PROJECT:

Tanauan Factory WWTP Upgrade

User Requirement Specifications
(Revision 0- January’14)

Designation Visa Date Issued

Prepared by: Mark Rusel Project Engineer

Approved by: Rolly Azucena Projects Head

Approved by: Louie Chow Factory Engineer

Seen by: Edwin Erasquin IS Head

Seen by: Rey Salazar EI Head

Seen by: Ricardo Cassina Chief Engineer

Introduction

In 2012, Nestle Philippines commissioned its newest and 5th (before acquisition of Pfizer
Nutrition) Factory in FPIP, Tanauan, Batangas, Philippines, The Nestle Tanauan
Factory. The factory was planned to produce Non-Dairy Creamer (NDC) at 10ton/hr
(now at 11t/hr) for the Philippine Market.

In 2013, due to the increase & strong demand of Bear Brand Instant Milk (BBI) &
Tanauan Factory’s capability to switch to BBI, it also started producing BBI. The
additional BBI production brought with it also an increase in the process’ waste water
influent characteristics / parameters (See Table 1). As the additional volume of BBI
being produced by Tanauan factory was not foreseen until the year of 2015, the factory’s
waste water treatment plant wasn’t fully capable of treating the BBI influent. Due to these
capacity issues the WWTP encountered both hydraulic & high COD overload.

At present - Nestlé Philippines plans to upgrade Tanauan Factory’s existing waste water
wreatment plant to treat combined NDC & BBI process generated waste water – Phase
1. Furthermore, an additional hydraulic load Of both high and low COD waste is
anticipated from the proposed 2nd NDC Tower. – Phase 2

Table 1 – Influent Characteristics of Phase 1 & 2, High COD

High COD Waste Phase 1 Phase 2

PARAMETERS BBI & NDC NDC
Flow, cum./day 230 250
COD, mg/l 40,000 16,000
TSS, mg/l 9,240 5,580
FOG, mg/l 1,840 740
TP, mg/l 660 620
TN, mg/l 470 210

Table 2 – Influent Characteristics of Phase 1 & 2, Low COD

Low COD Waste Phase 1 Phase 2

PARAMETERS BBI & NDC NDC
Flow, cum./day 75 75
COD, mg/l 500 500
The proposed upgrade to treat High COD waste (16,000 to 40,000 mg/l @ 480m³/day)
shall include installation of the following:

I. Pretreatment system
 Static Screening
 Chemical dosing (Equalization)
II. Modification of Existing Aerobic Treatment System
 Replacement of “Fixed” fine bubble diffuser to a “Lift able” type
 Relocation of existing membrane bioreactors from aeration tank to
separate MBR tanks
 Nitrogen & Phosphorous removal
III. Anaerobic Treatment
 Completely stirred tank reactor
 Dissolved biogas floatation system
 Dewatering system
 Concealed type gas flare

And it is expected to achieve the following effluent parameters (DAO / NER):

Table 3 – Standard Effluent Parameters

Effluent Parameters Limits

Ammonia as NH₃ - N, mg/L 0.5
Nitrate as NO₃ - N, mg/L 14
Color, Pt.Co. 100
pH 6.5 - 9
COD, mg/L 100
Settleable Solids (1 hr), mg/L 0.5
BOD, mg/L 30
Total Suspended Soils, mg/L 50
Surfactants, mg/L 15
Oil / Grease, mg/L 5
Phenolic, mg/L 0.5
Total Nitrogen, mg/L 10
Total Phosphorus, mg/L 2
*Deviation from these parameters shall be subject to agreed penalties stated in the project
contract between Nestle Philippines, and awarded supplier.
Contact persons
Support CO-Eng

Michael Corkery Team Leader

Support Nestlé Philippines Engineering Services

Ricardo Cassina Chief Engineer

Alfredo Ocampo Corporate Project Engineer
Mark Rusel Corporate IS Engineer

Factory Project Team

Louie Chow Factory Engineer

Rolly Azucena Projects Head
Edwin Erasquin Industrial Services Head
Mark Rusel Project Engineer/s
1 Scope

The scope of this specification includes the design & engineering (Process,
Mechanical, Civil & Electrical, Automation & Controls) supply, delivery, install and
commissioning for the complete upgrade of waste water treatment plant as described.

1.1 Pretreatment

a. Static Screening
A simple static screen will be used with waste water fed from the top and
flowing downwards through the spacing between the wedges. Solids larger
than the spacing will be retained on the screening surface and will fall down
into a collecting skip. A spray cleaning device will be installed to keep the
screens continuously clean.

Sample Pre-Screening Unit

Table 4 – Screening requirements

The screening equipment shall comply with the following requirements:

Estimated water flow rate capacity 8 m3/h
Material Stainless Steel 304
Slot Width 0.5 mm

b. Equalization (If needed is additional)

A concrete balance tank will be constructed to collect the influent wastewater
with high COD characteristics to provide a consistent and uniform load for the
treatment process.
The balance tank will have a volume of 50 m3. A submersible mixer will be
installed to keep the contents of the tank in homogenous condition. A feed
pump will be used to deliver the water at a constant rate through the
flocculation unit and dissolved air flotation unit.
1.2 Modification of Existing Aerobic Treatment System

a. Replacement of fine bubble diffuser system from “Fixed” to “Lift

able”.
It is preferred to use tubular / flexible sheath diffusers instead of dome, disc
type diffusers.
The diffuser shall be sectionalized into 2 – 3 sections and with provision of a
lifting device for maintenance & repair purposes.

b. Relocation of existing MBR from aeration tank to separate MBR

tank.
Two (2) MBR tanks will be constructed to store two (2) sets of (3 x 3) module
set. Volume of tank shall be sized based on 9m³/hr* MBR capacity.
Existing MBR submerged shall be cleaned internally & externally before
transferring to new MBR tanks. Spare MBR modules shall be used as the 2nd
set or back up.

c. Nitrogen & Phosphorous removal

Both NDC and BBI effluent contain high levels of nitrogen and phosphorus,
which are converted to ammonia and phosphates during anaerobic digestion.
It is for the supplier to propose to NPI suitable removal processes which are
both economical & requires minimal modification of existing installation. – Pre
/ post anoxic tanks for Nitrogen removal), Chemical dosing after MBR for
Phosphate removal.

1.3 Anaerobic Treatment

a. Completely Stirred Reactor Tank (CSRT)

High COD waste stream with COD – 40,000 mg/L @ 480 m³/hr shall be
separated from other streams and will be pumped directly to an anaerobic
reactor tank. This should reduce load to existing biological treatment system
(DAF – Aeration tank – MBR). Volume of the proposed reactor shall be sized
by supplier based on influent characteristics, required retention time (3-4
days) & standard effluent parameters. (Mesophilic process is preferred
compared to thermophilic to produce sludge which is more stable & less
sensitive to load variations & temperature fluctuations.
b. Dissolved Gas Floatation Unit (DGF)
Treated high COD waste in the anaerobic reactor shall flow through a DGF to
further separate secondary sludge from resulting effluent. The proposed DGF
shall use part of the produced biogas to maintain the anaerobic process
instead of atmospheric air. The resulting effluent (low COD) shall be treated
further through the aerobic process.

As required by this URS. The effluent quality shall comply with the
parameters with the future DAO 35 amendment & NER requirements (See
Table 3).

c. Dewatering System
Based on process design, an additional dewatering system shall be installed
if needed to separate final sludge produced from the dissolved gas floatation
unit.

1.4 Electrical Panel and Controls

The waste water system electrical requirements includes power for the panel board that
supplies power for the instrumentation & controls and motors for the blowers & pumps.

Table 5 – Electrical, Instrumentation & Controls Requirements

Electrical / Automation Parameters / Brand

Voltage 460AC, 3ø, 60Hz
Circuit Breakers ABB, Schneider
Motor Controllers Schneider, Tesys
VFD Danfoss
Soft Starters Danfoss

Controls

Programmable Logic Control (PLC) Allen Bradley

Human Machine Interface Wonderware
Instruments Rosemount, E+H
The data is presented on a human-machine interface system. The system allows remote
switching on or off for each component of the system. System startup will be done
manual for each.

1.5 Equipment Installation and Commissioning

Local installation works to be quoted separately if applicable. Equipment

supplier need to include supervision and commissioning works with the
supply of the equipment if they will not be quoting for the installation work.
The wastewater treatment system equipment installation and
commissioning includes the supply of all materials, labor, consumables,
tools and supervision necessary to install all the equipment as listed and
specified. The components and equipment shall be properly integrated
into one system, commissioned and tested to verify and confirm the
capacity requirement.
The entire work will have to meet all the requirements based on the
Philippine government permits and legal system. The work
implementation must follow the rules, regulations and policies of Nestlé
Philippines and the park rules and regulations of First Philippine Industrial
Park.
The installation work shall consider the following:
Contractor to carefully check and become familiar with the architectural,
structural, electrical, and mechanical drawings including details and take
note of all locations where walls, partitions, ceilings, structural members,
etc. are called for to be furred or closed in
Detailed installation drawings of the piping and equipment for approval
prior to actual installation works based on the Nestlé supplied industrial
services building and equipment layout
Layout drawings in general are made to scale. In order to clarify the work,
however, some of the piping may be shown on the drawings slightly out of
scale, in which case sufficient dimensions are given to indicate the
desired arrangement. The Contractor shall use figured dimensions and
grades, where given. All dimensions, whether figured, shall be checked in
the field by the contractor before final connections are fabricated. Do not
scale drawings.
Drawings for small bore piping are in general diagrammatic and the exact
location of these lines shall be determined by the contractor from field
measurements taken by him. The actual arrangement of the small size
piping, when erected, shall follow the general locations shown on the
drawings as far as practicable. The installation made in this way shall be
neat in appearance and convenient to operate, and shall provide for
proper expansion and drainage.
Installation of piping and equipment shall be coordinated with other works
to avoid blocking building openings, light fixtures etc. Piping shall not
interfere with access to valves or equipment and shall not obstruct
passageways.
Modifications to the design of the systems may be required to suit
structural conditions or to avoid interference with the work of other trades.
Contractor shall furnish all offsets, additional detail fittings, etc., as
required to meet the installation conditions whether detailed on the plans
or not
All bracket designs to be submitted with detailed drawings for approval
prior to fabrication and installation
Welding of pipe supports that are welded to the pipe directly shall
conform to the same requirements as for the pipe connection
All welding for the pipe or duct support shall conform to the standards of
the AWS (American Welding Society)
Welding electrodes to be used shall be of E70xx series
All supports shall be properly leveled and plumbed. Shims and wedges
may be employed for leveling and alignment of the supports
Supports permitting pipe movement shall be assembled to allow the
necessary movement of pipes as caused by thermal expansion and
contraction in accordance with the piping drawing
All materials to be used should be new (unused) and free of defects and
imperfections
Full lengths of pipes are used whenever possible. Short lengths of pipe
with couplings are not permitted
All welding procedures and welders shall be qualified in compliance with
the ASME code for pressure piping B31.1
Butt-welds made in the effective straight run of pipe, both up and
downstream of any measuring device, are ground flush with the inside
pipe diameter. The ground joints are inspected and approved by
Nestlé field representative prior to further fabrication or installation
All pipe ends are squared and smooth prior to welding. All chamfering
shall be done by machining, grinding or flame cutting
Welding shall not be used to join dissimilar metals. All such joints shall
be flanged or threaded according to the Piping Material Class
Tack welds are to be made by qualified welders. Tack welds not
removed or shall be removed, are made with an electrode of the same
or equivalent electrode as the first pass. Tack welds that have cracked
shall be removed
All components (pipes, fittings, flanges and valves) are fitted up and
restrained to ensure that root gap is maintained at a clearance of
3.0mm to 4.0mm for steel butt welded ends and 1.2 mm to 2.0mm for
stainless steel joints
Branch pipe reinforcement welding joint has a minimum throat fillet
weld equal to the thickness of the thinner materials being joined
The inside diameter of piping components to be joined are to be
aligned as accurately as is practicable within existing tolerances of
diameters, wall thickness, and out of roundness. Where internal
misalignment exceeds 2mm (1/16”), the component with the wall
extending internally will be internally trimmed to flush the adjoining
internal surfaces. However, the trimming should not result in piping
component wall thickness less than minimum design thickness and the
change in contour shall not exceed 30o
No welding shall be done if there is impingement of any rain or if wind
is strong
Special precautions are taken at all times during fabrication and
erection to prevent entrance of any foreign matter into piping or
equipment. Loose rust, slag, weld spatter, dirt, oil, grease or other
foreign substances are removed from interior surfaces prior to joining.
All surfaces for welding are cleaned to bright metal and free of paint,
oil, rust or other foreign matter for a distance of at least 2 times the
nominal diameter from the joint. After fabrication open ends of pipe
lines are capped or plugged to keep out dirt and other materials until
pipe lines are connected
Completed piping and metal ducting are cleaned with air, steam or
water flushed to satisfaction of Nestlé prior to final connection to the
equipment
All flange joints are made up perfectly square and tight with the bolt
holes aligned as to avoid bolt binding. Flanges are not to be aligned by
forcing or springing
Flanged joints are arranged so that it is not necessary to unduly strain
the associated pipe, duct or equipment to dismantle the joint
All bolt holes are fitted with locking washers and shall show a
minimum of two complete threads beyond the nut after tightening
During assembly, all bolts are coated with approved anti-seize
compound
Adequate space are provided around screwed joints for use of
appropriate tools for installation and maintenance works
Pressure and Temperature Gages shall be 6” face diameter end
connection, complete with thermo-well (for temperature gages) and SS
isolating ball valves (for pressure gages). Reading will be in metric
units
Unless otherwise shown on the drawings, all supply piping to
equipment including valves and strainers therein, will be installed at
line size. If a reduction is required at a pump or control valve, the
reducer shall be installed abutting the inlet and or outlet of the pumps
or valve
Piping are not to be covered until testing is completed
All pipes will be cut to exact measurement for installation without
forcing. After cutting, ends is to be reamed and cleaned to eliminate
foreign matter
Cutting or other weakening of the building structure to facilitate piping
installation will not be permitted
Any questionable information in the specifications, and drawings, shall
be called to the attention of the Nestle representative for clarification
before proceeding with fabrication or erection of the parts affected. If,
in the opinion of the contractor, any additional
detail drawings are necessary, the contractor shall prepare them at his
own expense, together with all Bill of Materials
After completion of installation works, a complete internal cleaning /
flushing is to be conducted on the pipeline and equipment
Supplier / contractor shall conduct hydrostatic pressure testing testing on
all pipe works and submit documentation to certify that all joints have
passed the test before turning over the completed system to Nestlé.
Supplier / contractor shall conduct plenum leak test to 1” water on all duct
works and submit documentation to certify that all joints have passed the
test before turning over the completed system to Nestlé.
All permits required for the installation and operation of the system to be
submitted to Nestlé prior to final payment of installation.

1.5 Owner (Nestlé) Supply Scope

Company supplied items or works shall be limited to the following:

Electrical power supply to the power or control panel
Utilities (compressed air, water, steam) supply to the system header
Other works specifically stated in a separate written agreement.

2 Project Stages and Milestones

2.1 Project Implementation Plan

Upon submission of bid proposal and prior to implementation, a detailed project

implementation plan, with timelines schedules and the critical project milestones, should
be submitted consistent with the time schedules set forth in the Nestlé industrial services
project concept.

This project plan will form the basis from which all future progress and acceptance
criteria will be measured. Any up-date and/or modifications on the project
implementation plan will have to be submitted to Nestlé project management for
agreement.

2.2 Project Status Report

The supplier will provide project status reports at agreed intervals covering schedules for
all parts of the project including, but not limited to:

Design data transfer between all parties and technical review meetings
Manufacturing, assembly and documentation
Factory Acceptance Tests (FAT)
Shipment & Transportation
Installation
Commissioning and Training
Performance Qualification

2.3 Project Coordination Meeting

Nestlé will regularly invite the supplier / contractor to participate in the Project
Coordination Meetings.
The project coordination meeting will be held to coordinate the development of
the project activities and highlight critical project milestones. Unforeseen technical
difficulties and problems that need decision and/or clarification would also be discussed
during the meeting.

3 Plant Facility, Location and Conditions

3.1 Plant site

The factory site location is situated inside First Philippine Industrial Park, Tanauan,
Batangas City.

The climate condition is generally typical of the area where the factory is situated.
Environmental conditions ranges from 30 ~ 35 to 22 ~ 26 with relative humidity of 71 to
85 % during the dry and wet seasons, respectively.

The area has a yearly precipitation level of 965 to 4,064 mm. It is located in a possible
earthquake zone area and the equipment and installation design should consider such
possibility in the design.

The electrical standard is 440 VAC, 3 phase at 60Hz for all power supply connections (±
10% fluctuations may occur). The control and lighting may use 220VAC, single phase at
60 Hz while PLC and instrumentation uses 24 VDC as standard.

The standard instrumentation electrical signals shall be 4 ~ 20 mA whereas pneumatic

signals uses 0.2 ~ 1 bar.

4 Safety Requirements

4.1 Basic safety requirements for equipment supply

As a minimum, Nestlé requires that the chiller system and its components follow the
standard safety requirements as required by pertinent codes and regulations.

For legal compliance, the Philippine Occupational Safety and Health (OSH) Standard
shall be the minimum reference and basis of the equipment supply for this project. Other
applicable international standards shall be clearly specified by the supplier and
communicated to Nestle Philippines, Inc. for approval

4.2 Additional safety requirements during installation

Additional safety requirements for the contractor / supplier during equipment installation
are outlined in the attached documents. Supplier / contractor should also identify any
additional risk and take measures to avoid or mitigate such hazards.
4.3 Noise level and Illumination

The noise level generated from the equipment during all operational modes should be
below that stated in the specification of the equipment as enumerated in section 1.
Sound absorbing materials or adaptation to be installed to meet requirement as
necessary.

Illumination level standard to be maintained in the building area will be 150 lumens.

4.4 Maximum chemical concentration in the machine surrounding

The system shall be designed in order to avoid chemicals exhaust in the machine
surroundings.

4.5 Safety risk warning and education

Places where there are identified risks have to be documented and highlighted during
the operator training.

Safety procedures and first aid to be included in the operators training.

4.6 Hot surfaces

Hot surfaces have to be identified and marked. Protections should be installed to avoid
direct contact whenever possible.

4.7 Accessibility

All parts that need interventions from operators, maintenance personnel, and instrument
calibration technicians or identified points for performance validation must be easily
accessible without special means

4.8 Moving parts

All moving parts have to be identified and marked. Protections should be installed to
avoid direct contact whenever possible.

4.9 Emergency switches

All emergency switches to be located for best protection to the operating and
maintenance personnel. Correct location to be discussed in coordination with the
electrical and operating department.
4.10 Lubrication systems leakage (motors, drives etc.)

Equipments should have no leaks (based on maintenance inspection) for people and
environmental safety.

4.11 Safety and Work Place Job Hazard Analysis

The supplier / contractor may be requested to assist in the study to identify all hazards
and risks in the operation and maintenance of the system

4.12 Lock-out Tag-out Requirement

Process equipment supplied shall be assessed for Lock Out Tag Out compliance. This
shall cover all energy sources such as electrical energy, potential energy, thermal
energy and mechanical energy.

All electrical & instrument panel doors shall be provided with proper and adequate lock
out devices such as standard hasps as shown below.

All circuit breakers shall be equipped with the miniature circuit breaker lock outs to
ensure that no accidental powering of the circuit breakers can executed
All isolation valves (manual or pneumatically actuated) of any type shall be LOTO
compliant.

4.13 Personal Protective Equipment (PPE) Requirement

Equipment suppliers / contractors after identifying the underlying hazards and risk
incorporated in their activities such as site visits and inspections, equipment delivery and
commissioning works and others shall identifying the personal protection equipment
required to reduce the result or impact of any hazards or risks when it happens.

As a minimum PPE requirement, hard hats, safety shoes, ear muffs or earplugs, working
gloves, goggles & face shields, body harness and lanyards of specific length, working
clothes.

All PPE shall be free from any signs of defects/damages and must strictly comply with
any international standards.

5 Documentation

5.2 Documentation set

As a minimum, the supplier is required to deliver a documentation set in English

language (2 copies) and one updated electronic copy:

Footprint Drawings of Equipment and its Parts

Mechanical and Equipment Layout Drawings
Motor List
As- built Drawings, Design and Calculations
P&ID: Flow sheet
List of input / output for PLC
3 sets - Operation manual (OM) and standard operation procedures
(SOPs) for start-up, operational parameters, operational
procedures, changeover, cleaning in (English language)
Trouble shooting manual
Automation programs with back-up file
Functional Description
Utility List Requirements
Cable List
Field Wiring Drawing
Commissioning Documents
Electrical drawings (EPLAN Version 5)
Inspection certificates
Maintenance Manual including preventive maintenance
Spare parts list grouped by sub assembly, spare parts named by
manufacturers, recommendation for minimal spare part stock (incl.
Price indication)
Consumable parts grouped by sub assembly
Training documentation
Safety manuals and safety sheets (chemical products)
Calibration certificates
CE-certificates, Specification about pressure and temperature
authorization tests. The CE conformity documents for the units and main
components are to be delivered with the operation documents. Particular
attention is required to achieve conformity with the latest EC machine
safety standard
Validation Documentation
Hazardous risk analysis
Electrical diagrams
All utilities connection points and connection specification
Nameplate to shows data for the unit and components and should include
manufacturer, flow, volume, pressure, main materials, power
Assembly drawings
Operation Log
Machine parameters and history
Alarm lists, description, including explanation of cause and results
All utilities connection points and connection specifications
Mechanical installation and operating permit from the city or municipality
and the Department of Labor and Employment

5.3 Certificates

The following certificates shall be included in the submittals of the equipment supplier:

Hydrostatic pressure testing and certifications

NSF/FDA certificates for lubricants and gaskets
Equipment Certification
Pressure Vessel Certification
5.4 Documentation required at the quotation stage

In addition to the standard documents the following documents have to be provided at

the quotation stage:

Brochures and catalogue of the specified equipment and its auxiliaries

Detailed dimensions of the main equipment and auxiliaries including
Autocad copy of all equipments to be supplied
Piping and Instrument Diagrams (P&ID’s) for the system and with
indication of battery limits of supply
Schedule of manufacturing, transport, installation, start-up
Specific requirements from the supplier on room and / or environment
have to be provided before placing order
Spare part list for 1year complete with quotation

5.5 Change Control Documentation

Change control documentation has to be in place during the installation and start-up and
commissioning phase in order to keep the documentation up-dated.
6 Training for operators, mechanics and electricians

The following forms part of the supply for the chiller system monitoring and control:

Supplier expenses for travel, accommodation, meals, etc. of its trainer

Training files and documentation in English
Training fees, if applicable
Theoretical training requirements will be included in the quote

The training will take place during the whole commissioning and validation phase. A
separate formal training session will be conducted after the commissioning of the
system.

The training program and schedule in the Supplier premises and /or on factiory site shall
be agreed between Nestlé and the Supplier.

Note: Nestlé Participant’s accommodation and travel costs are excluded.

7 System Acceptance and Testing

The qualification protocols and process to validate the work according to Nestlé
standards must be agreed and signed off by both parties.

7.2 Detailed Engineering

The detailed engineering includes all the standard equipment drawings, detailed
installation drawings including piping and ducting connection and support details, and
electrical power and control diagrams.

The supplier should submit the detailed drawings for approval by Nestlé prior to starting
installation work.

7.3 Inspection and checking of installation equipments

Prior to start of installation work at the site, all equipment of the contractor has to be
submitted to the safety officer for inspection. Only equipment declared safe are allowed
for use in the installation work inside the work site. Periodic checking will be conducted
at the discretion of the safety officer to determine their maintenance condition.

Inspection is done mainly to check electrical insulation, internal troubles

of the machines, lubrication, and electric current of the machines
Inspection is also done for the Electric Cables, Switches and Connections
of the machines
All machines shall be labeled and numbered for quantity and quality
control purpose and should be recorded in a list (periodically updated)
showing the locations and conditions of the welding machines being used
If it becomes necessary to move the equipment to another place or
temporarily install replacement machines, it must be reported to the
owner to receive his instructions
Location of each machine and their power supply panel to be connected
with them shall be decided in consultation with the project team to prevent
disturbance with other work as well as to prevent overloading of the main
panels, cables and electrical power sources
Portable power cables shall be carefully examined and repaired daily
prior to each use

7.4 Qualification of Welders

All welding on piping shall be carried out by suitably qualified welders, with recent similar
experience, who have passed an approved qualification test within one month of
commencing work.
Owner reserves the right to reject any welder, if in its opinion or by its third party
representative’s, does not have suitable qualifications, experience or competence for the
required work.

Certificates are given by the inspection engineer or instructor to welders who have
passed the qualification test. All welders should keep these certificates with them during
the welding work. Upon request of the owner or third party representative, they should
show said their certificates to him.

7.5 Post Installation Testing

The contractor shall take full responsibility for arranging and executing all testing in
accordance with their installation and the interpretation of the results, including all costs
and for ensuring that the appropriate inspectors are present to witness the tests

At least one (1) working day notice in writing shall be given to the owner or third party
representative of test to be done on any part of the piping system or equipment
commissioning on site. Where such notice is not given, the company shall have the right
to request that the tests be repeated at the contractor expense.

While the interpretation of the test results is the contractor responsibility, the owner
reserves the right to have the results interpreted by a third party at contractors own
expense. If this occurs, the contractor shall provide at no cost, all films and other
information taken during such tests. If there is a conflict in the interpretation, the owner
shall have the option to accept either interpretation or request a re-test.

After completion of the fabrication and installation works in the area and prior to pressure
test, line inspection checks will be carried out for all works to assure that works have
been performed properly and that quality of work is adequate.

Line Checks:

Piping and equipment layout is in accordance with the applicable

drawings including Piping & Instrumentation Diagrams
Sizes, dimensions, ratings, and material specifications are in accordance
with the applicable drawings and specifications
Bend, tee, reducer and other fittings are in accordance with the applicable
drawings and specifications
Drainage, vents, header and other components are in accordance with
applicable drawings
Valve, flange, blind, etc. are in accordance with applicable drawings, and
flange connection is properly made with correct use of bolts and gasket.
Crack in tack welds, welding slag on inter-passes, welding current
conditions, and finish after back chipping shall be checked
Bead appearance, under-cut, overlap, spatter, crater, reinforcement of
weldment and size of fillet weld shall be checked
Dimensions and orientation of spool assembly, and installed spool and/or
piping components shall be checked with the piping drawings
Width of root space, bevel angle and alignment of components on each
joint fitted up
Surfaces to be welded shall be checked to assure that they are clean and
free from foreign material such as grease, oil, paint, scale, galvanizing or
other for a distance of at least 25mm from the bevel ends
Orientation and direction of piping components are in compliance with
piping drawings.
Tightness and projection of flange bolts are adequate.
Thread connections are not damaged and free from weld spatter, slag,
etc.
All shipping and erection stoppers, welding jigs and temporary support
attachments are removed.
Welding quality and other workmanship complies with applicable
specifications.
Applicable examination or inspection and the heat treatment has been
satisfactorily completed and accepted.
All pipe supports such as anchors for guided points, bands, hangers are
to permit free expansion and contraction of piping in the specified
direction, and are assembled as indicated on support drawings
Enough and adequate supports are provided wherever necessary, to
keep the piping stable.

Radiographic Testing:

A minimum of 10% of the piping welds shall be X-ray tested at the

owner's direction. Each test must be of the complete pipe weld and paid
for by the contractor
If any weld joint fails during testing, the said weld joints shall be gouged
out, repaired and retested
The welds on each side of the failed weld shall also be tested
If any of the additionally tested welds fail, the above procedure shall be
repeated for the failed welds and adjacent welds
Welds or portion of welds that leak upon hydrostatic testing and which
have not been tested by X-ray previous to the test, shall be X-ray’d at the
affected areas before they are cut out and repaired. Such radiography,
repair and re-radiography shall be at contractor expense.
Where the owner agrees that effective radiographic interpretation is not
possible one of the following methods of inspection shall be employed:
 Wet magnetic particle method
 Liquid penetrant method
 Ultrasonic test method.
Test certificates shall be supplied for all X-ray or similar tests done.

Hydrostatic Testing:

The hydrostatic test pressure to be used for each line is internal pressure
service shall be not less than 1.5 times the design pressure. Pressure
shall be maintained for a minimum of 30 minutes
Pressure tests shall be performed in the presence of the owner or third
party representative.
Test media shall be water except that plant air, instrument air, atomizing
air and other lines designated by the owner or third party representative
may be pneumatically tested.
No insulation shall be made before testing, If insulation is applied before
testing, all welds and screwed connections shall be left exposed until
testing is completed
Piping system shall be fully pressure tested not only for field fabricated
piping but also for shop fabricated piping.

7.6 System Acceptance Test

When all prerequisites are completed, a system acceptance test is conducted to include
the following:

I / O tests done / documented after installation

Calibration of instrumentations
Safety function checks
Operation trial
Monitoring of performance and efficiency during regular runs for 2 months
(24/7 attendance)
Monitoring of actual chilled water supply temperature
Joint inspection for completion of punch list of works

7.7 How to handle deviations during testing

Deviations identified during the testing, validation and commissioning phases have to be
documented in reports and follow-up actions defined in an action-list.
8 Commercial Bid Proposal

All suppliers must follow and fill-up the below bid proposal and quotation:

Description of Supply Quantity Unit Unit Cost Total Cost

Equipment Supply
1.
1.1
1.2
2
2.1
.......
Spareparts Cost

Commssioning

Or

Bid Template.xls

Sealed bids must be sent to:

Nestle Philippines Inc.

Tanauan Factory
Attn: Jan Tenk / Louie Chow
Project Name: Tanauan Factory WWTP Upgrade