Doc.No.

: PH-10-32
System Philosophy and
Completion Rev : D1

Page : Cover

PTT Public Company Limited

Document No.

PH-10-32

PROJECT PHILOSOPHY FOR

SYSTEM PHILOSOPHY AND COMPLETION

D1 ISSUED FOR ITB GSP7 Maetee L. Tanawat U. Attaphon M. 08 Jul 20

Quality
Checked Approved reviewed Issued
REV. DESCRIPTION Prepared by
by by by date
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REVISION 01 D1
DATE 01-08-2005 08-07-2020
ORIG. BY TANAWAT U.
APP. BY ATTAPHON M.

CONTENTS

SECTION

1. INTRODUCTION
1.1 PURPOSE
1.2 PROCESS OVERVIEW
2. DOCUMENTATION

3. BASIS OF SYSTEMISATION
3.1 PLANT DIVISION
3.2 SYSTEM DEFINITION
3.3 SYSTEM SEQUENCING
4. SYSTEM NUMBERING &DESCRIPTION

5. SYSTEM IDENTIFICATION

6. ASSIGNMENT OF ITEMS TO SYSTEMS

6.1 INSTRUMENTATION
6.2 PIPING
6.3 MECHANICAL EQUIPMENT
6.4 ELECTRICAL
6.5 BUILDINGS
6.6 CIVILS, STRUCTURAL STEEL, AND LIGHTING
7. SYSTEMS REGISTER

8. SYSTEMS COMPLETION

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1. INTRODUCTION

1.1 Purpose

This specification defines the methods and objectives for dividing the PLANT into
discrete Systems for use in MECHANICAL COMPLETION, precommissioning,
commissioning, planning and implementation of the CONTRACT.
The objective of a phased completion by Systems is to enable each part of the PLANT
to be completed, commissioned and started in the optimum order so as to minimise
the overall project schedule.

1.2 Process Overview

The project comprises the installation of a new gas separation plant (GSP7) located
nearby to existing PTTLNG Terminal 1, LNG Re-gasification, Map Ta Phut Industrial
Estate, Rayong. The new gas separation plant includes:
 In plant power generation
 LNG interconnecting pipe to cold energy integration unit
 Feed gas, Sales gas and Ethane product interconnecting pipelines to
the existing PTT GSP Complex
 Propane, LPG and NGL products interconnecting pipelines to the
existing PTT GSP common rundown header
 The liquid products buffering storage tanks including pumping system

2 DOCUMENTATION
P&ID’s are used as the basis for the colour mark-up of the System.
Systems Completion Manuals are used as the basis for completion and handover from
CONTRACTOR to PTT.

3 BASIS OF SYSTEMISATION

3.1 PLANT Division

The PLANT shall be divided by CONTRACTOR into discrete Systems for
MECHANICAL COMPLETION, precommissioning and commissioning. These Systems
shall comprise utility or process Units, (or part of), and non-process sections, such as
buildings, pipe tracks, substations or switchyards etc. Each system shall be unique
and one system shall not run into another.

3.2 System Definition

Systems are defined as discrete sections of the PLANT that may be made
Mechanically Complete and precommissioned to achieve READY FOR START-UP in
isolation from other sections of the PLANT. The systems shall be defined by
CONTRACTOR on engineering drawings and shall be chosen such that they are

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manageable, continuous, isolatable and functional (especially with regard to optimising

the overall schedule).
Wherever practical the System limits shall terminate at physical break points that are
part of the permanent installation. This will enable the eventual coupling of adjacent
systems for pre-commissioning and commissioning activities.
In the final phase of construction the planning, scheduling, documentation, reporting
and control of multidiscipline activities leading to READY FOR START-UP shall be co-
ordinated by System.
The sum of the Systems shall include all items of the PLANT.

3.3 System Sequencing

The primary objective of the PLANT systemisation is to sequence the MECHANICAL
COMPLETION and precommissioning of Systems and Units up to READY FOR
START-UP and subsequent commissioning and start-up operations.
At Rayong the new PLANT consists of additions and revamps to existing facilities and
shall be sequenced such that it can be brought on line with minimum interruptions to
existing operations.
The systemisation of the PLANT shall reflect this requirement. All utilities and systems
required for the safe and effective start-up and operation of the PLANT shall be
sequenced accordingly.

4 SYSTEM NUMBERING & DESCRIPTION

Each System shall be assigned either an alpha-numeric or a numeric unique identifier
that will consist of, as a minimum, the following information.

 The identifier in which the System is located.

 Notation to identify process systems from non-process systems.
 A pertinent name referring to the operational service of the system.

5 SYSTEM IDENTIFICATION
Each System shall be clearly identified on engineering drawings, (P&ID’s) by
CONTRACTOR.
Typically this will be colour mark-ups of drawings showing System boundaries and
content. In this case each System is identified on the drawing with its own unique
number and colour code clearly marked. System limits shall be clearly indicated by a
unique coloured symbol.
Typically these will include:

Process and Utility Systems Shown on P&IDs.

Electrical Systems Shown on Electrical One Line
Diagrams.

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Instruments Assigned to Process or Utility

where the instrument/actuator is
located.
DCS, ESD, F&G Shown on Block Flow or Layout.
Compressor Control and
Telecommunications
Instruments Shown on Block Flow or Layout.
Buildings Shown on Layout or General
Arrangement.

Generally, the number of Systems will average about 10 for a process Unit and be,
say, (1) a large piece of equipment or supplier skid unit, (2) a complex reactor such as
a Hydrocracker, (3) a recycle gas compressor circuit or tower overheads system. The
CONTRACTOR shall define the Systems and plan the WORK in conjunction with
these Systems. The Utilities will normally have System divisions according to its
generation, off-site distribution and Unit distribution. Off-sites will generally be the tank
and its filling and discharge system.
The index and definitions of the Systems shall be used in construction planning so that
scheduling of construction completion is synchronised with pre-commissioning,
commissioning and start-up activities.
The System definitions, divisions, boundaries and completion schedule shall form part
of the CONTRACTOR’s instructions to a SUBCONTRACTOR with respect to work
planning.

6 ASSIGNMENT OF ITEMS TO SYSTEMS

6.1 Instrumentation
The break between Instrumentation Systems and other Systems shall be at the cable
marshalling cabinets.
Each field instrument loop shall be assigned a System number derived from the
process System in which the actuator is located.
Local indicators, pressure relief valves and other in-line devices will be assigned a
System number from their locations as indicated from the System identification.
Instrument loop pack numbering will contain, as a minimum, the System number in
which the instrument is located.

6.2 Piping
Line numbers will be assigned the System numbers as indicated in the System
identification.
Process Systems will generally consist of one or more pressure test packs. These
shall be numbered typically with the System identification number plus an additional
three digit sequential number.

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6.3 Mechanical Equipment

Mechanical Equipment shall be assigned the System number as indicated in the
applicable System identification.

6.4 Electrical
Electrical Systems will generally be identified on bus bar and voltage level. For
reasons of safety, System limits will be defined so as to ensure that power isolators
are always in the next down-stream System.
Equipment MCC, control cables and associated instrumentation are assigned to the
System in which the mechanical equipment is located.

6.5 Buildings
Each building will be considered as one System. All items within the building (HVAC,
F&G Lighting, etc.) shall be considered as part of the building System.

6.6 Civils, Structural Steel, And Lighting

Where not included in other Systems these will be considered on a Unit or Area as
appropriate.

7 SYSTEMS REGISTER
CONTRACTOR shall prepare and maintain a Systems register from the above
information. This register shall show the unique System reference code and all the
items of the PLANT contained within each System, in the form of a complete, detailed
list of all items of equipment in each System.

8 SYSTEMS COMPLETION

8.1 Completion Flow Diagram

Attachment 1 shows stepwise the typical activities from plant construction to FINAL
ACCEPTANCE in their expected sequence and provides a background to the activities
of this procedure. CONTRACTOR shall review and develop, as appropriate, to ensure
that it is made specific to the Project.
The division of the PLANT into Systems shall be submitted to PTT for review and shall
be revised in accordance with PTT’s comments as many times as are necessary until
PTT is in agreement with the most suitable breakdown of the PLANT to facilitate
mechanical completion, precommissioning and commissioning in the shortest possible
time. (refer to attachment 2.0).

8.2 System Completion Manual

A System Completion Manual Shall Be Prepared For Each System And Its “Contents”
Page Will Show The Sections:
 Contents Sheet
 System No.
 Description of the System and its Drawings (including “one line”
drawings for each System)

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 Detailed equipment list

 Piping Certification – Summary Document
 Mechanical Equipment Certification – Summary Document
 Painting and Insulation Certification – Summary Document
 Instrumentation Certification – Summary Document
 Electrical Certification – Summary Document
 Relief Valve Certification
 MECHANICAL COMPLETION Check List
 Pre-Commissioning Checklists
 Equipment, Vessel, Instrument and Electrical – Check Sheets
 Leak Testing Summary Record Sheets
 System Certification and Punch List
 Certificates of MECHANICAL COMPLETION
 Certificates of READY FOR START-UP

The documentation in each System completion manual shall record the inspection,
checking and testing activities required to achieve READY FOR START-UP (RFSU)
status, and thereby demonstrate that the System is safe to commission and operate.
(refer to attachment 3.). Details of certificates can be found in Appendix C, Definition of
Completions Responsibilities and Certificates.

RECORDS
The System Completion Manual will only be complete when all the records of
inspections, checks and tests acceptance have been appropriately signed off as
approved and summary certifications completed.

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ATTACHMENT 1
COMPLETION FLOW DIAGRAM

ACTIVITY ELEMENTS

ONGOING CONSTRUCTION QUALITY CONTROL RECORDS

1
NDT TEST RECORDS

2 PUNCH LIST SYSTEM (All disciplines) HYDROTEST RECORDS

FORMAL PUNCH LISTING PRE-OPERATING CHECKS

3 (for MECHANICAL COMPLETION)
DISCIPLINE PUNCH LISTS

PUNCH LIST ITEMS COMPLETED AND CONSTRUCTION COMPLETION

4 VERIFIED: MECHANICAL COMPLETION CHECK LISTS

PRE-COMMISSIONING PRE-COMMISSIONING
5 REQUIREMENTS

READY FOR START-UP: START-UP SYSTEM(S) COMPLETION

6 MANUALS ACCEPTED

COMMISSIONING
7 BRING UNIT ON LINE

ACHIEVE ON SPEC PRODUCT AT DESIGN

8 RATE STEADY OPERATION

UNIT PERFORMANCE TESTS AS DEFINED IN PROJECT

9 SPECIFICATION

INITIAL ACCEPTANCE
10

11 FINAL ACCEPTANCE

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ATTACHMENT 2.

SYSTEMS COMPLETION – HOME OFFICE

SYSTEM COMPLETION – HOME OFFICE

Define SYSTEMS
P&ID
Mark Up

PTT
Review

PTT
Approval

Data
Sheets

SYSTEM
Priorities

Construction/
Commissioning
Schedules
Systems
Equipment List/ P&ID Mark-up
Line List/ SYSTEM Numbers
Instrument/
Elec Data Base

PTT
Review

PTT
Approval

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ATTACHMENT 3.

SYSTEM COMPLETION - PROJECT SITE

QC
Check Shts
Prepare Prepare Procedures for
NDT RFSU PRECOMMISSIONING
Quality Control Leak Testing, RV
Records - 9 months Procedures
Dossier & Inst Testing, etc

Material
Ident
Review Procedures for
Shop by Cleaning
Inspection PTT CAT Loading etc.
Reports

PTT
Approval

System Offered RFSU

as Mechanically - 3 months Final
Complete Issue

Summary of
Defects Multi
vs Disciplinary
PROJECT Punch List
SPECIFICATION

Category
A, B - Items Cleared

CONSTRUCTION
COMPLETION Finalise QC PRECOMMISSIONING
Check Lists, Dossier SYSTEM
Site Reports

Summary of Testing
and Inspection Prepare Witness/Sign Off
Signed off by Pinnacle Procedures
Discipline QC Data

SYSTEMS Prepare Systems

COMPLETION Completion Manual
MANUAL

Submit Systems
Comp. Manual
to PTT

PTT
Approves

Safety
System in
Place

System
RFSU

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