11050146-CM-PRO-000-5017_RA

WARA PRESSURE MAINTENANCE PROJECT

COMMISSIONING PROCEDURE

Class 1 Doc. No. : 11050146-CM-PRO-000-5017 Rev.A of 63

REVISION SUMMARY

REV. DATE DESCRIPTION PAGE

A 22 Nov. 2013 Issued for Approval




TABLE OF CONTENTS

1. COMMISSIONING PHILOSOPHY .................................................................................................. 4

1.1 EXECUTION PLAN FOR THE COMMISSIONING PROGRAM ............................................................... 4

2. COMMISSIONING ORGANIZATION............................................................................................... 5

3. COMMISSIONING SCHEDULES ................................................................................................... 5

3.1 COMPLETION PROGRAM ............................................................................................................ 5

3.2 COMMISSIONING ....................................................................................................................... 7

3.3 COMMISSIONING EXECUTION ..................................................................................................... 8

3.4 TESTING OF ROTATING EQUIPMENT ............................................................................................ 9

3.5 TIGHTNESS TESTS .................................................................................................................. 13

3.6 INSTRUMENTS AND SAFETY CONTROL ...................................................................................... 14

3.7 OPERATIONAL FUNCTION TEST ................................................................................................ 14

3.8 PREPARATION FOR START-UP .................................................................................................. 16

3.9 CONSTRUCTION COMPLETION (CC) AND READY FOR COMMISSIONING (RFC)................................ 20

3.10 AFTER CONSTRUCTION COMPLETION (CC) ................................................................................ 20

4. SYSTEM COMPLETION PRIORITIES .......................................................................................... 22

4.1 EARLY ACCEPTANCE UTILITIES ................................................................................................ 22

4.2 SUPPORTING FACILITIES (TANKAGE & UTILITIES) ...................................................................... 22

4.3 PROCESS FACILITIES .............................................................................................................. 22

5. EXECUTION PLAN ....................................................................................................................... 22

5.1 HOME OFFICE PLANNING & PREPARATION PHASE ..................................................................... 22

5.2 SITE COMMISSIONING PHASE ................................................................................................... 26

5.3 SYSTEM TURNOVER ................................................................................................................ 27

5.4 COORDINATION ...................................................................................................................... 29

6. HEALTH SAFETY & ENVIRONMENT (HSE) ................................................................................ 29

6.1 HOME OFFICE PREPARATION ................................................................................................... 29

6.2 COMMISSIONING SITE SAFETY ................................................................................................. 29

6.3 ENVIRONMENT & HARMFUL EMISSIONS .................................................................................... 30

7. ATTACHMENTS............................................................................................................................ 31

ATTACHMENT 1: TABLE–SPLIT OF WORK FOR CONSTRUCTION, PRE-COMM. & COMMISSIONING ............. 32

ATTACHMENT 2: PRE-COMMISSIONING/COMMISSIONING ORGANIZATION .............................................. 63




1. COMMISSIONING PHILOSOPHY

A successful Commissioning for WARA PRESSURE MAINTENANCE PROJECT will require attention to

detail and close coordination between COMPANY and CONTRACTOR to successfully produce a safe

and reliable operating facility on schedule.

CONTRACTOR’s approach to a successful Commissioning for WARA PRESSURE MAINTENANCE

PROJECT is based on the fully integrated involvement of all concerned parties in all aspects, and in

each phase, of the project as described below.

This assures that all parties are fully familiar with their respective duties, are fully informed and trained

to safely carry out their duties and fully supported by the Team for the successful Start-up and operation

of WARA PRESSURE MAINTENANCE PROJECT.

CONTRACTOR will make use of the most experienced and specialized personnel in the execution of

the Commissioning.

Key members of this Team will be assigned as early as possible during the Engineering Stage and

preparations for the following work.

Establish an Organization.

Develop schedules and progress measurement tools for commissioning phases of the works.

Be responsible for the management and direction of all vendor representatives, specialists and

technical service providers

Manage, supervise, direct and control the Commissioning activities for the safe and assist

operation and test activities of the facility for successful turnover to COMPANY

1.1 Execution Plan for the Commissioning Program

The Commissioning program plan is a two distinct-phased approach to Commissioning – the Initial

Home Office Planning & Preparation phase and the Site execution phase which is defined as follows:

Phase-1 of the Commissioning program plan will be conducted / developed in CONTRACTOR’s home

office and will include, but not be limited to, the following activities:

Coordination with Engineering and Precommissioning on Commissioning requirement

Development of site specific Commissioning administrative and technical procedures

Incorporation of COMPANY procedures and testing requirements

Preliminary Operations and Maintenance Manuals of the area not provided by Licensor will be

prepared by process design team for review by COMPANY.

Preparation of "Scoped" drawings / databases for turnover package development

Development of Commissioning schedule with input from COMPANY’s project management

Development of the budget for all Commissioning activities.

Phase -2 of the Commissioning program plan will be conducted on-site and will include, but not be

limited to, the following activities:

Mobilization of the Commissioning Team

Administration system turnovers from Precommissioning to Commissioning Team.

Coordinate with precommissioning the completion of system punch lists in preparation for

turnover to the Commissioning Team.

Coordinate and conduct the equipment and systems Commissioning testing program.

Administration systems turnover to COMPANY’s Commissioning Team.




2. COMMISSIONING ORGANIZATION

CONTRACTOR will provide Commissioning personnel in the applicable disciplines as needed with

extensive experience to complete specified / identified Commissioning activities.

Commissioning Manager will have overall responsibility for coordination of all project Commissioning

activities. Commissioning Manager reports directly to the Site Manager and to the Project Manager.

The discipline test engineers, equipment vendor representatives, precommissioning craft, contract

support and Contractor’s Commissioning personnel assisting in the Commissioning effort will work

under the direction of the Commissioning Manager as a single Team.

Every effort will be made to maintain the continuity of all Commissioning Team members including

assigned support craft and COMPANY’s personnel throughout the duration of all Commissioning

activities. This continuity of personnel will aid greatly in the effectiveness and efficiency of the

Commissioning Team.

Refer to detailed Commissioning Organization.

3. COMMISSIONING SCHEDULES

The schedules for all Commissioning activities will be developed as early as possible at detail

engineering stage. This will include an overview of the sequencing of system preparations and the

critical path for these activities.

3.1 Completion Program

The completion of the facility, the preparation of the facility for operation, the Start-up of the facility

and the operation of the facility for proof of performance involves several steps or specific sets of

activities which are typically referred to as:

Facility Construction Completion (End of Pre-commissioning)

System Commissioning

Facility Initial Start Up

Facility Turnover (End of Commissioning)

Performance Test

Provisional Acceptance

Final Acceptance

These various steps, and the sequence of execution, are represented below:




CONTRACTOR is responsible for Construction, Pre-commissioning and Commissioning of the Facility

including test run. However, COMPANY’s operation team will work hand to hand, gaining experience

in plant Commissioning and Start up and ensure seamless transfer of responsibilities during take over

of the new facilities on completion of test run.

3.1.1 End of Pre-commissioning and Handover to Commissioning

End of Pre-commissioning is the 2nd

key step in the process of overall completion.

This is the stage where the basic pre-commissioning work has been completed and the pre-

commissioning quality control inspections and tests have been completed (and duly recorded) for all

the elements that make up a particular system within a unit or plant area.

This is attested by the various QA/QC Reports associated with each discipline and item of equipment.

These Tests and Records represent volumes of records and, in order to readily determine the status of

completion; these records shall be collated on a system- by -system or unit basis.

Pre-commissioning is achieved when the pre-commissioning work for a defined scope of piping,

electrical, instrumentation, civil/structural facilities buildings, underground, structural steelwork, and

miscellaneous items have been completed.

CONTRACTOR remedy or resolve to the satisfaction of COMPANY all pre-commissioning punch list

items classified as needed before starting Commissioning.




3.2 Commissioning

As soon as a System has been pre-commissioned and completed in accordance with the Contract and

is in compliance with the Scope of Work (excluding such minor items as finishing of insulation and

painting, and other items not materially affecting the operation or safety of the System) and has

passed any tests required on that System, the system is on ready for Commissioning.

Commissioning is the term used for the final tests, inspections and checks carried out by the

commissioning team to confirm that the equipment and systems within the unit and plant are

precommissioned in accordance with the approved design and specifications and will function to

specified operational requirements.

It is at this stage that the final preparations, checks and line out of the equipment and plant

(commissioning of the particular items or systems) can be carried out in preparation for introduction of

hydrocarbons and start-up of the facilities.

CONTRACTOR will confirm to COMPANY that all commissioning activities have been successfully

carried out. This is reflected by the Commissioning Checklists and “Test Record” Sheets, which record

the action taken by the Commissioning Team in the preparation of the systems for Turn-over.

It is typically at this stage, having confirmed for COMPANY that all End of Commissioning activities

have been successfully completed, that Turnover Certification for the plant will be issued for

performance test..

3.2.1 Scope

Commissioning involves the preparation of systems to achieve ready for Performance test status. In

this phase between system end of commissioning and the commencement of Performance test, a

considerable amount of operation work is required. This Commissioning work is be carefully planned

and executed by CONTRACTOR in close consultation with COMPANY and Manufacturer

representatives.

Throughout the Commissioning phase the CONTRACTOR maintain and update the formalized system

punch list. At this time the punch list will record any material items which remain outstanding for

Turnover (Commissioning Completion) status, and any corrective work which has become evident

during commissioning.

On successful completion of all of the required Commissioning work, CONTRACTOR will notify

COMPANY a system is Turnover (Commissioning Completion).

Upon successful completion of Commissioning, CONTRACTOR will apply for Turnover Certificate,

signifies the end of the commissioning phase.




3.2.2 Commissioning Responsibilities

All tools and equipment, all consumable materials, fuels and all services necessary to complete

Commissioning shall be planned and furnished by CONTRACTOR.

Certain utilities, such as water and power may be sourced from COMPANY’s utility distribution system.

Demineralized(or potable) water for Commissioning flushing and dynamic testing shall be provided by

CONTRACTOR.

CONTRACTOR will organize testing and water use to minimize waste of water.

CONTRACTOR will provide the plant air and instrument air used during the Commissioning of

instruments.

3.3 Commissioning Execution

Detail and specific commissioning procedures will be prepared for the project and presented for

COMPANY’s review and approval.

The following Basic Guidelines are provided only as a “typical” guide to the commissioning activities

which are normally involved in the preparation of a plant for operation.

It is important to note that fixed procedures for the execution of every commissioning activity cannot

always be applied in the same manner in each and every case. This is due to the nature of the work

and conditions of the facility that can vary from case to case.

It is not practical to cover all possible contingencies or emergencies conditions. Therefore, some of

the procedures and operating conditions stated herein may be require modification to meet unusual or

emergency conditions.

The intent is to ensure that the quality and integrity of plant preparations is maintained; regardless of

procedural methods.

The purpose of the Commissioning Guidelines will be to familiarize COMPANY’s operation group with

some of the basic aspects of Commissioning activities.

Detail procedures specific to the individual systems and equipment items on this project will be

prepared prior to the beginning of commissioning for the project.

All COMPANY’s operating and operations maintenance personnel will become familiar with all details

of the Commissioning activities, and the function of all operating equipment, during the course of the

On-The-Job training that will be given as they participate in each of the following activities.

3.3.1 P&ID Checks

The following Check List Procedure is intended as a guide to operators to assist in P&ID checking.

However, it does not in anyway suggest that the P&ID check is limited to the following list.

It is essential when carrying out the P&ID check the very latest revisions of the P&ID are checked. It is

important that items on the Check List are clearly defined and the item number entered on the P&ID.

3.3.2 Check Procedure

When P&ID checks are being carried out, and the persons checking are unsure of the validity of any




item, they should immediately contact a member of the site engineering team. This will save future

confusion and help to speed up the P&ID check.

(a) List all items, e.g. temperature indicators, pressure indicators, etc. are not installed or

incomplete.

(b) Check instrument tag numbers to ensue the correct instrument is mounted in the correct

location, note any deviation.

(c) Note whether vents at high point or drains at low point are omitted.

(d) Note dead legs and question drainage, purging etc.

(e) Note any obvious materials faults, e.g. carbon steel bolts on stainless steel flanges.

(f) Check (note deviation) of orifice plate orientation and tag number.

(g) Note tapping point orientation.

(h) Note if in line strainers are in place, check tag numbers.

(i) Visually check (note deviation) piping runs for abnormality. Ensure exchangers, vessels etc.

process/utility piping is routed to the correct nozzle.

(j) Note installation of relief valves, check seals, bolts, gaskets and tag numbers.

(k) Note all safety items, trip hazards, head room hazards, missing gratings, manholes, fire

hazards, poor access to emergency equipment etc.

3.3.3 P&ID Check List Control

To ensure that P&ID check results are properly recorded and subsequently acted on the following

method is suggested;

(a) P&ID check teams to mark up the P&ID with a highlighter, line by line, to reflect which

portions of the system have been checked,

(b) Faulty items are given a check number, this number is marked on the P&ID and

corresponding number entered on the Check List with a description of the fault.

(c) Make two photocopies of the Check List.

(d) Make two copies of marked up P&ID.

(e) Attach Check List to P&ID.

(f) One copy of Check List and P&ID is used as the operations work copy.

(g) One copy of Check List and marked up P&ID is the operating master copy and is kept in the

central work area.

(h) The work copy is used for rechecking purposes. The status of all items is noted on the work

copy and find out entered into the master copy.

(i) One copy of Check List and marked up P&ID is transmitted to COMPANY’s team who will

inform Contractor of any further defective / missing items noted by the COMPANY’s team.

(j) Operations will recheck the items to ascertain whether or not the item has been corrected. If

not, a note is made in the Check List.

(k) When Contractor has acted on the items he will inform COMPANY that the work is complete.

3.3.4 Check completion of Pre-commissioning Activities

Please refer to the Pre-commissioning Procedures.

3.4 Testing of Rotating Equipment

Before start of test runs on rotating equipment, the following personnel should be informed.

(a) Commissioning and start-up team.




(b) COMPANY’s start-up rotating equipment engineers.

(c) COMPANY’s operation group.

(d) Vendor service engineer for package items

Contractor maintenance specialists will instruct COMPANY’s team on how to carry out the testing of

rotating equipment. They will keep a continuous watch on the rotating equipment and monitor

performance.

Where practical, machinery will be operated, performance tested and systems operated prior to start-

up of the Plant.

For package systems, Operational performance of instruments and systems will be carried out.

Instrument inspection and calibration must be completed prior to this run-in-period.

Before the actual test is carried out, all inspection requirements and preparations, inclusive of

manufacturer's vendor representative requirements must be completed.

Inspection on any item of running equipment that could involve personnel coming into contact with

moving parts requires the power supply to be isolated and locked off.

Any internal inspection of running equipment, which involves opening of parts, which may contain

pressure, requires the suction and discharge to be isolated and the casing vent to be opened.

The casing must be at atmospheric pressure before any attempt is made to open the equipment.

If there is any doubt as to the security of the isolation, then blind flanges should be installed on the

equipment side of the suction and discharge valves.

Equipment should be isolated using blinds if hydrocarbons are present in the system during the test

run.

3.4.1 Electric Motors

Electric motors will be subject to a no-load testing i.e.: the motor is uncoupled from the driven

equipment. During the no-load test, the following items should be recorded:

(a) Check direction of rotation.

(b) Motor vibration levels.

(c) Bearing temperatures.

(d) Abnormal noises

Using the subsequent test with the driven equipment connected to the electric motor the following

items are to be measured and recorded:

(a) Electric motor current.

(b) Motor vibration levels.

(c) Bearing temperatures.

(d) The start-up current, and time for fin fan motors.

3.4.2 Pump Test Run Preparation




The following steps will be taken for the Pump Test Run Preparation:

Pump suction line should be fully flushed before Test Run

(a) The pump should still be uncoupled from the driver.

(b) Install strainers with (20~40) mesh size temporary start-up screens before aligning pumps.

Mark all strainers and keep a list similar to the blind list, so as to prevent a 'lost' screen.

Connect the suction and discharge flanges to the pumps and simultaneously

(c) Remove pipe stresses.

(d) Connect the pump to the driver and check alignments (cold alignment check).

(e) Rotate the shaft manually to check for freedom of movement.

(f) When a test run with water has been planned, carefully isolate the loop system from the rest

of the sections. The water should be sufficient to fill the whole loop and provide sufficient

head available to the pumps.

(g) A final check should be carried out that correct lubricating oil and grease have been put into

the pump, and that the oil glass shows proper level.

(h) Open the suction valve.

(i) Check that the seal does not leak and that seal flushing and cooling water connections are

correctly made.

(j) Rotate the centrifugal pump shaft by hand to test for free rotation.

(k) Flush water from the pump drain and the suction drain to remove scale (if possible).

(l) Check that the coupling guard is secure.

(m) Start lube oil system (if applicable).

(n) Switch the pump on and off as a final check for correct shaft rotation.

(o) Ensure that the pump is liquid full.

3.4.3 Centrifugal Pump Test Run

During the pump test the following items should be checked:

(a) Bearing temperatures.

(b) Vibrations.

(c) Abnormal noises, noise levels.

(d) Pump discharge pressure at shut off head and normal flow (if possible).

(e) Leaks identified and listed for repair if not pulled up.

(f) A test sheet is to be completed.

(g) The test duration is for a minimum of 30 minutes (if applicable).

3.4.4 Positive Displacement Pump Test Run

During the Initial run, the following items must be confirmed or checked:

(a) Confirm the liquid has sufficient lubricating properties.

(b) Supply cooling water where necessary.

(c) Start the pump with open suction and discharge valve. Check the mechanical performance of

the pump and watch bearing temperature, if applicable.

(d) Check flushing supply to seals, if applicable.

(e) When discharge pressure drops, stop the pump, inspect and clean the strainer in the suction

line.

(f) Check for excessive vibration.

(g) Check motor amperage, if applicable.

(h) Check for noise levels in excess of specifications.




(i) Check pump for leaks.

(j) A test sheet is to be completed.

(k) The test duration should be for a minimum of 2 hours.

3.4.5 Centrifugal Compressor Test Run

Before test runs on Centrifugal Compressors are carried out, a detail plan of action must be reviewed

with the Vendor specialists to confirm readiness. The plan of action should consist of the following

elements, as a minimum:

(a) Vendor’s commissioning instructions for review

(b) Detailed schedule of action with actual dates and milestones reached.

(c) All individual equipment tests, lube oil pumps, motors, filters, etc. should be specified

separately. In general the criteria for testing and inspection to be described individually for

such equipment items.

(d) Tests of all auxiliary systems lube oil, seal oil and cooling water etc. should be included and

scheduled well in advance of compressor test run.

(e) Anti surge control system to be tested and line up checked.

(f) In case the test run is carried out with a medium different than the design process gas,

restrictions on speed, discharge temperatures, pressures, etc. should be clearly specified.

(g) The compressor test run should be scheduled at the end of the test run series of the driver

(steam/gas turbine): however, it is to be carried out as a separate activity.

(h) All test results should be recorded on specified test sheets that are part of the test program.

As a minimum, the following parameters should be included:

(a) Oil pressures, temperatures, flows.

(b) Gas pressures, temperatures, flows.

(c) Vibration signals (during start-up and at operating speed).

(d) Noise levels.

(e) Speeds.

(f) Driver operating data.

3.4.6 Reciprocating Compressor Start-Up Preparations

The following steps will be taken for the Compressor Start-Up Preparations:

(a) Check that the inlet filter and fine mesh screen element is installed and that there is no space

between the filter element and the filter casing.

(b) Check that correct lubricating oil has been put in the compressor and oil glass is full.

(c) Check that all lines are connected properly to the machine.

(d) Bar the crankshaft over for at least one revolution to make sure that all-moving parts of the

compressor run freely.

(e) Check that the shaft guard is installed.

(f) The lubricator settings should be in excess of normal operating settings. Remove suction and

discharge compression valves, if required.

3.4.7 Reciprocating Compressor Test Run

In case a test run on a gas that is different from the design process gas is carried out, specific




attention should be paid to restrictions on power demand and discharge temperatures. Restrictions

should be clearly specified in the procedure.

The plan of action should consist of the following elements,

(a) Operate the compressor on a start-up procedure while the lube oil pump operates for about

five minutes.

(b) After bringing the unit to a standstill, check all bearings and other friction parts for

temperature rise. If no excessive temperature is observed and once all items have been

verified on tightness, start the compressor again and let it run for available hours.

(c) Regular observations should be made during available hours.

(d) After the mechanical run-in period, the suction and discharge compression valves should be

refitted in their respective places and the compressor started again on no-load e.g.: by means

of the application of valve unloaders.

(e) Increase to full load gradually and run for specified period, unless observations indicate the

presence of a defect.

(f) Check the oil pressures and temperatures of all bearings and seals and check proper

functioning of lubricator regularly.

(g) Check the gas pressures and temperatures regularly.

(h) Check for any gas leakage, vibration of machine and piping.

(i) Check the automatic loading and unloading device, if installed, for smooth operation.

(j) Check for noise levels in excess of specified requirements.

(k) A test sheet is to be completed.

3.4.8 Air Cooler/Condenser Fan Test Run

A test run to be carried out with preferably all fans of the particular bank section simultaneously in

operation. The following checks will be made:

(a) Check for vibration levels on electric motor and one point of the structure.

(b) Record electric motor amperage.

(c) Check for abnormal noises.

(d) Check whether belt/pulley engagement is over the full width during operation.

(e) Check for abnormal structural vibrations or loose bolts during operation.

3.5 Tightness Tests

This is normally the final stage before inerting the Plant prior to the introduction of hydrocarbons.

Although the various items of equipment will be “boxed-up” and the piping system lined up for start-up

a final “tightness” or leak test must be carried out.

A tightness test is a final check for leaks before the inert/purging step and the introduction of

hazardous materials into the plant. It is essential when preplanning this stage that particular attention

is paid to pressure breaks in the various sections of the plant, in order to prevent damage to

equipment by over pressurizing.

A leak of hydrocarbons during start-up poses a safety risk. It can also prove costly. The opening of

equipment after the introduction of hydrocarbons will require gas freeing and will also cause delays.

The equipment has to be isolated, drained, depressurized and purged with nitrogen to remove the




contents. Then, after repairs are completed, the system is again tightness tested and purged with

nitrogen to remove the air. These delays can be costly.

The following procedure is recommended to ensure that the unit is absolutely tight. When correctly

done, the chances of equipment having to be opened for leak repairs later will be minimal.

Mark-up the system to be tested on the P&ID, highlighting any pressure breaks within the system and

the isolation points for the system. Isolate the system being tested at its extremities by block valves or

blinds, closing all vents and drains. Line up valves within system ready for test.

Where block valves are used for isolation, open a vent, drain, or instrument connection to atmosphere

downstream of block valve. This will allow checks to be made as to whether block valves are passing

and also prevent pressuring of downstream systems.

Tape flanges in the system if required and make a pinhole on the tape at the top, mark clearly the

location of the pinhole.

During the test, the system must be protected against over pressuring by putting in service safety relief

valves, which have been calibrated and set. In the event that the flare system is operational, the relief

valves should be installed with the exhaust turned to atmosphere.

Identify the instruments which will be used to monitor the pressure. Use of control room instruments to

monitor the pressure is encouraged at this time, as it proves the output of instrument systems.

Pressure should be monitored and ambient temperatures taken into account for reasonable pressure

losses due to ambient temperature reductions. It is useful to set the relevant DCS instruments

on ’trend’ to record pressure variations.

Pressurize the system in stages up to the defined pressure by using of plant/instrument air or nitrogen.

Ensure soap solution being used is compatible with all metal and gasket materials etc.

As each desired pressure step is reached, spray a small amount of soap solution on the point of the

joints. Formation of soap bubbles will indicate a leak.

When the required pressure is reached, shut off the main air/nitrogen supply and monitor the pressure

over a fixed period of time. The standard set depends on the process being tested.

3.6 Instruments And Safety Control

The objectives of the instrument section of the Start-Up Team are as follows:

(a) To confirm that the instruments and safeguarding systems function as designed.

(b) To confirm that the instruments installation is according to design standards.

(c) To confirm that the instrument documentation reflects the as built status of the Plant.

(d) To advise and assist Production on a smooth transition of Plant from Precommissioning to

Operational status.

3.7 Operational Function Test

Operational Function Testing is to be developed in conjunction with and COMPANY’s commissioning

team to prove the instrument and safety control systems and the associated operability of equipment.




Operational Function Testing is to include the following requirements:

(a) To prove the operation and calibration of each instrument loop from its process connection to

final element.

(b) To prove that for all input conditions, the corresponding output actions occur as designed.

(c) To ensure the integrity of all safeguarding of equipment.

(d) To ensure that all systems are fully commissioned and ready for Start-Up.

Operational Function Testing Documentation is to be developed as follows:

(a) Standard calibration sheets for all instruments incorporating an in-situ calibration procedure.

(b) Supporting documents such as loop diagrams, and/or, marked-up logic diagrams.

(c) A cover sheet for documentation approval.

In addition to the above, complex procedures shall include the following:

(a) A planning sheet showing test equipment and manpower required and involvement from

other disciplines.

(b) A summary sheet showing a list of all instrument tag numbers involved, supported with

drawing numbers.

(c) A functional description of the system.

(d) A detailed step-by-step test procedure typically in the form of an input test condition versus

output action matrix.

(e) A diagram showing any independent relationships between test procedures.

The Operational Function Testing is to be witnessed by the COMPANY to ensure that all testing is

correctly executed and report sheets made and signed by both parties. If necessary,

recommendations are to be made to improve or remedy problems discovered during testing. Testing is

to be conducted so as to demonstrate to Operations that the systems operate as designed.




SAFETY: During the commissioning phase, the instrument system and operation teams will work very

closely, as part of the plant may be under pressure, people will be working in different areas, etc. It is

important to stress that function testing of instruments may only be carried out under a Work Permit

System, in order to prevent accidental discharge of air, etc.

3.8 Preparation For Start-Up

3.8.1 Introduction

The final activities to make the unit ready for initial start-up are described in this section. These

activities include:

(a) Filter media in filters.

(b) Loading of chemicals.

(c) Installation of orifice plates.

(d) Removal of blinds.

(e) Nitrogen purge.

(f) Dry-out of lines and equipment.(if required)

3.8.2 Packing (Air Dryer)

Confirm that the correct height of packing is installed, that the different layers of stacked packing are

crossed in order that the joints are not in line, but there is an overlapping.

Support grids and retaining grids should also be checked.

3.8.3 Filter Media Filling

Before filter medias are loaded in filters, they must have been thoroughly cleaned. They should be free

of debris. No excessive rust should be present.

General guidelines for loading include:

(a) Check that all nozzles and supports in and outside are as specification (vessel drawing).

(b) Ensure that clearances between screen layers and screen and vessel walls have been

checked and adjusted to prevent filter media falling below the support grid.

(c) Inspect the filter media before loading to ensure that drums have not sustained damage in

shipping or storage at site.

(d) Do not load filter media or dryer desiccant in rainy or humid weather.

(e) Only break filter media drum shipping seals as required to steadily supply the loading

operation.

(f) Provide loading personnel working inside a vessel with suitable protective equipment, such

as dust or mesh air masks. Refer to supplier’s safety recommendations.

(g) Mark in the same way the specified height of the filter media layer.

(h) Use a hopper with flexible height for loading.

(i) The sock attachment should be long enough to distribute the material without free fall

Otherwise, filter media breakage could occur and too many fines will be produced.

(j) Fill up with specified supporting material until the first mark.

(k) Check the layer in the middle with a dipstick and ensure level is uniform




(l) Fill up with filter media until the second mark from the screen.

3.8.4 Loading Of Chemicals

Prior to loading of any chemicals, vessels and lines should have been thoroughly cleaned and all

equipment and upstream piping work should be free of rust and debris.

If any chemicals are prone to oxidation, the applicable vessel should be inert and isolated as soon as

possible after loading is complete.

Safety precautions and procedures must be strictly adhered to (safety equipment used) during all

handling and all loading of chemicals.

3.8.5 Installation Of Orifice Plates

Install instrument orifice plates and restriction orifices (R.O's) in accordance with data sheets and

P&ID.

(a) Instrument orifice plates and R.O's must not be installed before piping runs have been

thoroughly cleaned.

(b) Consult orifice data sheets to determine bore size, use P&ID to determine the direction of

flow and plate O.D. size.

(c) Maintain an installation record of orifice plates and restriction orifices, to facilitate control over

the installation of the plates and to serve as a reference should problems occur later.

(d) Record the following information in the documentation pack for hand-over to COMPANY:

• Date of installation.

• Plate tag number.

• Bore size.

• Line number.

• Signatures of witnesses for correct installation.

(e) All orifice plate to be installed with the inscription stamp on the upstream side of the tab.

(f) Flow orifice plates to have the counter sunk side facing downstream, except conical orifices

which have the counter sunk side facing upstream

(g) If vent holes in the orifice plate are specified, locate during installation top or bottom of the

pipe dependant on liquid or gas service.

3.8.6 Plant Blinds Check

Inspect all plant equipment and piping for the removal of test blinds. Make a Blind Control list of all

operational blinds and spectacle blinds that should be installed. Indicate their operational position

clearly.

Check that blinds and spectacle blinds are installed in correct positions ready for plant start-up. The

Blind Control list shall be checked and confirmed by the field operators or each shift.




3.8.7 O2 Freeing

Before hydrocarbons are introduced into the unit, the O2 content must be reduced to avoid an

explosive mixture being created. Nitrogen can be introduced by hose connections or with fixed

injection points, hoses are better connected at low points.

• Pressure up unit being purged with nitrogen to utility service pressure.

• Then depress as rapidly as possible. Carry out this procedure three more times

• Ensuring that you purge out all high point vents and low point drains.

• Commence checking O2 content at several points to ensure the whole unit is virtually O2 free.

• Continue pressure purging with nitrogen until O2 content of less than 2 % vol. is achieved.

• The unit should be left under a slight positive pressure of nitrogen until the introduction of

hydrocarbons during normal startup.

NOTE: No entry into equipment permitted after introduction of nitrogen. After this step the flare header

and stack can be commissioned, if not already in operation.

3.8.8 Dry-out Of Lines And Equipment

Dry-out is necessary in Nitrogen Package units to avoid blocking lines and equipment by ice formation.

Drying out is finished when the water content measured with portable moisture analysis is at the levels

determined by vendor’s specification. Drying out of systems can be speeded up by using dry air during

commissioning and the use of nitrogen during the purging phase.

The early Commissioning work focus on a sequence of activities performed on individual systems.

Activities such as followings; these activities may be carried out in a simultaneous manner by

individual disciplines.

Air blowing

Water flushing

Leak test

Filter Media Loading

Piping reinstatement

Final instrumentation and electrical hook up

Vessel inspection and closure

Instrument loop / function tests

Preservation

During the stages of Commissioning, systems are combined to enable wider functionality checks to be

carried out, such as trial dynamic operation of pumps and compressors, containment / tightness

testing, flow route and flow rate testing, control sequence testing, process initiated trip tests, and

others.

The stages of Commissioning therefore require that several interfacing systems are brought to an

equivalent status to allow such testing to be carried out. At an appropriate point in the progress of

Commissioning, systems shall therefore be combined and integrated to enable multidiscipline dynamic

test activities to commence.




The tests may simultaneously involve many systems and supporting utility distribution systems.

Dynamic testing work is multidiscipline and sequential in nature, and CONTRACTOR will carefully plan

and prepare for the activities to ensure all systems, personnel and material are made available when

required.

After dynamic testing, all systems within a part of the Plant it is brought to an equivalent state of

readiness for commissioning operations to commence. CONTRACTOR will include for Manufacturer

specialists if required at site for Commissioning work and advice. This will include, but not limited to

the following:

Nut-shell Filter Package

Media Filter Package

Horizontal Induced Gas Floating Vessel(HIGF Vessel) Package

Air Compressors Package including operations

Chemical Dosing Package

Large multistage pumps

Critical Metering Systems

Safety Systems

High Voltage Switchgear

Uninterruptible Power Supply (UPS) system

Online Analyzers/Sampling system

Fire and gas monitoring system

Distributed Control System (DCS) and Safety Instrumented System (SIS)

Emergency Vent Systems

Critical HVAC

Vibration monitoring of rotating equipment

Flare

Throughout the Commissioning phase, CONTRACTOR provides evidence of the following:

Test, witness, and certification documentation.

Systems Package records.

All appropriate procedures and method statements.

All safety plans/permit to work/safety procedures.

Check sheets, record sheets and certificates or documents to support ready for Commissioning are

signed as complete by CONTRACTOR and witnessed by COMPANY. They also are recorded in the

System Manual.

3.8.9 Equipment and Process Dynamic Testing

Process and equipment dynamic testing have to be carried out during Commissioning in this Project.

These activities are to confirm, as much as possible, that equipment will be capable of safe and

secure operation when committed to the Start up sequence leading to operational service. Tests will

be conducted using relatively safe fluids (e.g. air, water, inert gas) to allow run-in and functionality

testing of individual equipment items and parts of the process. This functionality testing involves

activities such as followings;

Water circulation at pressure

Air circulation

Control system serviceability

Containment and valve integrity testing




Blow down and depressurization tests

CONTRACTOR will develop specific method statements for these activities and address issues of

area access and control, and the safety at interfaces. A safety risk analysis will be carried out prior to

commencing each activity. CONTRACTOR will arrange for Manufacturer specialists as appropriate to

direct, conduct or witness this dynamic testing, if required. CONTRACTOR will notify to COMPANY in

writing to start the dynamic testing in advance.

During this phase the Commissioning Team will confirm that the equipment and systems within the

unit and facility are pre-commissioned in accordance with the approved design and specifications and

will function to specified operational requirements. The Commissioning will be carried out in a system

base methodology.

At this stage the final preparations, checks and line out of the equipment and facility (Commissioning

of the particular items or systems) will be carried out in preparation for introduction of hydrocarbons

and start-up of the facilities.

3.9 Construction Completion (CC) and Ready For Commissioning (RFC)

Once the Pre-commissioning has been completed in accordance with the Contract and has passed

any tests required on that System, CONTRACTOR will notify the COMPANY in writing to issue the

certificate for “Construction Completion” (CC).

When CONTRACTOR submits a notice of system Construction Completion, There is a COMPANY

check of the following before agreement that the system is Construction Completion and then

COMPANY signs an accepted Construction Completion certificate for the system:

a) The resolved punch list for the system with all items required for Pre-commissioning is completed.

b) Check list of all pre-commissioning items for the system completed

c) Non-destructive Testing (NDT) records and QA/QC documentation for all Materials to confirm

checked/inspected/tested/calibrated to the requirements of the Project Standard and the

Subcontractor’s instructions and Standards for each separate System.

d) Confirmation of flow direction for all elements including control valves and flow elements.

e) Isolation and/or blinding are correct

f) Line by line check of system P&IDs

g) Rotational, alignment and other mechanical consideration are completed

Ready for Commissioning for a system is upon satisfactory completion of pre-commissioning activities,

Construction Completion Certificate, a system pre-commissioning review and a Certification of

Construction.

COMPANY’s approval of CC status will be governed by the effective administration, resolution of

outstanding punch list items, a system Commissioning plan and joint CONTRACTOR / COMPANY

safety review. All inspection instructions, witness and documentation for the system will be completed

and signed by COMPANY and CONTRACTOR as Construction Completion.

Commissioning safety review for a system (or joint CONTRACTOR / COMPANY safety review) will be

carried out based on PSSR (Pre Start up Safety Review) procedure.

Following Completion of Commissioning safety review, CONTRACTOR will commence the

Commissioning of the System.

3.10 After Construction Completion (CC)

After the Pre-commissioning Completion of a system/sub-system, the preparation of the facility for




operation, the Start-up of the facility and the operation of the facility for proof of performance involves

several steps or specific sets of activities which are typically referred to as:

System Commissioning

Facility Initial Start Up

Performance Test

Provisional Acceptance

3.10.1 System Base Commissioning Methodology

The tests to be carried out during Commissioning activities will be exhaustive, according to the

methodology described below. No equipment or part of the installation will be accepted without

associated check and tests prior to energization and Start-Up.

3.10.2 System Base Completion Approach

The checking and testing phase of a new facility is by necessity a relatively detailed and sophisticated

process. Not all parts of the facility reach the same degree of completion at the same time, hence

some areas or units may be mechanically completed while others are not. It would therefore be a

waste of time to wait for the whole facility to reach End of Pre-commissioning before starting

Commissioning activities.

The Commissioning activities can start even if all the Pre-commissioning activities are not completed,

provided that the system or subsystem concerned is in safe condition for doing the Commissioning

activities As examples, the Commissioning activities, such as Mechanical running test for the each

rotating equipment can start even if the Pre-commissioning of other piping or instrument portion in the

same system or subsystem are not completed, provided that the system or subsystem concerned is in

the safe condition for doing the Commissioning activities.

Since HVAC systems and Firefighting equipment inside/outside buildings are independent from the

process systems, these systems will be Pre-commissioned and Commissioned separately from the

process systems.

3.10.3 System / Subsystem definition

This specific partition of a facility into systems and subsystems for completions activities takes place

as early as possible, at Basic Engineering phase and will always be submitted for approval to the

COMPANY.

The partition of a facility is a key preparation activity that has a major impact on all aspects of

completion operation. The subsystems must be defined so as to be as independent as possible, not

too small, but of manageable size, and exactly adapted to the Start-Up sequence.

Refer to “11050146-CM-PRO-000-5013 System Definition Procedure” for system list.

3.10.4 Hand-Over Tool.

A software application tool, called, UNICCS (Unified Construction to Commissioning System),

CONTRACTOR In-house system, will be used as hand-over tool in order to cover the aspects of

project completion activities and to obtain a smooth transfer of the facilities from CONTRACTOR to

COMPANY, as quickly as possible and with the required safety.

The UNICCS functions are follows;




UNICCS is a database that tracks the completion progress of all tagged item, marked on the P&ID,

installed on the project.

Within UNICCS are links to the item which is fundamental to the requirements of inspection, test and

commissioning at each stage of the project.

Manage QC document

Manage Commissioning job check / Test sheet

Manage punch list

Handle output progress reports and the status

Import / Export data by using MS Excel.

4. SYSTEM COMPLETION PRIORITIES

In general, except Early Acceptance Utilities, the facilities will be commissioned and completed to the

following priorities to accommodate the staged Commissioning of the plant.

Testing and handover will be completed “system–by–system” (service-by service) basis.

4.1 Early Acceptance Utilities

Some specific facilities, requested by COMPANY, such as Utility Water, Site office complex,

interconnecting piping, interconnecting pipe racks will be available to run in advance until fixed

schedule.

4.2 Supporting Facilities (Tankage & Utilities)

The Utilities Systems will be commissioned and put onto service first and used for the Commissioning

and preparation of the rest of the plant. This generally applies to the water, air, nitrogen etc. services

required to prepare the other plants for operation.

The Commissioning of the Tankage Systems involves the final line up of the systems for introduction

of feedstock for start-up.

4.3 Process Facilities

The Commissioning and Start-up of the Process facilities involves a number of process steps, with the

primary operations/process procedures being outlined in the Operations Manuals.

A system comprises the equipment, piping and all support facilities within defined battery limit,

required for carrying out a specific function or service. The objective of defining systems and

subsystems is to facilitate sequential End of Precommissioning, Commissioning and Turnover to

COMPANY for Initial Start-up and Performance Test. System may comprise a verity of subsystems

such as mechanical items, piping, electrical and control systems.

5. EXECUTION PLAN

5.1 Home Office Planning & Preparation Phase

CONTRACTOR will commence the detail planning for the Commissioning of the facility.




This will include participation in the Process Safety Reviews, HAZOP Study and Constructability

Reviews to ensure that operational issues are fully anticipated in the design, construction and pre-

commissioning of the facility.

This involvement in the early basic design and engineering stage will assure the facility’s ability to be

properly commissioned and assist the Team in the development of the Commissioning Execution Plan.

During this initial stage, CONTRACTOR’s Commissioning Manager and his planning team will work

with COMPANY’s Commissioning Manager and Operating representative to commence basic planning

and development of the key execution tools. These Key Execution Tools include;

The basic Start-up Plan defining the sequential preparation and commissioning plan for the

primary processes, units and systems. This sets the overall priorities for Engineering,

Procurement and Commissioning.

The outline of the System Packages that will be used to define and record the completion and

readiness of the facilities for commencement of operations. These packages (or System

Dossiers) commence with the definition of the basic “systems” and “sub-systems” that will be

required for detailed planning for End of Pre-commissioning of the facilities.

Commencement of preparation of the Commissioning Procedures to be used for the specific

facility; in preparation for receipt of specific vendor and licensor data for the specific equipment

items and processes.




Commencement of preparation of the Operations Manuals that will include all data and

procedures necessary for the safe and efficient start-up and operation of the facility.

Detailed planning and preparation for Commissioning activities will start in CONTRACTOR’s Home

Office as early as possible at the Engineering stage.

5.1.1 Participation in Project Meeting & Design Input

CONTRACTOR's Commissioning Manager or his designee will attend daily / weekly engineering

meetings, as well as, regular project review meetings held by the Project Team during the home office

engineering phase of the project.

The Home Office phase will begin early in the design period of the project when key members of the

Commissioning Team will be on hand to input specific requirements for Commissioning and Start-up

procedures into the design phase.

CONTRACTOR's Commissioning Manager or his designee will participate in the Constructability,

Process Safety and HAZOP reviews if required with the other multi-discipline review Teams to ensure

that all operability and operations safety issues are addressed.

As the information becomes available, they will begin to review the basic process and utility system

designs with engineering and the design operating parameters for major equipment items and

packages.

5.1.2 Review of Project Drawing and Scope

During the engineering phase, the Commissioning Manager or his designee will review project

drawings for issues such as; system operability, lessons learned from previous projects to ensure

better productivity and system reliability, incorporation of Commissioning flushing connections (If

flushing is required), adequate system vents / drains and instrument taps for system Performance

Testing.

Electrical single lines and P&ID's will be used to "scope" the systems for development of turnover

packages. These scoped drawings will specifically define the system turnover boundaries for pre-

commissioning as bulk pre-commissioning finishes and the emphasis turns to system completion.

Once the system boundaries are finalized, the scoping boundaries will be included as a development

level in each electronically created drawing and maintained as the drawings are revised.

A turnover package numbering system will be developed during the scoping effort. The scoped

drawings will be assigned specific turnover package numbers for ease of identification. Engineering

databases, which are developed, will incorporate these specific turnover package numbers by adding

a turnover package number field to the database list.

These databases include the project's major equipment list, valve list, motor load list, instrument list,

cable and I/O lists. These lists will be sorted by turnover package number for inclusion into the

individual turnover packages. The combination of scoped drawings and the scoped databases will give

a detailed description of each system.

5.1.3 Development of Commissioning Documents

A detailed Commissioning strategy document will be developed for the COMPANY, which includes

execution plan for work at the project site with the first objective of optimizing the activities and

schedule of the Commissioning phase.




It will define the safe working practices, project site organization, responsibilities for the facilities and

the interfaces within the CONTRACTOR’s team, the phased MC and RFSU completion objectives by

system and Unit, the detailed method statements to be generated, and the completion documentation

to be prepared by CONTRACTOR.

The strategy document will also address the sequence and objectives of the Commissioning phase,

including outline manpower plans for operations, supervisory, safety, and maintenance functions and

technical support until the plant is released to COMPANY. CONTRACTOR will work closely with

COMPANY on these items.

Each system turnover from Pre-commissioning to Commissioning will be noted as a turnover

milestone activity to begin major testing for the specific system.

CONTRACTOR’s Commissioning Manager, in conjunction with COMPANY Operations, will develop,

revise and maintain the Commissioning schedule and will coordinate / schedule activities with

CONTRACTOR’s Project Scheduling Group to ensure timely Commissioning updates.

The Commissioning Schedule will identify, by system, the preferred sequence in which commissioning

should prepare and complete the scoped project systems. It will also identify walk-down dates for each

system, commissioning release dates by system, and specific Commissioning activities required to

test and pre-commission individual systems.

The schedule will include, and be used to track system turnover dates and Completion Plan showing,

individual commissioning target dates, Commissioning and RFSU targets and activities.

CONTRACTOR will develop a commissioning plan and performance test plan in close consultation

with COMPANY and ensure the commissioning and RFSU sequence for the Plant is consistent with

the Commissioning plan

The sequence and duration for commissioning work leading to RFSU of each system shall be

prepared in a system Completion Plan showing, individual commissioning target dates,

Commissioning and RFSU targets and activities. CONTRACTOR shall ensure the commissioning and

RFSU sequence for the Plant is consistent with the Commissioning plan.

5.1.4 Development of System Manuals

The Commissioning of the facilities will be carried out on a “system-by- system”.

Each operating facility, and the specific units involved, is divided into logical process and/or piping and

equipment “systems”.

A System Manual will be prepared for each system. COMPANY shall be furnished updated copy.

System Manual “CONTENTS” page will show the following minimum sections:

a.) System Name

b.) Contents Sheet (Index)

c.) System and Sub-system identification

d.) System summary sheet

The documentation in each System Manual record the inspection, checking and testing activities

required to achieve RFC and RFSU status.

The System 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 in

the System Manual.




5.1.5 System/Sub-System Division

CONTRACTOR will divide the Facility into system as a basic approach to Facility Commissioning

activities. Systems will be developed such that the individual systems can provide a practical, safe and

secure subdivision of the facilities on which to base completion.

The subdivision of the Facility into system provides a workable method to Schedule Commissioning

work according to a logical sequence of Commissioning and/or Commissioning activities;

Conduct Commissioning and/or Commissioning activities of some Facility systems while others

are still under pre-commissioning;

Complete the part on a system-by-system basis and in a systematic and controlled manner.

The approach takes full advantage of the fact that any given moment in the Facility, some areas (i.e.

systems) are already under Commissioning, while others are under construction or still under pre-

commissioning. The overall result of this approach is the earliest start-up date of the Facility as a

whole.

A defined subdivision of the Facility into system shall also be used by pre-commissioning staff as the

basis of its pressure test program (hydraulic, pneumatic).

Systems are first defined on the Facility P&I Diagrams; these are marked up using a clear

identification method to show each system and boundaries between systems and ensure that any

requirements for additional isolation for systems and operational areas will be included in the design.

5.2 Site Commissioning Phase

5.2.1 Site Mobilization Plan

Site mobilization of the Commissioning Team will occur to support system turnovers from pre-

commissioning and to ensure that subsequent testing will coincide with project schedule requirements.

Additional Commissioning Test Personnel will be scheduled onsite, as needed, until full staffing levels

are obtained.

The Commissioning Manager will relocate to site after completion of the home office planning and

preparations.

This plan will be developed at the beginning of site mobilization for Commissioning team considering

the actual progress of Commissioning activities and be reviewed with COMPANY’s Commissioning

Team.

5.2.2 Equipment Vendor Support Plan

Contractor will provide Vendor representatives for installation, Commissioning, and Commissioning

services. CONTRACTOR will advise the COMPANY Representative when Vendor representatives are

ready to mobilize to the Commissioning Site.

For all Vendor representatives providing Commissioning assistance and Training for Company

Employee before/after Mechanical Completion, CONTRACTOR will keep a daily time sheet for each

Vendor representative.

5.2.3 Punch Control Plan




Punch items are tasks not yet completed or tasks that do not meet project design and specifications

and can be related but not limited to

Equipment that is damaged, defective, inoperable, incomplete or not yet installed.

Any part of work, including documentation, which does not conform to project scope,

specifications, documentation, recognized engineering practices, relevant codes or statutory

requirements.

Any situation that can have HSE impact.

This Punch will not include any approved facility modification which has been implemented but not

reported on the master document, but incomplete facility modifications will be included on the Punch.

Punch list items will be categorized by priority as shown below.

A. Must be completed prior to Mechanical Completion

B. Must be completed prior to Start-up and Commissioning

C. Can be completed after Start-up but prior to Turnover

5.3 System Turnover

CONTRACTOR’s Commissioning Personnel will work with “COMPANY” prior to turnover of system to

assist Performance Test in the identification and correction of deficiencies that require resolution prior

to turnover.

Prior to the system turnover process will consist of system walk-downs by COMPANY’s

Commissioning personnel. The walk-down will result in the generation of a "System punch list". The

items on this list will be addressed by CONTRACTOR’s Commissioning Team and prior to system

turnover and acceptance by COMPANY’s Commissioning Team.

CONTRACTOR’s Commissioning Group will identify components or system activities / tests that will

be completed by commissioning prior to turnover.

As pre-commissioning progresses to the point of 65% ~ 70% of End of Precommissioning, where

various systems begin to reach mechanical, as well as, electrical completion, precommissioning

begins to switch over from a bulk pre-commissioning mode to a systems completion mode.

Turnover packages that define system boundaries using drawings and databases are developed and

issued to commissioning well in advance of the first scheduled system turnover dates.

The aim of the turnover packages is to provide commissioning with the necessary information to

complete systems or portions of systems (subsystems) in the required sequence for successful project

Commissioning.

Each turnover package will contain mechanical, electrical, and instrumentation components that

represent a usable part of a system or the entire system depending on system size.

As each of the system / subsystem packages near mechanical and electrical completion, the

Commissioning Team will coordinate with pre-commissioning to identify any deficiencies or incomplete

items that would prevent the orderly and systematic testing for the turnover package equipment.

The format, content, and detail of the Turnover Packages is usually defined through contract




definitions and requirements or can be discussed and agreed to in meetings during the EPC portion of

the project.

5.3.1 Turnover Documentation & Records

The following Commissioning documentation and records will be maintained by CONTRACTOR to

enable all parties to review the scope of the Commissioning works, the status of that work and the

confirmation that each element of the work has been satisfactorily completed.

5.3.2 System Manuals

The Commissioning of the facilities will be carried out on a “system-by-system” basis. Each operating

facility, and the specific units involved, is divided into logical process and /or piping and equipment

“systems”. These systems are generally defined by and incorporate equipment required for, a

particular service or portion of the operation.

5.3.3 Documentation for Commissioning

The following document related with Commissioning activities will be included in the system packages

(dossier) for each system.

Notification of Readiness for Commissioning

Commissioning “Punch” Status Report

Check Lists & Reports

Turnover Certificate Request

5.3.4 Commissioning QA/QC Records

The confirmation of completion of commissioning works suitable for Commissioning to commence is

represented by QA/QC Inspection Test Reports for the various elements of the facility. The records

are collated on a discipline basis for each area of the facility.

A QA/QC Status Register will be prepared that reflects the status of commissioning QA/QC

documentation relating to specific facility (by Unit) and systems (by Service).

CONTRACTOR’s QA/QC representatives will sign this Register as certification that the required items

have been completed and registered with COMPANY.

The QA/QC Status Register will be kept current and available for COMPANY and CONTRACTOR’s

Commissioning Team to confirm that all commissioning QA/QC releases have been made for a

particular facility or system prior to Start-up.

This Register will also reflect the issue status of all such QA/QC records such that COMPANY can

confirm readiness for Start-up.

5.3.5 Operating Manual

CONTRACTOR will prepare plant specific draft-operating manual of the unit. The Operating Manual

include procedure related with package items if any and will be submitted to COMPANY for review at

least 90 days prior to Commissioning.

Review of operating manuals shall be done by COMPANY within 30 days after receipt of draft

operating manuals. All the changes, additions, deletion required by the COMPANY will be discussed




with the CONTRACTOR and will be incorporated in the final operating manuals by the CONTRACTOR.

The 10(Ten) copies of final operating manual in English, (along with 1 CD of the same) will be

submitted to COMPANY. The manuals shall be submitted to COMPANY at least 60 days prior to

Commissioning.

5.4 Coordination

5.4.1 Correspondence with COMPANY

The Commissioning of the facilities will be carried out on a “system-by-system” basis.

As soon as a System has been pre-commissioned and completed for each Commissioning activities in

accordance with the Contract and has passed any tests required on that System, CONTRACTOR will

issue “Request for inspection” to notify the COMPANY in writing.

Company shall witness, finish his inspection and complete the Commissioning activities by sign off on

the relevant check sheet/test record sheet.

6. HEALTH SAFETY & ENVIRONMENT (HSE)

6.1 Home Office Preparation

All Commissioning activities are planned and implemented in accordance with the COMPANY and

Contractor’s HSE Guide Lines Procedure. Any accident or impairment to the health of personnel is

avoidable. Commissioning team shall maintain a safe working environment and ensure that injury and

harm to the health of personnel is mitigated.

6.2 Commissioning Site Safety

To meet the schedule & target, End of Pre-commissioning, Commissioning activities will have

schedule overlaps. Commissioning activities will begin early and will take place parallel with pre-

commissioning activities.

The management of hazards shall identify the possibilities of commissioning personnel being exposed

to hazards associated with the activities of the other. The potential for exposure to hazardous

situations increases with the large number of site personnel overlapping independent multiple work

phases.

Commissioning works is essentially the bridge activity between pre-commissioning and start-up. It

must directly interface with Facility Completion. Therefore, toolbox talks will have to be conducted prior

to starting any activity and will be repeated at each shift that will continue with the same activity to

ensure that the work force is familiar with the hazards involved:

Work scheduled to be carried out

Health, Safety, and Environmental requirements related to those activities

Familiar with the Incident Reporting System

6.2.1 Effective Communication

Effective communications is essential in conveying vital information to commissioning and operation




personnel for ensuring their safety and the efficiency of the project. All communication should be clear,

accurate, concise, and well planned to avoid ambiguities, confusion and/or misunderstandings.

Following methods for conveying the information should be utilized as applicable:

Commissioning meetings

Project site notices and placards

Banners and warning signs

Regular tool box talks

Handover log books and shift reports

Project daily progress reports

6.2.2 Isolations

During Commissioning activities, it is necessary to protect personnel from sources of energy

associated with the works by following a safe isolation procedure. Isolation procedures are designed to

protect the crew from unexpected energization, start-up, or release of energy, while working on

equipment or a unit.

Contractor will clear all equipment that will be affected by the equipment isolation. Cleaning of

equipment will be performed as outlines in unit/area specific procedure. Any chemicals or chemical

residual expected to be remaining in the equipment must be documented for each affected work

group.

6.2.3 Safe Use of Nitrogen

Nitrogen is used during Commissioning for leak check and inerting purposes. Nitrogen is an inert gas

that causes asphyxiation, if it is released in a space where it can lower the oxygen levels below

required to sustain life. The nitrogen hazards, consequences on uncontrolled release, protective

measures to be taken, shall be clearly specified in the procedures where nitrogen is used and shall be

discussed with working team prior to start using nitrogen at site.

6.3 Environment & Harmful Emissions

6.3.1 Piping Dewatering

Water used to test pipe work and the pipeline may contain chemical additives to prevent corrosion and

microbiological growth, if required, and where applicable a marker for leak detection. These fluids shall

be discharged in compliance with the Local Environmental Regulations and the Environmental

Management Plan. The medium selection shall take into consideration the environment and

compatibility with the final process fluids without compromising other testing criteria and requirements.

6.3.2 Venting and Flaring

Start-up procedures shall include provisions to minimize flaring and venting; however, flaring and

venting may occur as a result of testing and while bringing the facility up to specifications.

6.3.3 Waste Disposal

Waste disposal shall be in accordance with the COMPANY’s Waste Management guidelines and

wherever it is possible, the re-use or recycling of any solid or liquid waste shall be considered. The

commissioning manager, jointly with the COMPANY, will make a plan for the control of waste




generated during water flushing. The plan shall include permitting, means for storing and disposing

contaminated fluids and material.

6.3.4 Noise Management

Although every effort has been made in the design to minimize noise, the design still has to be tested

to ensure noise levels are within the acceptable range. The Commissioning Team shall make possible

recommendations for improvements, where noise levels do not meet the acceptance criteria. Potential

for excessive noise increases during Commissioning activities.

Therefore, Commissioning strategy shall be evaluated to minimize noise; e.g., consider the use of

water versus air blowing, or reducing the noise level by using silencers or other means. To minimize

the exposure against noise, air blowing will be considered to be done during night time or shift change

as possible.

The personal Noise Dose (a function of noise level and exposure time) shall not exceed 85 dB on a

continuous basis over an eight-hour day. Proper ear protection shall be worn in areas where the noise

level exceeds 85 dB.

7. ATTACHMENTS

Attachment 1: Table – Split of Work for Construction, Pre-commissioning and Commissioning

Attachment 2: Pre-Commissioning/Commissioning Organization




[텍스트 입력]

Attachment 1: Table–Split of Work for Construction, Pre-Comm. & Commissioning

Section Description

1. General

2. Electrical

3. Instrumentation

4. Buildings

5. Air Conditioning

6. Communications Equipment

7. Tie-ins to Existing Facilities

8. Safety & Fire Protection Equipment

9. Civil/Structural

10. Piping and Accessories

11. Flare System

12. Vessels

13. Columns

14. Tanks

15. Exchangers

16. Pumps

17. Compressors

18. Gas Turbines

19. Heaters

20. Miscellaneous

21. Chemicals

22. Package Units




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LEGEND:

Cy = Company, Ctr = Contractor,

X = Perform the work, A = Assist as required, W = Witness and sign off, R = Review and Approve, I =

Inspect and Approve.

1.0 GENERAL Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase

Ctr Cy Ctr Cy Ctr Cy

a) Obtain vendor assistance where necessary for

Mechanical Completion, Pre-commissioning and

Commissioning.

X X X

b) Obtain any permits and approvals from government and

regulatory agencies required in the name of the

Contractor.

X A X A

c) Make application to the Company for all necessary

permits issued in the Company’s name that are required

for the Work.

X R X R

d) Maintain an adequate vendor instruction file so that

information may be readily reviewed through the Work. X R X R X R

e) Transmit to the Company all ’As Built’ Records,

Operation and Maintenance Manuals, spare parts lists

and all other documentation required to obtain

Turnover.

X R

f) Remove all rust preventatives, oils, greases and paints

used to preserve equipment during transportation and

construction whenever these protective materials will be

detrimental to operation.

X W/I

g) Provide a list and the lubricants of Approved

Manufacturer recommended for use in the Facility.

X R

h) Prepare detailed flushing and testing procedures for the

specific systems.

X R

i) Flush systems and perform initial charge of all

lubricants. Dispose of all flushing oil in accordance with

the Company’s instructions.

X W/I

j) Maintain lubrication after initial charge to achieve Pre-

commissioning.

X




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1.0 GENERAL (Contd.) Construction

Phase

Pre-

commissionin

g

Phase

Commissioning

Phase

k) Remove all temporary supports, bracing or other foreign

objects that were installed in vessels, ducts, piping,

transformers, machinery, or other equipment to prevent

damage during shipment, storage, and erection and

repair any damage sustained.

X

l) Inspect and check Work during construction stage and

perform such non-operational test as are necessary to

assure the integrity of the installation in accordance with

the Issued for Construction drawings and specifications.

X W/I

m) Complete all necessary insulation, painting, grating,

fencing, paving, touch-up concrete and grouting, and

items of like nature.

X I X I

n) Make initial charge of non-production materials, such as

desiccants and transformer oil.

X W

o) Make check of lighting intensities in buildings and plant

areas in accordance with Project Specifications.

X W

p) Verify that the Work, or portion thereof, is complete and

that all required inspections, tests, reviews and

approvals are complete and recorded.

X R/I

q) Document all inspections, test and other

Precommissioning activities. Document all deficiencies

discovered during the course of the activities along with

corrective actions taken.

X R

r) Prepare punchlists, by system, of deficiencies between

as-built plant and latest P&ID, specifications and vendor

instructions. Correct deficiencies.

X R/I X R/I X R/I

s) Check all items of equipment for adequate, safe and

functional access per Project specifications.

X I

t) Provide, install, slip and/or remove all temporary and

permanent blinds and spectacle plates required to isolate new systems from existing systems.

X I X I

u) Thirty (30) days prior to expected Mechanical

Completion, the Contractor is to send a notification of impending Mechanical Completion to the Company.

X R

v) Completion of fire-proofing and insulation to limit heat

loss during Commissioning and for protection of personnel.

X I

w) Removal of scaffolding and other temporary works,

debris, tools, and extraneous material from areas to be turned over.

X I X I




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Phase

Pre-

commissioning

Phase

Commissioning

Phase

x) Ten (10) days prior to expected Mechanical

Completion, the Contractor is to send request for the Company punchlist, with copy of master punchlist status.

X R/I

y) Prepare and submit notification of Mechanical

Completion when all Work items identified by the Contractor and the Company as required for Commissioning are completed. Each notification shall identify plant system(s) submitted for acceptance, copy of master punchlist for those system(s), list of uncompleted (“exception”) items with the reason for their late completion and estimated completion date, inspection and test and check-out reports, and copies of marked-up `As Built’ P&ID’s and one line diagrams and logic diagrams and list of start-up spare parts on site.

X W

z) Verify all instruments and electrical panels and local

instruments and valves are accessible for operation and maintenance.

X I

aa) Conduct all flushing, blowing and

chemical/mechanical cleaning operations where such operations can be accomplished without using permanent installed equipment.

X W

ab) Conduct all flushing and blowing operations where

permanently installed equipment must be used to obtain proper line velocities.

X W

ac) Provide any special media for flushing and/or

cleaning purposes.

X R

ad) Maintain flushing and/or blowing records as required. X I

ae) Conduct all operational tightness tests. X W/I

af) Prepare detailed purge procedure for specific

system.

X R X R

ag) Maintain tightness test records, as required. X I

ah) Install inerting connections. X W

ai) Provide inerting materials and introduce where

specified.

X W/I

aj) Submit application for Turnover Certificate when all

activities identified by the Contractor and the Company are completed. Each notification shall identify plant system(s) submitted for acceptance and copy of signed-off report forms for Commissioning activities.

X R




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Phase

Pre-

commissioning

Phase

Commissioning

Phase

ak) Provide raw materials, such as reservoir crude Feed,

brackish water, utilities etc.

X

al) Check the integrity of system shutdown and prove

the reliability before Commissioning.

X W

am) Proceed to Commissioning as per operating manual

instructions.

A X

an) Conduct individual equipment noise surveys, as

required by the Company’s specifications documents results.

A X

ao) Prepare and submit Performance Testing

procedures.

X A

ap) Notify when the system(s) are on stream, at design

conditions and steady for the Performance Tests.

A X




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2.0 ELECTRICAL

Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


2.1 TRANSFORMERS

a) Check physically for damage, oil leaks, etc. X W

b) Check insulation resistance between primary to

earth, secondary to earth and primary to

secondary.

X W

c) Perform oil dielectric strength tests. Provide

samples to Company for independent check.

Perform oil filtration, if required.

X W

d) Perform operation of Buchholz relay. X W

e) Check alarm and trip contacts for actuation. X W

f) Check off-load changer for proper mechanical

operation.

X W

g) Check polarity of terminals and the phase

sequence.

X W

h) Perform High Voltage DC Test in accordance with

the Project specification.

X W

2.2 H.V. SWITCHBOARDS

a) Check physically for damage, missing parts,

moving parts, clearance, etc.

X W

b) Measure the insulation resistance of each bus

from phase to phase and phase to earth with all

circuit breakers in service position, but with the

circuit breakers open.

X W

c) Draw out each circuit breaker and starter out of

the panel and push it back to ensure that the

operation is smooth.

X W

d) Draw out each circuit breaker and starter to the

isolated position, close them manually and

measure the insulation resistance from phase to

earth.

X W

e) Draw out each potential transformer to the

isolated position and measure the insulation

resistance from phase to earth.

X W

f) Check all current transformers by Primary

injection testing.

X W/R




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2.0 ELECTRICAL (Contd.)

Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


g) Close and open each circuit breaker and starter in

test position, electrically using the control

switch/push buttons at the H.V. switchboard.

Check tripping of the circuit breaker and starter with

its emergency mechanical trip device at the H.V.

switchboard.

X W

h) Check all interlocking between earthing switches

and circuit breakers/starters. Close and open the

earthing switches and check for correct operation.

X W

i) Check the control circuit of each circuit breaker and

starter with all the interlocks and check for correct

operation. Check remote start/stop controls for

starters.

X W

j) Check castell key interlocking between the circuit

breaker and other devices as applicable.

X W

k) Check the phase sequence. X W/R

l) Check the characteristics and operation of each

relay by secondary injection testing.

X W/R

m) Simulate the operation of each of the protective

relays, trip receive and auxiliary relays, and ensure

energising of the lock-out relays and tripping of the

respective circuit breakers.

X W/R

n) Simulate and ensure correct operation of pilot wire

feeder protective relay.

X W/R

o) Check the automatic change over from mains

supply to stand-by supply and vice versa and

ensure correct operation. Check the manual

change over scheme mode.

X W/R

p) Set all protective relays to their correct setting. X W/R

q) The Contractor shall establish a Tag and Lock-out

Procedure, including a Work Permit Procedure for

the construction, Precommissioning and

Commissioning (The Company Work Permit

Procedure shall be followed to energize circuits for

powered checks/tests and start-ups).

X R X R X R

r) Energize all circuits required for the Contractor’s

Work responsibilities.

X W/I




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Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


s) Check High Voltage DC Test as per Project

Specifications

X W

2.3 440V SWITCHBOARDS

a) Check physically for damage, missing parts,

moving parts clearance.

X W

b) Measure the insulation resistance of each bus from

phase to phase and phase to earth with all circuit

breakers, starters, and switchfuse feeders in

service position but open.

X W

c) Draw out each circuit breaker, starter and

switchfuse feeder, and push it back to ensure that

the operation is smooth.

X W

d) Draw out each circuit breaker and switchfuse

feeder to the isolated position, close them manually

and measure the resistance from phase to phase

and phase to earth.

X W

e) Close and open each breaker is test position and

service position electrically. Check tripping of the

circuit breaker with its emergency mechanical trip

device.

X W

f) Check the control circuit of each circuit breaker with

all interlocks and check for correct operation.

X W

g) Draw out each starter feeder to isolated position

and check the insulation resistance from phase to

phase and phase to earth on the load side with the

starter open, for power and control circuits.

X W

h) Draw out each starter feeder to the test position,

use the test control supply and check the starter for

correct operation with all the interlocks from remote

start and local/remote stop.

X W

i) Close and open switchfuse feeders and ensure

correct operation.

X W

j) Check the current transformers by Primary Injection

Testing.

X W/R

k) Check the characteristics and operation of each

relay by secondary injection.

X W/R




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2.0 ELECTRICAL (Contd.) Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


l) Simulate the operation of each of the protective relays

and auxiliary relays and ensure energizing of the

lockout relays and tripping of the respective circuit

breakers.

X W/R

m) Set all the protective relays to their correct setting. X W/R

n) Set all the thermal overload relays to their correct

setting.

X W/R

o) The Contractor shall establish a Tag and Lock-out

Procedure including a Work Permit Procedure for the

construction, Precommissioning and Commissioning

(Company Work Permit Procedure shall be followed to

energize circuits for powered checks/tests and start-

ups).

X R X R X R

p) Energise all circuits required for the Contractors’ Work

responsibilities.

X W/I

2.4 MOTORS

a) Check physically for damage, free rotation of fan and

movement of parts.

b) Check the insulation resistance value and dry out the

machine if the value is:

- less than 50 megohms for 3.3KV motors

- less than 5 megohms for 440V motors.

The method of drying out and retesting shall be in

accordance with Approved Manufacturers’ instructions

c) Check condition of grease in grease lubricated motor

bearings and lubricate the bearings if necessary.

X W

d) Check and ensure that all electrical connections are

tight.

X W

e) Check the direction of rotation running the motor

momentarily. Run the motor uncoupled for four (4)

hours and check for any abnormalities. The

temperature rise of motor shall be recorded at the end

of this period.

X W

2.5 BATTERIES AND CHARGERS

a) Check physically for damage.

X W

b) Check the control circuit of charger for correct

operation. Ensure that current limiting circuits, auto-

changover circuits from float to boost mode and vice

versa are functioning correctly.

X W




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Phase

Pre-

commissioning

Phase

Commissioning

Phase


c) Top up the electrolyte level in the batteries as

required.

X W

d) Boost charge the batteries. X W

e) Energize the charger and keep batteries on float

charge.

X W/R

f) Perform battery acceptance tests on batteries X W/R

2.6 CABLES

a) All high voltage (above 1KV grade) cables shall be

subjected to high voltage DC test before

termination. Insulation resistance value from

phase to phase and phase to earth shall be

measured before and after H.V.D.C test.

X W

b) Before making the H.V. cable joint at each

location, the insulation resistance shall be

measured from phase to phase and phase to

earth. After completion of all joints and before

termination, the entire cable shall be subjected to

high voltage D.C. test followed by insulation

resistance check.

X W/R

c) For all low voltage cables (up to 1KV grade), the

insulation resistance value from phase to phase

and phase to earth shall be measured before

termination. Cable conductor continuity shall be

checked for each and every cable.

X W

d) For any existing control cable which requires any

joint, the insulation resistance shall be measured

between conductors to earth before and after

completion of the joint. For such cable the voltage

at which the insulation resistance check is carried

out shall be determined by the Company.

X W/R

e) Phase sequence and matching checks shall be

conducted before connection of each and every

high voltage cable.

X W/R

f) The insulation resistance checks for 11KV system

shall be done with 5KV Megger, and 3.3KV system

with 2.5KV Meggars and for LT system with 1000V

Meggar.




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Phase

Pre-

commissioning

Phase

Commissioning

Phase


2.7 EARTHING

a) Measure and record the earth resistance value of

each electrode.

X W

b) Check the continuity of the earthing system. X W

c) Ensure that the earth resistance value of the

complete earthing system does not exceed 4 ohms.

X W/R

2.8 LIGHTING AND SMALL POWER

a) Install lamps (incandescent, bulbs, mercury vapour

lamps, fluorescent tubes, etc.) required to fill the

fixtures, verify all lights and switches operate

properly. Test photo cells for proper operation.

X W

b) Verify that all lights are operational using normal

and emergency power.

X W/R

c) Test small power systems for correct operation. X W/R

2.9 CONTROL PANELS FOR 11KV AND 3.3KV

SWITCHBOARDS

a) Check physically for damage.

X W

b) Close and open each circuit breaker and starter

from control panel and ensure correct operation.

X W

c) Check and ensure correct operation of the Variable

Speed Drive Control Panel.

X W

d) Check and ensure correct operation of the

annunciator.

X W

2.10 UNINTERRUPTIBLE POWER SUPPLY

SYSTEM

a) Carry out checks and tests for the battery and

charger of UPS as in Clause 2.6 (a) to (f) above.

X W X W/R

b) Check circuits of inverter for correct operation.

Check the output waveforms including harmonic

distortion. Verify the current limiting circuit. X W/R

c) Check the bypass transformer and associated AVR

circuits.

X W/R

d) Check the static switch circuits. X W/R




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Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


e) Initiate transfer from one source to another, verify

the transfer timings, transient voltage dips.

recovery times, etc.

X W/R

f) Check all alarms and signalling circuits. X W/R

g) Energize all circuits required for the Contractors’

Work responsibilities.

X W/I

2.11 MISCELLANEOUS

a) Check out cathodic protection system.

X W/R

b) Paint or tag all electrical apparatus (switchboards,

breakers, push button boxes, connecting boxes,

etc.) according to the Company’s colour code or

regulation.

X W




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3.0 INSTRUMENTATION Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


a) Check instruments and tag data supplied against

specifications sheet (type, range, material).

X I

b) Install instruments and make all specified

connections.

X W/I

c) Perform required pressure tests on instrument take-

off piping and air piping and tubing.

X W/I

d) Blow-out instrument air piping with dry air

reconnecting after pressure tests, and site

instrument air regulators.

X W/I

e) Check continuity and identification of transmission

and control system for each instrument to ensure

proper hook up and compliance with Project

specifications. This applies both to pneumatic and

electrical, analog and digital-systems. Perform

insulation test with instruments isolated or removed

for instrument electrical wiring.

X R/I

f) Check pneumatic and electrical instrument systems

for proper installation including tagging, supports,

accessibility, correct material, ratings and calibrated

fittings. Synchronise transmitter and receiver

readings for each instrument.

X R/I

g) Remove control valves, flowmeters, venturis, orifice

plates, and other in-line instruments prior to pipe

cleaning/flushing and hydrotesting.

X R/I

h) Leak-test `tight shutoff’ rates safety and control

valves at grade before installation.

X W/I

i) Install instrument after line flushing/cleaning and

hydrotesting.

X I

j) Perform all instrument calibrations at site before

installation.

X I




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3.0 INSTRUMENTATION (Contd.) Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


k) Prepare calibration sheets for each calibration,

showing as a minimum the following:

- date of calibration

- instrument tag number

- instrument spec. sheet number

- reading before and after calibration, problems

noted and corrected

- description of calibration, method/equipment

- name of person doing calibration, and indication of

acceptance when achieved

- reference to other instruments calibrated

simultaneously.

These sheets shall be submitted as part of the loop

check data package.

X R

l) Inspect all flow elements. Micrometer check at

grade.

X W

m) Check all emergency and safety systems for

operability, by simulation, including bypass

switches/lights and resets.

X W/I

n) Perform site acceptance tests on computerised

Distributed Control System (DCS) in accordance

with Approved Manufacturers test procedures. The

DCS may not be powered up until the UPS is

completely checked out and operable. (item 2.11 &

a)

X W

o) Perform site acceptance tests on computerised

Integrated Control System/Distributed Control

System (ICS/DCS) in accordance with approved

Manufacturers test procedures. The ICS/DCS may

not be powered up until the UPS is completely

checked out and operable. (Item 2.11 & a)

X W

p) Provide sealing fluids (for example, manometers,

gauges, etc.) where required.

X I

q) Test annunciators and individual alarms by

simulating alarm conditions where possible.

X W/I

r) Stroke control valves, solenoid valves and

emergency isolation/shutdown valves, adjust the

valve movements, limit switch and air operation/air

failure actions as required.

X W




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3.0 INSTRUMENTATION (Contd.) Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


s) Operate and adjust as necessary timers, switches,

relays, push buttons, interlocks and other

instrumentation components.

X W

t) Confirm that all elements in each instrument loop

have been checked and tested for compliance with

the drawings and specifications, after the loop

elements are all complete and correct, install sealing

compound in seals where required.

X R/I

u) Prepare and submit to the Company loop check

packages for the Company approval prior to full loop

checking by the Contractor. Data package shall

contain (as applicable to each loop) installation

check sheets, wire and tubing test sheets,

instrumentation check sheets, with copy of the

respective loop diagram and P&ID and

instrumentation specification sheets.

X R/I

v) Perform full loop checks. Identify and log any

problems for the Contractor Resolution.

X W/R




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Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


4.0 BUILDINGS

a) Operate electrical and mechanical equipment such as

lighting, fans, and air conditioning systems to the

extent required to verify its operability. All Work

necessary to properly safeguard the equipment must

be complete.

X W

b) Install furniture, if any. X W

c) Conduct test on HVAC systems, building

pressurisation system, emergency switching system,

and safety equipment (refer to sections 3,5 and 6).

X W

d) Clean toilets, basins, sewers and water systems. X R/I

e) Operate and adjust doors, windows. Buildings shall

be tested for leak tightness and maintenance of

internal positive pressure.

X R/I

f) Perform roof leak test. X W/I

g) Commission air conditioning, building pressurisation

system, gas detection and fire control/halon systems

X R/I

h) Check the slope of roofing in order to ensure runoff of

rainwater.

X W

5.0 AIR CONDITIONING

a) Air conditioning air handling units, and individual

components thereof, appurtenances, piping and

wiring connected to the units and instrumentation

controlling the units shall be Pre-commissioned per

requirements, of the Company’s specifications and

Approved Manufacturers instructions and sections 2

& 3 of this document.

X W/I

b) Provide all Freon or other cooling medium required to

charge/recharge the air conditioning units.

X W/I

c) Charge or recharge the units as required. X W/I

6.0 COMMUNICATIONS EQUIPMENT

a) Install checkout, calibrate and test PABX, telephone

communication, internal TV system, all cabling and

associated equipment included in Work, as per

Approved Manufacturer’s instructions.

X W/I

7.0 TIE-INS TO EXISTING FACILITIES

a) The Contractor to perform all tie-in work including the X W/I




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Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


preparation of hot tap forms. (See Note 1).

b) Prior to starting the Work, Contractor to obtain Work

Permit approval for tie-in and carry out the Work, as

required by specifications and as directed by the

Company.

X R

c) Isolate, Drain and Depressure Process

Equipment/Piping to which Tie-in is being made.

X

d) Provide and Install Temporary Blinds as required. X W/I

e) If necessary, purge existing Equipment with N2 to

make existing Equipment/Piping safe for Hot Work.

X W/I

f) Remove blinds, reinstate Piping as required. X W/I

NOTE 1:

The Contractor shall be provided with minimal shutdown

period for the existing facilities during the tie-in work.

In order to obtain necessary work permits, it would be the

Contractors’ responsibility to give adequate prior notice to

the Company to obtain the necessary `shutdown’.

8.0 SAFETY & FIRE PROTECTION EQUIPMENT

a) Install relief valves or dummy spools during

construction.

X W/R

b) Submit complete PSV (Pressure Safety Valve) and/or

VSV (Vacuum Safety Valve) test authorisation

package (testform, PSV or VSV specification sheet,

P&ID) with PSV or VSV.

X R

c) Install all protective shields. X W/I

d) Arrange for on-Site testing and calibration of all PSVs

(Pressure Safety Valves) and VSVs (Vacuum Safety

Valves). Provide new tags showing the Company

serial numbering system. Paint all valve bodies per

the Company specifications.

X W/I




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8.0 SAFETY & FIRE PROTECTION EQUIPMENT

(Contd.)

e) Paint and/or tag all PSVs (Pressure safety valves)

and/or VSVs (Vacuum safety valves), car sealed (i.e.

locked open or locked close) valves, and safety

equipment as approved by the Company. Provide

and lock all valves per P&ID positions.

Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase

Ctr

X

Cy

W

Ctr Cy Ctr Cy

f) Inspect and tag all portable fire extinguishers. X W/R

g) Install portable extinguishers, first aid kits and similar

fire and safety equipment. Locations shall be

approved by Company based on Fire & Safety

Equipment Location Plan.

X W/R

h) Remove, prior to equipment testing, all safety devices

such as rupture discs and safety valves. Deliver

safety devices to KOC workshop for testing.

X W

i) Retrieve safety devices delivered to KOC Workshop

for testing and replace after equipment testing all

safety devices such as rupture discs and safety valves

in accordance with P&ID.

X W

j) Check the operability of sudden lighting shut-off

switch, if any.

X W

k) Commission all new fire protection equipment.

Conduct system capacity tests.

W A

l) Test safety showers for proper installation, flow rate,

and water temperature.

X W

m) Testing, Commissioning and start-up operation of the

fire pumps, diesel engine drive, flow measurement,

pressure check, performance test, etc.

X W




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Construction

Phase

Pre-commissioning

Phase

Commissioning

Phase


9.0 CIVIL / STRUCTURAL

a) Sewer and drain lines shall be flushed and

gravity tested, for leaks, then the sewers

cleaned and all clean-outs, seal pots and

service connections shall be checked for proper

installation and functioning.

X W

b) All installations shall be checked for invert

elevation using the mirror and light test.

X W

c) Operate and inspect plumbing systems to

confirm proper functioning and leak tightness.

X W

d) Check that all required areas are fireproofed. X W

e) Check the working areas around equipment

such as turbines, heat exchangers etc. are free

of any obstacles and properly compacted/paved

per specification.

X W

f) Check the area under suction filters of turbines

is paved, cleaned and protected against sand

drift.

X W

10.0 PIPING AND ACCESSORIES

a) Clean piping and hydrostatically or

pneumatically pressure test, as required by

codes, specifications and the Company’s

instructions.

X W

b) Before flushing/cleaning or pressure testing,

remove any control valve, orifice plate and the

like which might be damaged, and re-install

after that Work is completed.

X W/I

c) Coordinate the flushing, cleaning, pressure

testing and corrosion prevention requirements

with all other Pre-commissioning activities, such

as vessel/exchanger internal inspections, oil

system cleaning and flushing and run-in,

tightness testing and all other Work activities.

X R

d) Remove blanks and install spectacle blinds to

required positions after pressure testing.

X W/I

e) Check piping for correct slope and, for process

gas lines, that no `pocketed’ sections exist

upstream of flare. Correct as required.

X I

f) Provide and install all line vents, drums,

strainers - both temporary and permanent,




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Construction

Phase

Pre-commissioning

Phase

Commissioning

Phase


blinds and non return valves called for on

relevant drawings and specifications.

X W




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10.0 PIPING AND ACCESSORIES (Cont.)

Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


g) Provide and install other temporary blinds and

bypasses required for Commissioning and start-up as

specified by the Company.

X W/R

h) Check packing and packing materials and lubrication

of valves, repack and lubricate as required.

X W

i) Supply and install line identification tags, signs and

flow arrows. To be coordinated with Company.

X W

j) Provide list and location of all blinds installed. X R X R X R

k) Check spring hangers, supports, guides, expansion

joints, and other pipe specialities for the removal of

all shipping and erection stops and for the

correctness of cold settings for the design service.

X W

l) Check piping to be free of bulges and imperfections. X W

m) Check piping is properly resting on support and

installed in accordance with drawings to provide

thermal movements where applicable.

X W

n) Provide all replacement gaskets, spool pieces,

hoses, temporary connections, riggings/hoistings,

and blind required for cleaning, treating, flushing and

inerting activities. Supply supervised labour and

necessary tools/equipment for air and/or water

flushing, oil flushing, chemical and/or steam treating

and flushing, as required. This will include removing

control valves, check valves/flappers, flow elements,

installation of temporary spool pieces, and

replacement of those items when the

cleaning/flushing activities are completed.

X W

o) Perform flushing operations as foreseen, after

Mechanical Completion.

X R/I

p) Perform operational tightness tests of the process

systems, using pressurised instrument quality air to

bring the process systems to their adequate

pressure.

X R/I

q) After operational tightness tests completion, purge

process piping and equipment with nitrogen per

purging procedures.

X R/I




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10.0 PIPING AND ACCESSORIES (Cont.)

Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


r) Adjust spring hangers, supports, etc. in `Hot’

conditions.

X I

s) Prepare detailed flushing procedure for the specific

system.

X W

t) Visually check the overall system to be

Commissioned to confirm its integrity.

X W

u) Prepare purging procedure for specific system and

ensure oxygen limit to be 2% or less.

X W

10.1 SPECIAL PROCEDURES FOR PIPE LINES

a) Verify that all components, piping, pigging facilities

are installed in accordance with the design

drawing/specification and vendor instructions.

X I

b) Prepare flushing procedure including purging. X R

c) Perform cleaning and flushing operations, after

Mechanical Completion, using storage tanks, transfer

pumps and pigging facilities.

X W

d) Perform gauging of pipeline before hydrotesting and

record the gauging results.

X W

e) Conduct functional tests on pigging facilities. X W

f) Hydrostatically pressure test pipeline, as required by

codes, specifications and the Company’s instructions.

X W

g) Undertake all elec. & inst. tests as per the relevant

sub-section of sections 2 & 3 of this document (refer

to sub-section for responsibilities).

h) De-water, dry, purge and Commissioning of pipeline

as required by codes, specifications and the

Company’s instructions.

X W




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11.0 FLARE SYSTEM

Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


a) Verify that all components, piping, electrical and

instrumentation are installed in accordance with the

Project drawings/specification.

X I

b) All system lines shall be checked during construction

to be free of dirt and debris.

X I

c) Verify that pipe guides and anchors on flare line

allow for thermal expansion and that saddle supports

rest fully on concrete supports/slide plates. Correct

as required.

X I

d) Verify the flare lines are continuously sloping towards

ground flare, burn pit and/or stack at a specified rate

of inclination.

X W

e) Pneumatically test flare lines and service lines. X I

f) Conduct functional test on ignition system utilising

propane.

X W

12.0 VESSELS

a) Check the nameplates data for correctness, per

P&ID and specification sheets. Resolve any

differences.

X W

b) Clean out all vessels, open manholes and openings

for inspection.

X W

c) Inspect internals and coatings, signify complete and

ready for final closure.

X W/I

d) Witness inspections to extent desired. W

e) Prepare purge procedure as per code of practice

(pressure cycle procedure) and repeat the cycle until

safe limits of oxygen (2% or less) are obtained.

X W

f) Dry out, if required, and install materials such as

desiccants, catalysts, resins, chemicals etc.

X W

g) Issue to the Contractor, in writing, instructions to

close- up each vessel.

X

h) Properly close-up all vessels, manways, and

openings after final inspection (items c and d).

X W

i) Check ladders and platforms with the Company for

required access, per specification.

X W




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12.0 VESSELS (Contd.) Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


j) Calibrate/test and designate the Company

numbering system for all safety valves including tank

pressure vacuum valves.

X W/I

13.0 COLUMNS

a) Check the nameplates data for correctness, per

P&ID and Project specification. Resolve any

differences.

X W

b) Clean out all columns, open manholes and manhole

trays for inspection.

X W

c) Inspect internals, trays as per Approved

Manufacturer’s drawings, signify complete and ready

for final closure.

X W/I

d) Witness inspection to the extent desired. W

e) Prepare purge procedure as per code of practice

(pressure cycle procedure) and repeat until the safe

limits of oxygen (2% or less) are obtained.

X W

f) Issue to the Contractor, in writing, instructions to

close- up each column.

X

g) Properly close-up all vessels, manways, and

openings after final inspection (items c and d). X W

h) Check ladders and platforms with the Company for

required access, per specification.

X W

i) Calibrate/test and designate the Company

numbering system for all safety valves including tank

pressure vacuum valves.

X W/I

14.0 TANKS

a) Open manholes for cleaning and inspection. X W/I

b) Inspect internal distributor/collectors and coating,

signify complete and ready for final closure.

X W/I

c) Perform hydrostatic test of tank and internal piping, if any. Clean tank after testing.

X W

d) Perform settlement survey prior to, during and after hydrostatic test.

X W/I

e) Inspect tank internals and gauging equipment, painting/coating, P.V. valves and foam pourers, signify as complete and ready for final closure.

X W/I




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14.0 TANKS (Contd.)

Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


f) Check tank for required access, with the Company, per Project specification.

X W/I

g) Calibration measurements, calculations and tables. (Tank Strapping)

X

h) Calibrate/test and designate the Company numbering system for all safety valves all over the Facility including tankage pressure vacuum valves.

X W/I

i) N2 purging of tanks. X W

15.0 EXCHANGERS

15.1 SHELL AND TUBE EXCHANGERS

a) Perform internal inspection or testing in field, if

required, of exchangers that have previously been shop inspected. (To be done only if specially called in Specifications or Drawings.)

X W

b) Open channel heads on covers of exchangers that have been tested with water at the shop.

X W

15.2 AIR COOLED EXCHANGERS

a) Inspect exchangers to ensure that temporary

shipping supports and erection materials have been removed.

X W

b) Adjust fan assemblies to obtain specified tip clearance and test.

X W/I

c) Check operation of louvres, if any, and operating linkage.

X W/I

d) Open ten (10) plugs at each bundle of the exchangers that have been tested with water at the shop.

X W/I

15.3 PLATE HEAT EXCHANGERS

a) Open inlet and outlet connections for inspection.

Remove any temporary shipping supports.

X W/I

GENERAL:

Calibrate/test and designate Company numbering system

for all safety valves all over the Facility including tankage pressure vacuum valves.

X W/I




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Construction

Phase

Pre-

commissioning

Phase

Commissioning

Phase


16.0 PUMPS

a) Rotate pumps by hand to ascertain that they turn freely.

X W

b) Check motor for rotation, run-in four (4) hours uncoupled and check bearings. Submerged oil pump/motor may be run-in coupled after oil flushing activities are completed. Recouple pump to motor.

X W/R

c) Align pump with driver after motor run-in and coupling installation.

X W/R

d) Check for and eliminate any loads imposed on the pumps by piping connections (to be done simultaneously to alignment operation).

X W/R

e) Install proper lubricants prior to Commissioning after review by Company.

X W

f) If the pump is to be used for flushing, install temporary packing if permanent packing or mechanical seal is not suitable for flushing.

X W

g) Install temporary strainers in suction piping. X W

h) Re-install permanent packing if permanent packing or mechanical seal on any pump used for flushing, if required.

X W/I

i) Make final cold alignment on any pump used for flushing (items f and h).

X W/R

j) Check and run-in pumps, maintain them after Mechanical Completion; make final alignment check, and do any required dowelling of the pumps and drivers.

X W

k) When necessary, clean pump strainers and remove temporary suction strainers after pumps have been in operation for a reasonable period.

X W

l) Check the general compatibility of the pumps with respect to any cavitation problem, discharge head, undue or excessive vibrations, excessive noise etc. which may hint at the abnormal operation of the pump.

X X I

m) Obtain the assistance of the Approved Manufacturers if required.

X X




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Construction

Phase

Pre-

commissioning Phase

Commissioning

Phase


17.0 COMPRESSORS

a) Ensure suction and discharge piping has been correctly installed according to Approved Manufacturer requirements or recommendations.

X W/I

b) Check that the cold alignment and grouting have been carried out satisfactorily and that documentary evidence of this is to hand.

X W/I

c) Chemically clean any completed lube and seal oil system, when specified. Disposal of wastes and cleaning media in accordance with the Company’s instructions.

X W/A

d) Charge the lube oil, control oil, and oil cooling systems with the flushing oil and circulate for cleaning purposes. Dispose of any flushing oil on accordance with the Company’s instructions.

X W/A

e) Charge the lube oil, control oil, and oil cooling systems with the operating oil recommended by the Approved Manufacturer in accordance with the Company’s specifications.

X W X W

f) Operate the autochange over of the oil coolers and

oil filters.

X X W

g) Operate equipment and carry out vibration, trip,

governor and safety device checks and any operating tests and adjustments, as required.

X W

h) Obtain the assistance of Approved Manufacturer, if required.

X X X

i) Perform all the tests as specified in the relevant data sheets and specifications.

X W/I X W/I X W/I

17.1 SPECIAL TEST FOR RECIPROCATING COMPRESSORS

a) Check fit and clearance of bearings, connecting rod, crankshaft and cross-head slides.

X W/I

b) Check run-out of piston rod and cross-head slide. X W/I

c) Check valve lift. X W/I

d) Check rod seal assembly. X W/I

e) Check that vent lines from seals and distance housings are free from obstruction and routed to safe location.

X W/I

f) Obtain the assistance of Approved Manufacturer to perform the specified test.

X X X




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17.0 COMPRESSORS (Contd.)

Construction

Phase

Pre-

commissioning Phase

Commissioning

Phase


17.2 SPECIAL TESTS FOR SCREW

COMPRESSORS

a) Check carefully compatibility of operating oil

recommended by Approved Manufacturer with process product in order to avoid problems during run-in.

X R

b) Obtain the assistance of Approved Manufacturer and perform all the tests as per the relevant specifications and data sheets.

X X X

18.0 GAS TURBINES

a) Check physically for any damage, defects on the surface, mountings and leakage etc.

X

b) Remove all rust preventatives, oils, paints and blinds used to protect the equipment during shipment and construction period whenever these protective materials will be detrimental to operation.

X W

c) Check that the cold alignment and grouting have been carried out satisfactorily with the documentary evidence. As the gas turbine is to drive compressor and/or pump, the suction and discharge should have been aligned and freed of stresses.

X W/I

d) Inspect the combustion chamber/plenum chamber and the enclosure.

X W/I

e) Check and prepare starting system in accordance with the Approved Manufacturer’s recommendations.

X W/I

f) Check and prepare burner system in accordance with the Approved Manufacturer’s recommendation.

X W/I

g) Prepare and charge lube oil and control oil systems in accordance with the Approved Manufacturer’s recommendations. (Operating oil shall be in accordance with Company’s Specifications.) Check the control and the oil system.

X W/R

h) Check and conduct all blowing operations on gas

lines.

X W

i) Operate equipment and carry out vibration, trip, governor and safety checks and any operating tests and adjustments, as required, in accordance with Approved Manufacturer’s instructions.

X W/R




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18.0 GAS TURBINES (Contd.) Construction

Phase

Pre-

commissioning Phase

Commissioning

Phase


j) Check and run turbines, maintain them after Mechanical Completion in accordance with Approved Manufacturer’s operating manual instructions.

X W X I

k) Obtain the assistance of Approved Manufacturer and perform all the tests and checks as per data sheets and specifications

X X X I

19.0 HEATERS

a) Check physically for any damage, leakage etc. X

b) Remove all temporary support, bracing or other foreign objects that were installed in heaters to prevent damage during shipping, storage and erection, and repair any damage sustained.

X W

c) Inspect the heater for completeness and correctness of installation and perform all non- operating pre-firing check in accordance with the Approved Manufacturer’s instructions.

X W/I

d) Blow fuel lines, check them for cleanliness, and connect burner piping. Internally inspect oil bath heaters to ensure all dirt and debris is removed.

X W/R

e) Obtain and charge liquid heat transfer media, if required in accordance with the Approved Manufacturer’s instructions.

X W

f) Precommission and Commission auxiliaries as

detailed elsewhere under the appropriate equipment type.

X W X I

g) Conduct refractory dry out with necessary adjustments to firing to establish temperature profiles in accordance with refractory Approved Manufacturer’s instructions.

X W/R

h) Conduct all operating tests and obtain the certification, if required, in accordance with the Approved Manufacturer’s instructions.

X W/I

i) Obtain the assistance of Manufacturer, if required.

X X X

20.0 MISCELLANEOUS

a) Install all miscellaneous mechanical equipment such as cranes, hoists, etc., carry out all the required site tests including based test and provide test certificate from testing and certifying authority (e.g. Lloyds, Bureau Veritas, ABS etc.).

X W




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20.0 MISCELLANEOUS (Contd.) Construction

Phase

Pre-

commissioning Phase

Commissioning

Phase


b) Install, lubricate as required, perform mechanical

check and adjust all equipment prior to turning over to the Company.

X W/I

c) Provide and install guards, barriers warning signs

and other safety devices in accordance with Contract Safety Requirements.

X I

d) Provide noise reduction devices or noise `walls’ if required to comply with specifications.

X I X I

21.0 CHEMICALS

a) Store and protect chemicals, desiccants, oils, refrigerants and other fluids/gases to be filled or charged into the Work, in a sheltered area.

X

b) All fluids/gases per item (a) to be labelled, and located in a safe and proper area outside the Work area until ready for installation.

X

c) Test samples of transformer insulating oils, and any other fluids deemed necessary by Equipment Manufacturer’s to confirm that such meets with the requirements and/or Company standards.

X W

d) Replace and/or refill fluids with permanent charge where required, this includes, but not limited to, halon (after halon discharge test) nitrogen (for inerting and/or tightness test).

X

e) Allocate proper sheltered areas in the Gathering Centre for storage of chemicals, desiccants and lubricants, etc.

X A/R

22.0 PACKAGE UNITS

a) Check physically for any damage, defects on the

surface, mountings and leakage etc.

X

b) Remove all rust preventatives, oils, paints and blinds used to protect the equipment during shipment and construction period whenever these protective materials will be detrimental to operation.

X W

c) Inspect package for completeness and correctness of installation and perform all non-operating checks in accordance with Approved Manufacturer’s instructions.

X W/I

d) Obtain and charge liquid, chemical as required. X W

e) Pre-commission and Commission auxiliaries as detailed elsewhere under the appropriate equipment type.

X W X W/I




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22.0 PACKAGE UNITS (Contd.)

Construction

Phase

Pre-

commissioning Phase

Commissioning

Phase


f) Pre-commission and Commission piping, electrical,

instrumentation as detailed elsewhere under the relevant section.

X W X W/I

g) Conduct initial start, making the associated checks

and adjustments in accordance with Approved Manufacturer’s instructions.

X W/I

h) Conduct all operating test and obtain the certification,

if required, in accordance with Approved Manufacturer’s instructions.

X W

i) Obtain the assistance of Approved Manufacturer, if

required.

X X X




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Attachment 2: Pre-Commissioning/Commissioning Organization

11050146-CM-PRO-000-5017_RA

Documents

Transcript of 11050146-CM-PRO-000-5017_RA