyst loading procedures.
7. Sign authorization to head-up each vessel.
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4.5 Heaters and Boilers

Completion of Phase I for heaters and boilers requires the
following procedures by Constructor.
1. Clean heaters and boilers of all construction debris,

blocking, and bracing.
2. Submit pre-operational tube cleaning, dry-out, and boil-
out procedures for Company approval.
3. Arrange for pre-operational tube cleaning as required and
in accordance with Company approved procedure.
4. Perform a hydrostatic test on completed steam generators
and heater tubes utilizing Company approved testing
medium.
Note: Test austenitic stainless steel with a 1-1/2% to 3%
solution of low chloride soda ash and the lowest chloride
water available. If water is available with chloride
content of less than 50 ppm, soda ash is not required.
5. Perform the following for initial operation:

a. Connect burner piping after all fuel lines have been
flushed and checked for cleanliness.
b. Check operations of registers and dampers.
c. Check burners for alignment and height setting in
presence of Company inspector.
6. Install stacks and appurtenances (ladders, platforms,
etc.) in accordance with manufacturer's procedures and
drawings.
7. Install flue gas ducts and expansion joints, connecting
the boiler to the economizer and the stack to the fans in
accordance with the manufacturer's procedures and
drawings. Insulate and seal all flue gas ducts.
8. Arrange for state inspection or registration if required
by state boiler code. Arrange for boiler inspection by
local and insurance officials as required.
4.5.2 By Company
Completion of Phase I for heaters and boilers by Company shall
comply with the following procedures.
1. Witness hydrostatic tests and sign test reports.

2. Check and approve installation of all control systems and
mechanical equipment.
3. Approve Constructor's pre-operational tube cleaning,
dry-out, and boil-out procedures.
4. Perform initial firing, dry-out, and boil-out as part of
initial operation.
PAGE 8 OF 37
4.6 Insulation and Painting

Completion of Phase I for insulation and painting shall comply
with the following procedures by Constructor:
1. Complete painting and insulation except that which will be

completed during Phase II, as determined by the Company.
This includes stenciling of equipment names and numbers,
cut outs of insulation for inspection monitoring points,
and installation of safety instruction signs or markers.
2. Test fit removable insulation covers. As required by
Company, store covers for installation after start-up.
3. Work in certain critical or hazardous areas shall be
completed during Phase I. Constructor shall review these
areas with Company representative.
4. Remove scaffold prior to start up, except as stated under
“clean up” section of this specification.
5. Protect all gage glasses, transmitters and other
instruments, control valve stems, equipment nameplates,
etc., prior to painting.
6. Clean all sight glasses, pressure gages, etc., after
painting.
4.6.2 By Company
Completion of Phase I for insulation and painting by Company
shall comply with the following procedures:
1. Approve painting and insulation work that Constructor may

defer to Phase II.
2. Sign inspection and completion reports.
4.7 Piping
The following procedures shall be completed by Constructor for
completion of Phase I piping.
1. Check all flanged connections to ensure:

a. Proper gasket installed.
b. Bolts have been properly torqued.
c. Bolts extend at least one thread past their nuts.
2. Check valve stems.
a. Stems shall be oriented as indicated on piping
drawings.
b. Stems and threads shall be lubricated.
3. Check that split disc wafer type check valves are
installed with shaft in vertical position.
4. Unless otherwise specified, check that globe valves are
installed with bottom of disc facing the flow direction.
5. Perform required pressure tests in accordance with GEMS J-
1P. Test with joints exposed to permit examination of
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welds and flanged connections by Company representative.

If piping changes are made, the revised sections shall be
retested. Instrumentation shall be protected in accordance
with Section 4.8.
6. Clean all lines for operations as required.
a. Lines shall normally be flushed with water.
b. Lines shall be flushed until flushing medium appears
clean at the discharge point as verified by Company
inspector.
c. Flushing shall be performed without unit pumps, unless
Company specifically approves them for this use.
d. Provide all labor for dropping control valves and other
mechanical work in connection with cleaning lines.
e. Control valves and other “wetted” instruments will be
handled as described in “Instruments” section of this
specification.
7. Clean steam lines prior to running-in steam turbines.
a. Valves shall be operated by Company representatives.
b. Steam out lines until targets at outlets indicate all
debris, rust, scale, etc., have been removed from the
system. Targets shall be constructed of aluminum plate
with 1/8 inch minimum thickness and cover a minimum of
20% of flow area.
c. Targets shall be inspected by Company's machinery
inspector.
d. Disconnect turbines, control valves, orifices,
strainers, and similar items prior to cleaning steam
lines.
e. Re-connect such items after approval of Company's
construction manager.
8. After hydrostatic tests and line cleaning are complete,
install plugs and caps at all vent and drain connections.
9. Install all operating blinds as required on drawings and
specifications, including those on drains and vents.
Review these locations with Company representative prior
to installation.
10. Provide a flow-diagram and checklist to Company indicating
where operating blinds are installed and where test blinds
were installed.
11. Provide and install all strainers, both temporary and
permanent, required on drawings and by project specs.
Unless otherwise specified, remove and reinstall strainers
as required during line cleaning.
12. Repack valves, if required, to ensure that all valves do
not leak.
13. Clean and test all sewer systems.
14. Stamp and provide reports as required for ASME, Section I,
or appropriate ANSI Code.
PAGE 10 OF 37
15. Maintain stress relief, pressure test, and NDE records,

and submit them to the Company in an organized and orderly
manner.
16. Perform any special tests and special chemical cleaning or
pickling required by specifications or by equipment
manufacturers. Submit special procedures for approval.
17. Check all piping during initial operation for proper
support and secure lines that are found to be vibrating.
a. Particular attention should be given to steam and other
hot lines.
b. Guides and slides shall move freely.
c. Pipe shoes shall be properly located as indicated on
the drawings and shall be long enough to adequately
support lines while expanding or contracting.
d. All instances of vibrating, unsupported pipe shoes
(including expansion requirements) shall be brought to
Company for resolution.
18. Check all branch piping connections 1-1/2 inches and
smaller for proper weld construction, wall thickness, and
correct metallurgy. Constructor may elect to inspect all
nipples for wall thickness and metallurgy in the warehouse
and permanently stamp them to reduce onsite inspection.
19. Check spring hangers and expansion bellows to verify that
temporary blocks or inserts are removed and supports are
properly adjusted.
20. Test austenitic stainless steel piping and equipment with
a 1-1/2% to 3% solution of low chloride soda ash and the
lowest chloride water available. If water is available
with chloride content of less than 50 ppm, soda ash is not
required.
21. Check that all check valves are installed properly as to
flow direction and location (horizontal or vertical).
22. Coordinate with plant inspection and test department,
through Company's construction manager, the hydrotesting
of new piping systems that tie into existing systems.
a. The exact location for division of testing
responsibilities shall be determined on a line by line
basis after completion of piping design work.
b. Prepare procedures and test P&IDs as required.
4.7.2 By Company
The following procedures shall be completed by Company for
completion of Phase I piping.
1. Witness all field pressure tests and sign test reports.

2. Company's construction manager shall arrange for delivery
of steam from the plant's steam main as soon as practical
after notification by Constructor that steam systems are
ready.
3. Company's construction manager shall designate
responsibility for operation of plant's steam main block
valve during cleaning procedure.
PAGE 11 OF 37
4.8 Instruments
Phase I for instruments shall be completed as follows by
Constructor.
1. Instrument storage, handling, and tagging:

a. Reference GEMS K-20D for instrument storage, check-out,
and calibration requirements.
b. Attach instrument tags with stainless steel wire.
2. Installation of wetted instruments:
Constructor shall provide personnel to perform the
following:
a. Instruct installers in proper installation of each type

of instrument such that piping arrangement is simple
and direct.
b. Verify that installers have installation details for
each instrument, advise installers of the location and
position of instruments, and verify that instrument
connections and flow directions in lines are labeled.
c. Check each installation to verify that the instrument,
as installed, will accomplish its stated purpose.
(1) Verify that all Company requirements as to
accessibility, arrangement, materials of
installation, range, and size are satisfied.
(2) Any discrepancies found in checking shall be
corrected.
3. Test and Checks
After completion of installation, perform the tests
specified in GEMS K-20D, along with the following tests:
a. Flow Measurement
(1) Check all piping between process line and meter
for cleanliness and tightness.
(2) Install orifice plates and pitot tubes after
lines are clean.
(a) Sharp edge (lettering on tab) shall face
upstream.
(b) Gaskets shall not protrude into the line.
(c) Bore shall be concentric to I.D. of pipe.
(d) Where segmental or eccentric orifice plates
are used, check that the orifice hole is
properly located at the bottom of the line.
(3) Close all orifice shutoff valves and disconnect
meters for hydrostatic tests. Upon completion of
piping hydrostatic test and blowing through root
valves, re-connect meter leads.
(4) Check slip on orifice flange taps for proper
drilling into process lines.
PAGE 12 OF 37
(5) Remove vortex meters and mass flow elements

prior to flushing.
(a) Unless otherwise specified, reinstall after
flushing is complete.
(b) Remove baskets from strainers preceding
meters during flushing.
b. Pressure Measurement
Before hydrostatic testing, close block valves and
disconnect meter piping. Upon completion of piping
hydrostatic test and blowing through root valves,
re-connect meter leads, and test meter piping.
c. Level Measurement
(1) During tightness test of vessel, block valves
shall be checked for tightness by closing block
valves and opening bleeder valves.
(2) Block in all level displacers and level D/P
transmitters before hydrostatic testing of
vessels and piping.
(3) Do not apply hydrostatic test pressure to level
displacers or D/P transmitters.
d. Control Valves
(1) Remove control valves when flushing lines.
(2) All valves, regardless of size, with multiple
series ports, labyrinths, or mesh within fluid
flow path, shall be removed from line during
flushing.
e. Analyzers
Before hydrostatic testing, close block valves and
disconnect meter piping. Upon completion of piping
hydrostatic test, reconnect meter leads, and test meter
piping.
f. Junction Boxes (Instrument Thermocouple and
Electrical)
(1) Check that each entry is properly sealed and
weatherproofed.
(2) Check that each wire is properly identified,
connected to proper terminal, and tightly tie-
wrapped.
(3) Spare wires shall be identified and ends shall
be properly coiled and taped.
(4) There shall be no moisture collection.
(5) Confirm proper operation of junction box purges,
if provided.
g. Power Supply Tests
(1) Test 120 V A-C power supply, 24 V A-C chart
drive power supply, and 24 V D-C power to
control panels and to each control loop.
Voltmeter shall have at least 1000 ohms per volt
sensitivity.
PAGE 13 OF 37
(2) Test power supply to each section of the control

board. Voltmeter shall have at least 20,000 ohms
per volt sensitivity.
h. Instrument Nitrogen Supply
(1) If nitrogen is used as an emergency source to
supply pneumatic type instruments, the system
shall be tested in similar manner to instrument
air supply as described in GEMS K-20D.
(2) Check supply pressure to high pressure selector
relays to ensure proper action.
i. Safety Valves
(1) Within 60 days prior to completion of Phase I,
remove safety valves from unit and arrange for
testing of safety valves by a Company approved
vendor. Constructor shall coordinate these
activities with Company's construction manager.
(2) Pick up safety valves after testing. Valves
shall have blanks placed on inlet and outlet to
prevent damage to flange faces and entry of
debris during transport to site. Return valves
to unit and reinstall.
(3) Check all flanged connections after blind
removal to confirm that proper gaskets have been
installed.
j. Pressure test instrument impulse lines and connections
in accordance with GEMS J-1P.
4.8.2 By Company
Phase I for instruments shall be completed by Company as
follows:
1. Witness all above tests and those performed in accordance

with GEMS K-20D and sign test reports.
2. Calculate and verify the correct meter coefficients.
3. Caliper each orifice plate and record the measurements.
4. Observe the work of constructor/subcontractor to obtain
information needed for maintenance of plant instrument
system.
5. Witness orifice plate installation after water flushing
and/or air blowing. Torque flange bolts, if required.
6. Verify that Constructor/subcontractor has satisfactorily
completed all pneumatic and electronic loops as required
above.
7. Perform the following activities jointly with Constructor:
a. Wiring reports.
b. Testing and calibration.
c. Loop check.
PAGE 14 OF 37
4.9 Electrical
Completion of Phase I electrical requirements by Constructor
shall comply with the following:
1. General
a. Test the unit's electrical equipment in accordance
with GEMS L-1P.
b. Test procedures and documentation forms shall be
approved by Company prior to Constructor performing
the tests.
c. Perform all tests, mechanical adjustments, and checks
in accordance with manufacturer's recommendations and
other local requirements. Adjustments and checks shall
be performed in the presence of the manufacturer's
representative when deemed necessary by Constructor or
Company.
d. Conduit seals shall be inspected to ensure that they
have been properly installed in accordance with GEMS
L-1P.
e. Prepare, submit, and obtain Company approval of
electrical lock-out and safety procedures prior to
energizing onsite facilities.
f. Energize unit electrical facilities from point of
utilization as defined by Company construction
manager.
2. Checks and Tests
In addition to the requirements specified in GEMS L-1P,
the following specific checks and tests shall be performed
by Constructor.
a. Transformers
(1) Sample insulating fluid in accordance with ASTM
D 923. Sample shall be laboratory tested for:
(a) Dielectric breakdown voltage (ASTM D 877 or
D 1816).
(b) Acid neutralization number (ASTM D 974).
(c) Interfacial tension (ASTM D 971 or D 2285).
(d) Color (ASTM D 1500).
(2) Perform insulation resistance tests, winding-to-
winding and winding-to-ground, utilizing a
meghometer with suitable test voltage. Test
duration shall be for 10 minutes, with
resistances tabulated at 30 seconds, 1 minute,
and 10 minutes. Calculate and record the
dielectric absorption ratio and the polarization
index.
b. Switchgear and Motor Starters
(1) Check all connections for tightness.
PAGE 15 OF 37
(2) Take resistance measurements from each bus to

ground and between busses with all circuit
breakers open and with main feeders
disconnected.
(3) Measure insulation resistance of main
connections and auxiliary wiring. Perform AC
overpotential test on main connections.
c. Wiring
(1) Where DC high potential (hi-pot) testing is
required, remove conductors from equipment
terminals prior to test.
(2) Conductors and equipment not under test shall be
grounded.
4.9.2 By Company
Completion of Phase I electrical requirements by Company shall
comply with the following procedures:
1. Observe the work of Constructor in completing above items

to obtain information needed for maintenance of the plant
electrical system.
2. Approve test procedures and documentation forms. Witness
all required tests, and sign test reports.
3. Connect main incoming service feeders to point of
utilization on unit when not included in Constructor's
scope. Energize service feeders.
4.10 Safety and Fire Facilities
For completion of Phase I for safety and fire facilities,
Constructor shall perform the following procedures:
1. Provide equipment and systems necessary for safe operation

and maintenance of the facilities. This includes, but is
not limited to, the following:
a. Provide and install additional necessary guards not
furnished by equipment vendors on pumps and compressor
couplings, compressor flywheels, and other exposed
rotating elements for the safety of operators.
b. Provide and install all other necessary safety devices
such as safety showers, eye wash fountains, and
warning signs (e.g., dangerous high voltage areas,
danger-acid, danger-caustic, danger-chlorine, high
noise level area).
c. Install all firewater monitors, hydrants, and hose
reels located inside unit limits. Open monitors,
hydrants, and hose reels to flush system.
d. Provide and install chains for lock systems on relief
valves. Company shall provide locks when required.
e. Provide personnel protection in accordance with GEMS
I-2M for certain hot lines that shall be left exposed.
2. Complete all required exit facilities and fire protection
equipment as part of Phase I. (Refer to OSHA 1910.36C.)
PAGE 16 OF 37
3. Perform required inspections and testing of firewater

hydrants and water spray/deluge systems in accordance with
GEMS M-4D and NFPA 15. Hydrants shall be tested for
adequate rate of flow at design conditions.
4.10.2 By Company
For completion of Phase I for safety and fire facilities,
Company shall perform the following procedures:
1. Review and approve safety and fire facilities.

2. Provide and install hand fire extinguishers. Provide fire
hose, except 1-1/2 inch hose on hose reels.
3. Provide locks to Constructor for relief valve locking
systems when required.
4. Review Company safety procedures with Constructor's
employees.
4.11 Pumps and Fans
Completion of Phase I for pumps and fans by Constructor shall
comply with the following:
1. Cover suction and discharge flanges prior to piping or

ducting hookup to prevent entry of foreign materials.
Protect all material in storage from damage due to adverse
weather.
2. Remove and tag greasers, lube glasses, etc., which may
become damaged during construction. Replace prior to
run-in.
3. All equipment (pumps, fans, turbines, gears, compressors,
etc.) shall be aligned using either reverse dial indicator
method or laser techniques.
a. Make final alignment of pump/fan and driver for cold
and/or hot setting as recommended by manufacturer or
Company specifications, whichever is more demanding.
b. Alignment should be done with suction and discharge
piping/ducting disconnected and then checked after
connecting the piping/ducting.
c. Provide record of alignment, including signature of
Company's representative.
d. Cold alignment values as specified by the O.E.M. at
the movable machine supports shall be within 20% of
actual.
e. Soft feet shall be eliminated prior to alignment
within 0.001 inch.
4. Refer to subsection 4.9, “Electrical”, and subsection
4.12, “Mechanical Drive Single Stage Turbines” (General
Purpose Turbines), of this specification for driver
run-in.
5. Prepare base plates as specified in the project grouting
and installation procedure prior to setting. Each pump/fan
shall be set, leveled, and grouted in accordance with this
procedure.
PAGE 17 OF 37
6. Remove preservative oils, if necessary, and install all

operating lubricants.
7. Couple pumps/fans to drivers after testing for correct
rotation.
8. Check all vents, drains, seals, bypasses, seal flushes,
seal coolers, etc., for conformance to specifications and
drawings. Flush seal oil lines before connecting the
seals.
9. Check pumps for proper installation of stainless steel
plugs.
10. Install temporary start-up strainers in suction piping.
11. Correct any piping/ducting misalignment that is necessary
after run-in of equipment.
12. Install inlet filters/screens to the fans.
13. Install expansion joints and seal inlet and outlet fan
ductwork.
14. Adjust settings and alignment of pumps/fans for hot
position when requested by Company during Phase II.
4.11.2 By Company
Completion of Phase I for pumps and fans by the Company shall
comply with the following:
1. Witness and approve Constructor alignment.

2. Initial flushing water shall not go through pumps but
shall be drained at flange.
3. Run-in pumps prior to start-up operations.
a. Run-in shall be done by circulating clean water with
the applicable water quality (i.e., chloride level) to
be used.
b. Circulating water through pumps should depend on
results of initial flushing procedure, whether pump
driver has adequate power to pump water, whether
pumped fluid lubricates pump bearings, and whether
water lubrication of bearings is acceptable.
4. Check temperature of bearings, vibration, etc., during
flushing operations, and report any malfunctions to
Constructor.
5. Check bearing temperature, vibration, etc., after first
running under operating conditions, and coordinate hot
alignment with Constructor as required.
6. When necessary, clean pump suction strainers after
completion of Phase I.
7. Remove temporary suction strainers after pumps have been
in operation for a reasonable period.
4.12 Mechanical Drive Single Stage General Purpose Turbines
Completion of Phase I for mechanical drive single stage general
purpose turbines by Constructor shall comply with the
following:
PAGE 18 OF 37
1. Protect all materials in storage from damage due to

adverse weather.
2. Setting and alignment shall comply with manufacturer's
recommendations.
a. Alignment check shall be witnessed and approved by
Company.
b. Refer to 4.11.1.3 for additional alignment
requirements
3. Remove preserving lubricants in accordance with
manufacturer's recommendations.
a. Clean and install running lubricants prior to run-in.
b. Turbines with separate circulating lube oil systems
shall have their systems cleaned and flushed (under
supervision of manufacturer's representative) before
installing operating lubricants.
4. Couple turbines to driven equipment.
5. Constructor shall adjust settings and alignment of
turbines when requested by Company during Phase II.
4.12.2 By Company
Completion of Phase I for mechanical drive single stage general
purpose turbines by Company shall comply with the following:
1. Witness and approve Constructor's alignment checks.

2. Commission piping systems required for run-in tests.
3. Company operator shall open steam valves to turbines in
order to check operational rotation, set over-speed trips,
etc., when running uncoupled. This shall be done in the
presence of Company's mechanical inspector and
manufacturer's representatives.
4. Check bearing temperatures, vibration, etc., after first
running under operating conditions. Check lube oil during
operation for water or other contamination.
5. Set turbine speed when operating under load.
4.13 Compressors and Multi-Stage Steam Turbines
Phase I completion for compressors and multi-stage steam
turbines by Constructor shall comply with the following:
1. Have manufacturer's service representative check all

components and auxiliaries prior to grouting.
2. Place grout, under supervision of manufacturer's
representatives, where required by Company.
3. The maximum difference in vertical elevation of the
mounting surface of each soleplate shall not exceed 0.003
inch. This shall be verified with precision levels prior
to grouting.
4. Constructor, coordinating with equipment vendor, shall
provide a detailed (barchart) schedule to Company 6 weeks
prior to start of work.
PAGE 19 OF 37
a. Schedule shall cover all necessary work required to

properly prepare and check out the compressor,
drivers, and oil systems for start-up in order to
prevent delays and minimize start-up problems.
b. Schedule shall include:
(1) Cleaning of lines.
(2) Detailed field testing procedures.
(3) Commissioning and checkout of instruments and
controls.
(4) Lube oil circulation for flushing.
(5) Bearing replacement.
(6) Alignment.
(7) Static instrumentation checkout.
(8) Electrical systems checkout.
(9) Driver run-in, coupling up, etc.
5. Compressor/steam turbine manufacturer's service
representatives shall review the schedule (barcharts) for
possible additions or modifications upon their arrival at
the jobsite. Their review shall also include an inspection
of the process piping for acceptance from the standpoint
of cleanliness.
6. Give special attention to the cleaning of all lines
related to or serving mechanical equipment (compressors,
lube and seal oil systems, etc.) to ensure that no
start-up problems occur with equipment due to improperly
cleaned lines.
7. Chemically clean reciprocating, centrifugal, and helical
screw compressor suction lines, interstage piping, and
suction knockout drums, as required by Company mechanical
inspector, according to the following procedures:
Note: alternate procedures are permissible with Company's
approval.
a. Preparatory work prior to chemical cleaning:

(1) Install temporary piping as required.
(2) Isolate designated piping system to be
chemically cleaned from other systems. Do not
allow flushing water or cleaning solution to
enter compressor.
(3) Remove demister pads from each suction knockout
drum. Mechanically clean and spray chemicals for
degreasing and pickling of interior.
(4) Perform complete hydrotesting of lines.
(5) Provide safety signs and barriers and rope off
working area to keep out unauthorized persons.
(6) Provide emergency washdown hose for dilution of
acid spillage and for personnel.
PAGE 20 OF 37
b. Flush out all circuits with available raw water until

they are clear of debris, trash, and foreign
materials.
c. Degrease system prior to pickling to remove traces of
oil, grease, paint, wax, and similar materials
adhering to surfaces prior to acid clean.
(1) Degreasing shall be performed by the use of
suitable heavy-duty alkaline or detergent
cleaning solutions.
(2) Solutions shall be maintained at a temperature
of 170°F to 200°F and circulated for 4 or more
hours depending on the degree of contamination.
(3) Solution temperature shall be raised gradually
in order to avoid thermal shock to the system.
(4) Drain the solution and dispose in a safe and
legal manner.
(5) Open system as required for inspection of
degreasing results.
d. Rinsing after degreasing:
(1) Flush the system with potable water for at least
15 minutes or until the effluent pH is below 8.0
(Target for neutral 7.0). Water shall be heated
to 100°F to 120°F to facilitate removal.
(2) Drain contaminated rinse water in a safe and
legal manner.
(3) Thoroughly rinse or flush with water all
degreased surfaces to remove as much of the
degreasing solution as possible.
e. Pickling - for carbon steel pipe (not to be used for
stainless steel pipe):
(1) Use a solution of inhibited hydrochloric acid,
30% by volume, or equivalent descaling acid.
(2) Use fresh acid batches for each acid cleaning
operation.
(3) Heat the solution to 160°F and circulate for 15
minutes per hour for at least 6 hours.
(4) Hammer the piping and joints approximately 10
minutes out of each hour.
(5) Sample the solution once every hour. Check acid
strength and total iron concentration.
(6) Maintain the acid strength above 5%.
(7) Continue treatment until acid and iron
concentrations remain constant for 1 hour.
f. Neutralization and Passivation:
(1) Cool the solution to 150°F while continuing to
circulate.
(2) Inject anhydrous ammonia into the circulating
stream to bring the pH to 9.5. (It will take
PAGE 21 OF 37
approximately 1% of ammonia based on total

solution weight.)
(3) Add sodium nitrite to the solution for
passivation to make 0.5% solution.
(4) Circulate the solution continuously for 4 hours.
(5) Drain the solution and dispose in a safe and
legal manner under a nitrogen blanket.
g. Rinsing after Passivation:
(1) Flush system twice with potable water heated to
150°F.
(a) Chloride content shall be less than 50 parts
per million (ppm).
(b) If the chloride content exceeds 50 ppm,
refer to subsection 4.14.1. paragraph 4.,
“Precautions”, for water treating details.
(2) Drain the initial flush in a safe and legal
manner.
(a) Drain the second flush to the nearest
designated sewer.
(b) Both drainings shall be done under a
nitrogen blanket.
(3) Open system as required for inspection of
pickling results.
h. Drying after Passivation:
(1) After the passivation solution or rinse water
has been drained away, oil-free commercial
nitrogen or oil-free filtered dry air (-20°F or
lower dew point) at 150°F to 170°F shall be used
to blow out any residual solution or water to a
safe and legal location.
(2) Continue to purge with gas until no free liquid
comes out of all low point drains, and then
purge for 5 minutes more.
i. Hydroblasting of compressor suction line, interstage
suction piping, and suction knockout drums may be
offered as an alternate to chemically cleaning as
follows:
(1) Alternate shall be offered if Constructor can
achieve comparable results for removal of scale,
rust, and loose weld metal.
(2) Alternate hydroblasting procedure shall be
submitted for Company's review and approval.
j. Post cleaning protection, nitrogen pressurization:
(1) Blind, close, or plug all openings to keep a
tight system.
(2) Introduce oil free commercial nitrogen and
briefly purge out remaining nitrogen or air from
the drying step.
PAGE 22 OF 37
(3) Pressurize the system to 5 - 10 psig with

nitrogen.
(4) Maintain positive nitrogen pressure until
start-up.
(a) Valves which are to be left open or closed
for pressurizing shall be tagged as such
with a durable tag.
(b) Locked-open or locked-closed valves may be
used.
8. Perform cold alignment as directed by manufacturer's
erection superintendent. Provide record of cold alignment,
witnessed and approved by Company.
9. Check installation and support of all small piping to
ensure against vibration and fatigue in operation. Provide
properly designed metallic hose between equipment and
rigid piping when specified.
10. Schedule vendors' service representatives as early as
possible in order to obtain firm commitments for qualified
personnel.
11. Check and test electrical equipment and circuits
associated with the compressor in accordance with the
electrical section. Motor vendor representative shall be
present as required to ensure that adequate and complete
checks are made.
12. Using Constructor's listing of switches, alarms, etc., add
the actual field setting. This shall be initialed by the
person performing the check. Vibration monitoring
equipment representative shall check installation,
calibration, and operation of all vibration monitoring
equipment.
13. Check all piping supports to make sure that they are
installed properly and that all spring hangers are set to
the proper load.
14. Perform run-in activities for compressors in accordance
with manufacturer's/contractor's procedures. Constructor
shall provide support if running on air is allowed.
15. Couple drivers to load, and run combined unit in presence
of Company representative.
a. Perform all tests necessary to confirm that equipment
is satisfactory for initial process operation in
accordance with compressor manufacturer's
recommendations.
b. Test includes a 4 hour mechanical run-in on air of
entire train at maximum continuous speed. Not all
compressors can be run on air. Check with manufacturer
prior to performing this step.
c. After air run-in, check condition of all train
bearings and shaft end seals.
d. Record all mechanical data at 15 minute intervals.
e. Vibration monitoring equipment representative shall
monitor and record vibration data and motor electrical
PAGE 23 OF 37
data (amps, volts, watts) for analysis and baseline

record.
f. All instrumentation shall be in operation for this
run-in.
g. Compressor run-in shall be under Company direction and
supervision.
16. Correct all piping misalignment that is necessary after
run-in of equipment.
4.13.2 By Company
Phase I completion for compressors and multi-stage steam
turbines by Company shall comply with the following procedures:
1. Witness all erection and alignment procedures. Become

familiar with use of special tools and equipment.
2. Commission piping systems required for run-in tests.
3. Check bearing temperatures, vibration, etc., in operation.
Check lube oil during operation for water or other
contamination.
4. Remove all temporary screens, etc., after initial
operation, and check alignment, if necessary.
5. Witness all testing of equipment and instrumentation. Sign
procedures and test reports.
6. Specify where piping is to be broken for any air tests
required.
4.14 Lube Oil System for Special Purpose Rotating Equipment
Phase I completion for the lube oil system for special purpose
rotating equipment by Constructor shall comply with the
following:
1. General
a. Constructor's inspectors shall make certain that seal
and lube oil piping is adequately cleaned by the
compressor manufacturer, coated, and protected for
shipment. Note requirements of GEMS J-1D.
b. At jobsite storage location, entire system, including
reservoir, shall be filled with Regal “32” Rust and
Oxidation Inhibited Lubricating Oil.
c. When console is needed at unit site, the oil shall be
drained before moving the console. When in place, the
console system shall be refilled with flushing oil.
d. All sections and branches of the oil system shall be
thoroughly flushed and checked for cleanliness.
e. Temporary piping shall be installed such that
contamination is avoided.
f. Temporary piping shall have throttling valves and
pressure gages for regulating the flow. During
flushing, uniform flow rates and pressures shall be
maintained at each bypass.
PAGE 24 OF 37
g. When all field interconnecting piping has been

assembled, degreased, and cleaned, the sealed console
flange covers shall be removed in the presence of
Company representatives and connections made up.
h. After lube and seal oil piping is assembled, oil flush
entire system (under the supervision of compressor
manufacturer's representative). Refer to paragraphs
below for recommended oil flushing procedure.
2. Recommended Oil Flushing Procedure
a. This procedure is applicable for flushing the lube oil
console and external piping. All work shall be done
under Company direction and supervision.
b. Piping supplied within this console has been cleaned
and operated during shop tests of the compressor.
Openings have been properly blanked or plugged prior
to shipment.
c. Hydrotest, water flush, degrease, and clean
interconnecting piping before oil flushing.
(1) Degrease with a suitable heavy-duty alkaline or
detergent solution.
(2) Maintain solution at 170°F to 200°F, and
circulate for 4 or more hours, depending on the
degree of contamination.
d. Thoroughly inspect all accessible areas of the
console. Remove contamination before charging flushing
oil.
e. Disconnect piping from critical control devices and
drain to reservoirs or suitable locations. Cover
openings to the control device to prevent
contamination.
f. Remove flow restrictive devices, including orifices
and check valve flappers before flushing. Tag all
orifices.
g. Install clean oil filter elements if contaminated.
h. Install 100 mesh screens between flanges at
appropriate locations in the piping to determine when
system has been sufficiently flushed. Screens should
be checked and cleaned at least every 4 hours or more
frequently if necessary.
i. Remove journal and thrust bearings and oil seals from
the equipment for the initial flushing of the system.
j. Install temporary bypass lines around the bearing/seal
cavities for initial flush.
(1) Use suitable transparent hose to observe the oil
flow.
(2) Ensure that temporary hoses have proper pressure
rating for system.
(3) Hose shall be the same size or larger than the
supply piping to which it is attached to prevent
flow restriction.
PAGE 25 OF 37
k. Check pump to driver alignment. Check over-speed trips

and adjust if necessary before placing them in
service.
l. Remove reservoir cover and clean reservoir using lint-
free wiping cloths. Replace cover and immediately fill
with clean operating oil (Regal 32 R&O) to properly
flush the system and maintain pump suction.
m. Energize power or steam as provided to reservoir panel
heating elements.
(1) Additional heating can be achieved by injecting
live steam into the piping upstream of the oil
cooler water inlet.
(2) Confirm with engineering contractor that cooler
design is adequate for heating service, and
advise of any cooler temperature limitation.
(3) Maintain effluent oil temperature at 160°F to
180°F.
n. To prevent entrainment of air, open and bleed vents on
filters and coolers with other system high points.
(1) Close valves when all air has been vented.
(2) Accumulators shall be blocked out of system
during flushing to prevent damage to bladders.
o. When all field interconnecting piping has been
assembled, degreased, and cleaned, remove blinds and
reconnect piping.
p. Circulate oil through the system with a flow rate at
least twice normal if possible.
q. Hammer periodically along piping in direction of flow,
concentrating on welded joints.
r. Cycle oil temperatures between ambient and 160°F to
180°F to supplement the effect of vibration of the
piping. During heating and cooling, inject air at
predetermined points in the piping to agitate the oil
and help sweep out particles in stagnant areas.
s. Flush through control valves and bypasses alternately.
Open all key valves and needle valves.
t. Periodically vent air from oil coolers, strainers,
filters, etc. Manually lift relief valve levers to
flush piping sections between valves and reservoir.
u. Check the pressure gage readings and sight flow
indicators for indications of restricted flow.
v. Check oil return lines for free flow back to
reservoir.
w. Continue flushing until no particles are collected on
the 100 mesh screen in a 2 hour period. Screen
cleanliness shall be witnessed by Company mechanical
inspector.
x. Remove temporary bypass lines and reconnect the supply
and drain lines to the bearing/seal housings. Install
felt, muslin, or gauze pads (40 micron or less) backed
PAGE 26 OF 37
with fine stainless steel screen in the bearing/seal

oil supply lines near the bearing/seal housings.
y. Check above filter pads at hourly intervals. System
can be considered clean if no accumulation of
contaminants occurs during three consecutive hourly
checks. Checks shall be witnessed by Company
mechanical inspector.
z. Blanked off portions of the system shall be reopened
and flushed clean.
aa. Continue oil circulation, but cut off all heating
sources, and allow system to reach 120° F. Open all
low point drains from lines and reservoir and reclaim
oil.
ab. Inspect tube bundles and shells of the oil coolers for
cleanliness.
(1) Pull and inspect upstream cooler first.
(2) Follow with other coolers until all are clean.
(3) After assembly, hydrotest the shell side (using
oil) with the channel covers removed to detect
tube to tubesheet leakage.
ac. Remove all traces of flushing oil and contaminants
deposited by the flushing from the bearing housing,
filters, and system low points. Install new filter
elements.
ad. Remove reservoir cover and clean reservoir using lint
free wiping cloths. Replace cover and immediately fill
with clean operating oil (Regal 32 R&O).
ae. Install all orifices, check valves, flappers, etc., in
their proper locations.
af. Replace bearings and seals making up the bearing
housing joints with an oil resistant sealant.
ag. Prime main and auxiliary oil pumps.
(1) Operate the main pump, bleed the system of any
air.
(2) Check for oil leaks at all fittings and
connections.
(3) Operate the auxiliary oil pump and repeat
venting the system.
ah. Remove all temporary strainers, pads, and back-up
screens from system.
ai. After venting, check for leaks, set and check all
pressure control valves, controls, and safety devices
for proper operation before initial start-up. This
should be accomplished with system at normal operating
temperature.
3. Inspection of Chemically Cleaned Compressor Suction Lines
a. Choose inspection points in areas least likely to be
completely cleaned. This includes large diameter
piping sections, vessels, and other equipment which
are dead ends.
PAGE 27 OF 37
b. Select inspection points such that inspections can be

carried out quickly and efficiently. Examples include
flanged joints or openings and full bore valves.
c. Visually inspect piping and equipment to determine
degree of cleaning. For chemical cleaning, such
inspections shall be made, as a minimum, after the
water rinse following the acid cleaning step and also
after the rinse following degreasing.
d. After degreasing there shall be no traces of oils,
greases, waxes, paints, or similar contaminants.
e. After acid cleaning there shall be no scale, rust, or
loose weld metal. A very light superficial rust which
is normal after cleaning is permitted.
f. Contaminants that are judged to show insufficient
cleaning shall be considered reason for rejection. The
necessary steps shall be repeated until inspection
passes.
4. Precautions
a. Piping and equipment containing austenitic stainless
steels or chromium content above 5% shall not be
contacted by:
(1) Hydrochloric acid solutions or acid solutions
containing halides. Alternative solvents shall
not have a chloride content over 15 parts per
million.
(2) Caustic soda solutions. Use soda ash or
trisodium phosphate for degreasing, provided the
chloride content does not exceed 50 ppm.
Chemicals used for passivating shall not have
chloride content exceeding 15 ppm.
(3) Rinse water following degreasing with chloride
content above 50 ppm.
(4) Water used to make acid solution or water for
rinsing following acid cleaning (if used), with
chloride content above 50 ppm.
b. If potable water supply exceeds chloride limits shown
above, treat potable water with low chloride soda ash
to make a 1-1/2% to 3% solution.
c. Piping and equipment shall have high-point vents and
low-point drains for proper filling and for complete
removal of solutions.
d. Equipment and piping containing acid solutions shall
not be heated directly. Acid solutions shall be heated
externally to the equipment being cleaned.
e. Where systems are to be chemically cleaned or flushed,
all operating mechanisms such as pumps, turbines,
compressors, bearings, cylinders, etc., shall be
disconnected and a temporary bypass installed to
provide continuous circulation. Heat exchangers shall
be considered on an individual basis.
PAGE 28 OF 37
f. Remove fabricated silencers, such as suction silencers

for centrifugal compressors, during field chemical
cleaning.
g. Pulsation suppression bottles on reciprocating
compressors shall be inspected for cleanliness and
cleaned separately if required.
(1) Special precaution shall be taken as internals
may be different metallurgy than shell.
(2) Bottles shall be isolated from field chemical
cleaning of piping systems.
h. Safety
(1) Normal safety steps shall be observed during the
mechanical or physical phases of the cleaning
(gloves, goggles, etc., for clothing).
(2) In addition, the following safety procedures
shall be observed during chemical cleaning:
(a) Handle all cleaners and chemical solutions
with caution.
(b) Wear proper protective gear such as safety
goggles, face shields, rubber gloves, rubber
boots, rubber aprons, and hard hats.
(c) Provide adequate ventilation to avoid
accumulation of hydrogen gas which is highly
flammable and explosive.
(d) Ventilation also reduces concentrations of
vapors which would be harmful or irritable
to working personnel.
(e) For diluting acid solutions, pour
concentrated acid into water slowly and
carefully with continuous stirring. Do not
pour water into concentrated acid.
(f) Make certain that no hydrocarbon oils can
get on piping and equipment which will be
used for oxygen service.
(g) No rust preventive oils shall be applied.
Any air or nitrogen used shall be oil free.
(h) Hoses shall be resistant to the solutions
used and shall be in good condition.
(i) Equipment and tools used for cleaning shall
be maintained in good condition.
4.14.2 By Company
Phase I completion for the lube oil system for special purpose
rotating equipment by Company shall comply with the following:
1. Inspect the work.

2. Approve the procedures and sign reports.
PAGE 29 OF 37
4.15 Packaged Equipment and Units

In general, any equipment, vessels, piping, and instrumentation
shall be checked out and tested in accordance with applicable
sections of this specification, unless manufacturer's
representative or manufacturer's instructions specify a
procedure to follow.
4.15.2 By Company
Witness all tests on packaged equipment.
4.16 Flares and Incinerators

Completion of Phase I for flares and incinerators by
Constructor shall comply with the following procedures:
1. Simulate ignitor operation.

2. Test blowdown system as specified in testing procedure.
3. Test autostart of spare pump using level control
instrumentation system.
4.16.2 By Company
Completion of Phase I for flares and incinerators by Company
shall comply with the following procedures:
1. Light pilots on flare.

2. Witness pressure tests and sign test reports.
3. Establish levels in seal pans.
4.17 Cooling Towers
Phase I completion for cooling towers by Constructor shall
1. Check fan and pump motors and pump steam turbines as

outlined under motors and turbines in appropriate sections
of this specification.
2. Check fan rotation; run fans; check vibration, vibration
switches (if any), and blade pitch setting; balance fans;
check blade clearance.
3. Provide motor ampere readings and vibration readings to
Company.
4. Install permanent operating lubricants.
5. Check basin and fan deck for cleanliness.
6. Install screens in basin.
7. Check for proper installation of water distribution
nozzles.
8. Clean circulating water system.
PAGE 30 OF 37
9. Check control systems for operation, including each

control valve for each hot water bay.
10. Test return water distribution header for pressure by
filling vent stacks located on the cooling water return
riser with water.
11. Keep tower wet prior to operation.
4.17.2 By Company
Phase I completion for cooling towers by Company shall comply
with the following procedures:
1. Check bearing temperatures and vibration during initial

operation.
2. Provide pretreat chemicals and pretreat water system.
3. Witness required tests, including cleaning and pretreating
operations, and sign test reports.
4. Conduct an acceptance test in accordance with GEMS U-1M or
applicable project specifications.
4.18 Tanks
Completion of Phase I for tanks by Constructor shall comply
1. Clean roof and all exterior surfaces of all weld splatter

to ensure proper bonding for painting.
2. After erection, unhead and check internals with Company's
representative.
3. Perform hydrostatic testing in accordance with soil report
and project specifications.
4. A rust preventive during waterfilling, such as TRI-182 or
equal, is required only when specified by Company.
5. Check settlement at regular intervals, record data, and
provide copies to Company. Re-level tanks where excessive
settlement occurs.
6. Clean out for final Company inspection after completion of
hydrostatic testing.
7. For floating roof tanks, inspect roof seals, shunts,
drains, and vents.
8. Head-up after final inspection, execute the closure
permit, and obtain written authority from Company.
9. Provide new manway gaskets where required.
10. Ensure that mixers are operational and lubricated.
11. Check gaging equipment.
12. Subcontract tank strapping in accordance with Company's
specifications, and provide data to Company.
13. Submit X-ray records to Company.
PAGE 31 OF 37
4.18.2 By Company
Completion of Phase I for tanks by Company shall comply with
the following procedures:
1. Prepare tank capacity tables using strapping data provided

by Constructor.
2. Inspect before final heading.
3. Witness hydrostatic testing.
4. Issue to Constructor written authority to head-up each
tank.
4.19 Clean-up
Completion of Phase I clean-up by Constructor shall comply with
the following procedures:
1. Thoroughly clean all facilities and areas of all debris,

weld rod, scrap, etc., to the satisfaction of Company.
a. This debris shall be disposed off Company property.
b. Burning shall be prohibited.
Note: All facilities and areas shall be maintained in a
clean and orderly manner throughout construction.
2. Remove all temporary construction materials, facilities,
and equipment, including warehouses and shops (except for
those construction facilities and buildings indicated by
Company to remain).
3. Remove all scaffolding from the plant.
a. With Company's approval, a small amount of single deck
scaffold may be left to complete painting or
insulation during Phase II.
b. This remaining scaffolding shall not interfere with
safety or operations.
c. Scaffolding shall be removed by Constructor upon
completion of insulation or painting.
4. Gather and organize surplus construction equipment and
materials that are the property of Company for disposition
in accordance with Company's instructions.
4.19.2 By Company
Completion of Phase I clean-up by Company shall comply with the
following procedures:
1. Confirm that clean-up and removal of temporary facilities,

if any, has been satisfactorily completed.
2. Approve any scaffolding left after completion of Phase I.
3. Provide instructions for disposition of surplus materials.
PAGE 32 OF 37
4.20 Lubrication
Completion of Phase I for lubrication by Constructor shall
1. Remove all rust preventives, oil, grease, etc., used to

preserve the equipment during construction.
2. Apply all lubricants necessary for construction, testing,
and initial operation of the unit equipment.
3. Apply necessary lubricants in accordance with
manufacturer's and Company's instructions.
4. Provide lubricants and fuels for operation and maintenance
of Constructor's construction tools and equipment.
5. Install preservative lubricant and re-apply as required to
protect equipment during idle storage. Pumps, turbines,
motors, etc., shall be rotated by hand at least once per
week.
6. Execute preservation procedures, in accordance with the
vendor or Company requirements, for special equipment,
such as oxygen-free equipment.
4.20.2 By Company
Completion of Phase I for lubrication by Company shall comply
1. Provide lubricants to Constructor for field lubrication of

equipment that is an integral part of the plant.
2. Lubricants normally installed before shipment by the
manufacturer, such as transformer oil, and rust
preventives, shall be obtained by manufacturer or
contractor and included in the equipment cost.
3. Provide a project lubrication list of Company products or
acceptable alternates for use as a guide in lubricating
equipment.
4.21 Completion of Phase I
1. Near the end of the project, Company shall schedule a meeting with
Constructor to discuss possible changes in the order of completion
of various portions of the project based on actual construction
progress.
a. Items, such as painting, insulation, and clean up, which may be
deferred by Company and completed by Constructor as a part of
Phase II, shall be reviewed and approved by Company.
b. Constructor shall keep minutes of the meeting and distribute to
all concerned parties.
2. When all requirements of Phase I are complete for the project or a
portion of the project designated by Company, Constructor shall
notify Company in writing that the project or that portion of the
project is ready for initial operation by Company.
3. Company shall complete inspections and obtain approvals for
starting up the facilities in accordance with the location's safety
review procedures.
PAGE 33 OF 37
4. If, in Company's opinion, the construction is not sufficiently

complete for initial operation, Company shall promptly advise
Constructor of deficiencies noted at the time.
5. When the deficiencies have been corrected to Company's
satisfaction, Company's designated representative shall confirm
that the Company's safety reviews/approvals have been completed and
issue a “Completion of Phase I” statement for the project or that
portion of the project, confirming the completion date. The notice
of completion shall state that the new facilities comply with OSHA
1910.119, Paragraph (i), “Pre-Startup Safety Review”.
5. PHASE II
1. Upon issuance of “Completion of Phase I” statement, Phase II shall

begin, and the project or that portion of the project shall be
available to Company for initial operation. Constructor may proceed
with the deferred work until Company commences initial operations.
2. At some time after issuance of “Completion of Phase I” statement,
Company shall commence initial operation with Constructor's
construction personnel off the unit. Initial operation is defined
as start-up of the project or portion of the project and operation
until safe sustained operations have been attained.
3. When operations are deemed safe, Company shall authorize
Constructor's forces to return for completion of the deferred work
and for correction of any deficiencies noted during initial
operation.
4. Before removing construction facilities and personnel from the
project or portion of the project, Constructor shall obtain
agreement from Company's construction manager that all
Constructor's work has been completed.
a. Upon agreement, Constructor shall remove the construction
material and equipment and clean up that portion of the
project.
b. Upon agreement that the entire project has been completed,
Constructor shall remove all construction material, equipment,
and all facilities and construction buildings other than those
that are to be permanent as directed by Company.
c. Constructor shall then clean up all project areas occupied by
Constructor and his subcontractors, including storage and
fabrication areas.
5. When all the requirements of Phase II have been completed for the
entire project, Company's construction manager shall sign the
“Completion of Phase II” statement confirming the date of
completion of construction for the project.
6. PHASE III
6.1 Acceptance Test

6.1.1 General
1. An acceptance test may be conducted by Company at
Company's option to determine the ability of the work to
meet any process/ operating guarantees.
PAGE 34 OF 37
2. In the absence of any performance agreements addressing

process/ operating guarantees and acceptance tests, the
following shall be adhered to:
6.1.2 Period of Test
1. The acceptance test shall be started within a period of
365 days from the time licenser’s units are available to
Company for initial operation, as evidenced by the date of
the “Completion of Phase I” statement signed by Company.
2. Any period of time before the expiration of the 365 day
period, during which the plant is not operated through
fault of contractor, constructor, subcontractors, or
suppliers, or any material provided by them, shall be
added to the 365 day period.
3. The acceptance test shall extend continuously over the
period determined necessary by Company to evaluate average
performance.
a. Such period shall be a minimum of 24 hours or one
complete cycle on cyclic operation, whichever is
longer.
b. The test period for certain equipment which requires a
longer run to evaluate performance shall be mutually
agreed upon by Company and the necessary parties.
c. In the event the acceptance test is interrupted by any
cause, the condition causing the interruption shall be
corrected and steady test operations restored as
determined by Company.
d. Company shall determine whether the acceptance test
shall be completely re-run or whether the test may be
resumed and continued after the interruption, with the
run period prior to the interruption considered valid.
e. The parties providing process/operating guarantees to
Company for these facilities may be requested by the
Company to participate in evaluation of the acceptance
test.
6.1.3 Test Conditions
The acceptance test shall be conducted with feed stocks and
under physical conditions as near as practical to design
conditions.
1. Note that exact duplication of design conditions is

improbable during acceptance test, and certain
non-controllable variations will occur, such as ambient
air temperature, wet bulb temperature, and feed stock
temperature, pressure, and composition.
2. Note that, at Company's option, an adjustment of the
process/operating guarantees shall be made and mutually
agreed to by Company and the pertinent parties.
3. Operating data obtained during the acceptance test on
non-controllable conditions shall serve as a basis for
calculations when used with the original design methods
and procedures to determine the adjustments to the
process/operating guarantees.
PAGE 35 OF 37
6.1.4 Data To Be Recorded

1. Before start of acceptance test, Company and the pertinent
parties shall mutually agree on operating data to be
recorded, methods of measurement and recording data,
sampling and testing procedures, and other matters
concerning procedures for the test.
2. Unless otherwise specified, taking of all samples shall be
by Company personnel. Unless otherwise specified, testing
shall be performed by Company in Company's laboratory.
3. Upon request, Company shall provide duplicate samples to
the pertinent party for their own analysis.
6.1.5 Test Operators
1. All operations during the acceptance test shall be by
Company operators.
2. A pertinent party, at its option, may observe the
acceptance test and may delegate observers to make
suggestions to Company concerning operations during the
acceptance test.
6.1.6 Evaluation of Test Data
Evaluation of acceptance test data:
1. Shall include operating and laboratory data accumulated

during or as part of the acceptance test.
2. Shall be jointly undertaken by Company and all pertinent
parties.
3. Evaluation of plant performance shall be on the basis of
the average performance over the entire acceptance test.
6.1.7 Submission of Test Data
Within a reasonable period of time after the completion of each
acceptance test, the appropriate party shall submit to Company
in writing the results thereof indicating whether the
process/operating guarantees related to the acceptance test
have been satisfied.
6.1.8 Acceptance of Test Data

Within a reasonable time after notification by the appropriate
party of the results of such acceptance test, Company shall
signify in writing its agreement with the conclusions or shall
specify in which respect such process/operating guarantees have
not been satisfied.
6.1.9 Deficient Units

Upon receiving Company's notification that the units are
deficient and do not meet the process/operating guarantees, the
appropriate party shall adhere to the following:
1. At his expense and without increase to the contract price,

the appropriate party shall immediately take such steps as
are necessary to correct such deficiencies in a manner
acceptable to Company.
PAGE 36 OF 37
2. If the appropriate party shall fail to do so, Company may

cause such deficiencies to be corrected, and the expense
thereof shall be paid by such appropriate party.
6.1.10 Retests
If the process/operating guarantees are not met during the
first acceptance test, Company shall do the following:
1. It may, at its option, conduct additional acceptance tests

after the deficiencies have been corrected by the
appropriate party.
2. Any additional acceptance tests that may be necessary
shall be carried out under the same conditions as provided
for the first acceptance test.
6.2 Completion of Phase III
1. When both “Completion of Phase III” by Constructor and a
satisfactory acceptance test confirming compliance with the
process/operating guarantees has been evidenced in writing by
Company to the appropriate parties, Company shall sign a
“Completion of Phase III” statement which will establish
fulfillment of the process/ operating guarantees but will not
relieve any party for continuing liability as provided by any
material and workmanship guarantees.
2. If Company elects not to make the acceptance test within the period
established above under 6.1 and such failure is not attributable to
some act or omission by Constructor, its subcontractors, or
suppliers, or to fault of materials provided by any of them, the
process/operating guarantees shall be deemed satisfied without
issuance of “Completion of Phase III” statement by Company.
3. Lack of an acceptance test shall not relieve any party of other
liabilities under the contract, such as material and workmanship
guarantees.
4. None of the following shall constitute “Completion of Phase III” or
acceptance of all or any part of the project by Company:
a. Issuance of statements by Company acknowledging performance of
field test.
b. “Completion of Phase I” statement.
c. Satisfactory project operations.
d. “Completion of Phase II” statement.
e. Satisfactory acceptance test.
PAGE 37 OF 37

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DEC 97 PROCEDURES FOR THE COMPLETION OF WORK GEMS G-2P1

6. PHASE III .......................................................... 34

This specification defines minimum technical requirements for the start-

2.1 Company Specifications

This specification contains references to the following Company

1. GEMS I-2M, “Thermal Insulation”.

2.3 Codes and Standards

2.3.1 American Society for Testing and Materials (ASTM)

2.3.3 National Fire Protection Association (NFPA)

2.3.4 Occupational Safety and Health Administration (OSHA)

1. Constructor shall be responsible for complete construction of the

responsibility for performing work associated with such

1. Provide, install, and conduct tests where required in the

1. Audit Constructor's performance with regard to inspecting

equipment, or work which does not comply with project

1. Test mechanical facilities.

b. Check fins for damage and repair if required. Clean

1. Witness and approve all required tests.

1. Field Installed Vessel Internals

internal inspection, unless specifically waived by

1. Visually inspect trays and internals in the area of the

4.5 Heaters and Boilers

1. Clean heaters and boilers of all construction debris,

5. Perform the following for initial operation:

1. Witness hydrostatic tests and sign test reports.

4.6 Insulation and Painting

1. Complete painting and insulation except that which will be

1. Approve painting and insulation work that Constructor may

1. Check all flanged connections to ensure:

welds and flanged connections by Company representative.

15. Maintain stress relief, pressure test, and NDE records,

1. Witness all field pressure tests and sign test reports.

1. Instrument storage, handling, and tagging:

a. Instruct installers in proper installation of each type

(5) Remove vortex meters and mass flow elements

(2) Test power supply to each section of the control

1. Witness all above tests and those performed in accordance

(2) Take resistance measurements from each bus to

1. Observe the work of Constructor in completing above items

1. Provide equipment and systems necessary for safe operation

3. Perform required inspections and testing of firewater

1. Review and approve safety and fire facilities.

1. Cover suction and discharge flanges prior to piping or

6. Remove preservative oils, if necessary, and install all

1. Witness and approve Constructor alignment.

1. Protect all materials in storage from damage due to

1. Witness and approve Constructor's alignment checks.

1. Have manufacturer's service representative check all

a. Schedule shall cover all necessary work required to

a. Preparatory work prior to chemical cleaning:

b. Flush out all circuits with available raw water until

approximately 1% of ammonia based on total

(3) Pressurize the system to 5 - 10 psig with

data (amps, volts, watts) for analysis and baseline

1. Witness all erection and alignment procedures. Become

g. When all field interconnecting piping has been

k. Check pump to driver alignment. Check over-speed trips

with fine stainless steel screen in the bearing/seal