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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No.

Khalda Petroleum Company

Project: Northern Gas Compression Facilities, El Alemein

Location: El Alamein, Egypt

Ennpi Project No; 7917-470


Clients Project No.: 05-2892

COMMISSIONING PROCEDURED

Doc. No.

Revision 0

Date Feb. 4,2009

File Ref.

Revision History

Rev Date Description of Change

Owner Developer Reviewer Approver

Summary

These procedures deal with the Commissioning and testing of equipment & systems of
the Northern Gas Compression Facilities following the Mechanical Completion.
Commissioning phase covers additionally the preparation for plant start up, subsequently
followed by start up and performance guarantee test run.

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

INDEX

Sr.No. Topic Page No.

1.0 Introduction 3
2.0 Health, Safety & Environmental Procedures 4
3.0 Brief Process Description 7
4.0 Commissioning Plan 9
5.0 Commissioning Spares & Consumables 12
6.0 Lubrication Schedule 12
7.0 Preservation & Maintenance 12
8.0 Equipment & Instrumentation Commissioning 12
9.0 Test Run of Rotating Equipments 13
10.0 Preparation for Plant Start up 16
11.0 Commissioning & Start up Sequence 17
12.0 Performance Guarantee Test Run 18
13.0 Initial Operation 18
14.0 Hand Over 18

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

1.0 Introduction
1.0 General
This document is developed for Commissioning of the systems / equipments
installed in the Northern Gas Compression Facilities, after Mechanical
Completion (MC), followed up by Start up & stabilization and Performance
Guarantee Test Run.

1.1 Definitions
Project Northern Gas Compression Facilities Project No.

Company Khalda Petroleum Company (KPC), EGYPT.

Contractor J.P. Kenny / Enppi

Supplier Party who supplies equipment, materials and/or services


(or Vendor) as specified in the scope of supply.

Subcontractor Petrojet.

Site El Alemein Desert, Egypt.

Facilities Northern Compression Facilities.

Pre-Commissioning Corresponds to non operating adjustments and cold checks


performed at the end of the construction phase to verify
that the installation conforms to plan, specifications,
drawings, instructions and applicable codes and rules. This
phase leads to ready for commissioning (RFC) stage, also
called mechanical completion (MC).

Mechanical Completion Status of the plant when all systems / subsystems are made
Ready For Commissioning (RFC).

Commissioning Corresponds to dynamic test and pre-start up activities


associated with operation of items of equipment or
facilities for Hydrocarbon Feed Introduction followed by
Performance Guarantee Test. The utility system is
operational during commissioning phase and utility
streams are available at the required specifications
[for example, Instrument Air (IA) with required dew point].

1.2 Purpose
The purpose of this Commissioning Manual is to familiarise the personnel involved in
carrying out the commissioning activities of the Northern Compression Facilities Project
and also to prepare the plant ready for start up, followed by start up & stabilisation and
performance guarantee test run.
1.3 Scope
Commissioning includes activities such as: simulated runs, hydrocarbon feed introduction,
start-up & stabilization and performance guarantee test run.

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

It is envisaged that this Commissioning Manual will be used by the Commissioning Teams
of both Contractor and Company. Commissioning Team who execute the activities is
responsible for generation and submission of the relevant documents also.

Appendix A shows the split of commissioning responsibility.

Appendix A
Responsible for
Organization Phase Works
Contractor Commissioning Pre Commissioning. All Equipments, Systems, and
Team. Units.
Contractor Commissioning Commissioning, Start up and Utilities, Infrastructure,
Team and Company Performance Guarantee Test Telecom Systems, and Start up
Commissioning Team. Run. & Performance Guarantee Test
Run.

The Process Units of the Northern Compression Facilities are divided into Systems and Sub
Systems to facilitate the Substantial Completion of Commissioning including Start up and
Performance Guarantee Test Run. These systems have been defined with respect to their
logical operational function. Systems and Sub-Systems are defined in a list and their
boundaries are indicated in the marked-up P&IDs.

This manual contains procedures and general guidelines for carrying out the
commissioning activities.

2.0 Health, Safety & Environmental Procedures

2.1 General
HSE is a key element of the Project and must be made an integral part of all Project
activities, including Commissioning. It is the responsibility of all personnel involved in the
Commissioning to promote HSE in the pursuit of an incident and injury free project.
This document does not intend to present in detail all the HSE procedures and practices
but provides a route map of guidance in meeting the HSE requirements.

2.2 Safety during Commissioning

Safety during commissioning is a continuation of the safety rules during construction and
pre-commissioning, which defines the organization and procedures adopted by
Contractor, Sub Contractors and Vendors while performing site activities in a manner that
provide a risk and security free, safety oriented working environment; thereby,
protecting the health of the workforce and keeping the environment pollution free.

The required labour force for Commissioning activities will be taken from construction.
The Commissioning Operator / Technician Team will be developed jointly by Contractor
and Company as shown in the Site Commissioning Organization Chart and Integrated
Start-up Organization (Ref Page No. 12 & 13 of this manual). Inducting the personnel and
ensuring their HSE compliance for commissioning is the responsibility of the respective
Commissioning Managers of Company (KPC) and Contractor (Enppi).

Although the HSE Site Manual covers all the site activities, the intent of this Safety
Section is to highlight the hazards of the Commissioning activities, control measures put
in place to manage these potential risks / hazards and the safety requirements to be
followed up. Potential risks that need to be controlled during the commissioning
execution are:

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

Use of hose and temporary hose connections for compressed air, nitrogen, and
pressurized water supplies.
Temperatures above ambient during warm-up operation of the Heating Medium
System and Compressors start-up/operations.
Flammable Hydrocarbon Gas used during system pressurization
Energizing of electrical systems.
Concurrent construction work in the neighbouring area during commissioning.
Running of machinery and rotating equipment during testing.

2.3 Permit to Work (PTW) System

The Permit to Work system is a formal written system used to control the potential
hazards in carrying out certain types of works during execution of commissioning. PTW
system acts as a medium of communication among the site / installation / commissioning
management, supervisors and technicians and the work force that carry out the work.
Essential features of the PTW system are:
Clear identification of Issuing Authority, Receiving / Performing Authority and
the necessary precautions and control measures to implement and follow up.
Training and induction in the issue and use of permits.
Monitoring and auditing to ensure that the system works as intended.

The aim of the PTW System is to ensure that proper planning and consideration is given
to the potential risks of a particular job in order to minimise the risk of harm to people,
environment and the assets. The Permit is a written document, which authorizes certain
people to carry out specific work at a specified time and place, and sets out the
precautions required to follow up for completing the job safely.

2.3.1 PTW Management and Responsibilities

The PTW system is used to control and manage specific hazards during the course of
Commissioning activities. The purpose of such a system is to achieve a safe working
environment by implementing necessary management control in carrying out various
activities that may have potential for hazards.

The PTW system requires the involvement of competent and responsible persons as well
as the application of required safety measures in a controlled sequence. The PTW system
ensures that responsibility and accountability for safe working practice is passed in a
logical sequence to those responsible for the work being carried out and ensures that
adequate safeguards are provided.

Permit to Work (PTW) will be controlled by Contractor Enppi till Mechanical Completion
(MC) stage and there after it will be controlled by Company (KPC) following their existing
PTW system during commissioning phase.
2.3.2 Training and Induction

All the key personnel within the PTW System will be adequately given training and
induction on the roles and responsibilities of:
Issuing Authority
Receiving Authority / Performing Authority and
The workforce

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

All members of the workforce who are required to work within the PTW system shall
receive instructions on the specific procedures applicable in their area of work execution
and also briefed on a general overview of the PTW system and the specific
responsibilities of every member of the workforce. The Issuing / Receiving / Performing
Authorities shall receive additional training based on their level of competency.

Vendor specialists who will work on the site to do a specific task under the PTW System,
will receive the instructions on the PTW System, and be supervised by the PTW Receiving
Authority until the work/activity is completed and the system or unit is handed over.

2.3.3 Communication

Since a large number of people are involved in the PTW system with large number of
interfaces, communication is one of the most important areas of concern for effective
functioning of the PTW system. Special attention shall be paid for managing the
possibility of communication problems on the site because more than one language is
spoken.

Areas of specific emphasis include:

Person requesting the Permit to Work (Receiving Authority) must state clearly the
location, exact nature and scope of the work, the number of workers, different
disciplines and special tools involved.
Person issuing the permit (Issuing Authority) must communicate clearly the
potential hazards existing in the worksite (location), the precautions taken and
control measures in place, and the additional precautions to be taken by the person
in charge of the work (Receiving Authority). The Issuing Authority shall also ensure
that any person or organization working nearby that may be affected by the work is
communicated accordingly.
Person in charge of the work (Receiving Authority) must communicate clearly to the
members of the workforce (Performing Authority), the information received on
hazards, and precautions & the actions required to be taken in the event of an
emergency. He must also inform the Issuing Authority in case any change occurs in
the working conditions, which may affect the validity of the permit.

2.4 Safe Isolation

Safe isolation is established through the minimum safety requirements for protecting
personnel from events that may be caused by the unexpected energizing or start-up of
machines or equipment, or release of stored energy while carrying out commissioning
activities. This will be accomplished by locking out and tagging out energy isolation
devices, and otherwise disabling machines or equipment to prevent unexpected
energizing, start-up or release of stored energy. Separate measures may be required to
prevent damage to equipment.

2.4.1 Lock Out and Tag Out

Implementation of lock-out and tag-out shall be performed only by authorized personnel.


All machinery or equipment shall be isolated and rendered inoperative before anyone
proceeds with the assigned task, in order to prevent from unexpected start-up or release
of stored energy. An approved locking device shall be used to isolate and render the
machine or equipment inoperative, also a Do Not Operate Tag will be displayed on it.

2.4.2 Isolation and De-Isolations

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

The isolations and de-isolations of the equipment under commissioning shall be done
electrically and mechanically by authorised personnel only and shall countersign for the
same before and after the jobs are declared complete by the job performing authority
after issuing signatures on the work Permits.

2.5 Personal Protective Equipment (PPE)

PPEs form the basic requirement for carrying out any kind of job defined in the work
Permit. Necessary PPEs required for a particular job shall be used by the workers and it
shall be well explained during the Tool Box Talk (TBT) by the Person in charge of the work
(Receiving Authority). Basic PPEs required to use during the Commissioning shall comprise
of but not limited to Overalls, Hand gloves, Helmet, Safety Glasses, Ear Protection, Nose
Mask, Safety Harness, Safety Boots, etc.

3.0 Brief Process Description

The Bapetco/Tarek/Salam gas export pipe line has been hot tapped across a pipe line
block valve. In order to allow the gas compression facilities to extract gas form the
export line, re-compress the gas and discharge the gas at a higher pressure back into the
export pipe line.

For the purpose of description Compression Train A shall be describe with Compression
Trains B, C&D being equal to train A.

Export Gas from pipe line flow rate is 965.3 mmscfd at a pressure of 67.5 barg.
The gas temperature is 32/55 deg C.

Gas to the compressor manifold for A, B C&D is 964.8 mmscfd at a pressure of


66.5 barg. The gas temperature is 32/55 deg C.

Gas to Compressor Train A is 321.6 mmscfd at a pressure of 66.5 barg. The gas
temperature is 32/55 deg C.

Compressor A Suction is 319.4 mmscfd at a pressure of 66.0 barg. The gas


temperature is 32/55 deg C.

Compressor A Discharge is 319.4 mmscfd at a pressure of 94.4 barg. The gas


temperature is 60/84 deg C.

Gas Discharge Cooler discharge is 319.4 mmscfd at a pressure of 93.4barg. The gas
temperature is 55/55 deg C.

Compressor Export to the export pipe line (accumulative) is 958.1 mmscfd at a


pressure of 93.4 barg. The gas temperature 55/55 deg C.

Fuel Gas to Power Generation is 0.495 mmscfd at a pressure of 66.5 barg. The gas
temperature is 32/55 deg C.

Seal Gas to Turbines is 0.25 mmscfd at a pressure of 93.4 barg. The gas
temperature is 55/55 deg C.

A typical Main Process Flow Diagram is shown below:

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

Northern Gas Compression Facilities

From Gas Export Line Gas Inlet Manifold

Gas Filter

Gas comp. Suction


Scrubber

Gas Comp.
Package A

Gas Compressor
A

Gas Compressor
Discharge Cooler

To Gas Export Pipe Gas Discharge


Line Manifold

4.0 Commissioning Plan

4.1 General

The Commissioning Team will impart the knowledge gained from construction and pre-
commissioning into the commissioning phase, to achieve a safe & successful
commissioning.

Planning and performing the commissioning activities will be managed in a controlled and
structured manner in order to provide visibility to the interested parties and also to
ensure that all critical milestones are achieved as per the plan.

4.2 Commissioning Scope

Commissioning Plan comprises of multi-discipline activities related to testing of


functionality and operability of various systems, preparation for process plant start up,
Start up (Hydrocarbon Feed Introduction) & Stabilization followed by Performance
Guarantee Test Run.

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4.3 Commissioning Organization

The Site Commissioning Organization Chart shown on page No.11 briefs in detail about
Pre Commissioning / Commissioning Organization and Interface with Company Team for
carrying out the Commissioning activities and the personnel involved in the Site
Commissioning Organization.

4.3.1 Commissioning Organization / Roles & Responsibilities


The Commissioning Organization comprises of:
Commissioning Manager
Commissioning Coordinator
Commissioning Engineers
Turnover Coordinator
Maintenance Engineer (mechanical)
Ad hoc support from Instrument / Electrical discipline engineers as required.

Site Commissioning Organization Chart and Integrated Start-Up Organization are shown
on page no. 11 & 12 of this Manual.

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

Site Commissioning Organization Chart


PRE COMMISSIONING / COMMISSIONING ORGANIZATION AND INTERFACE WITH COMPANY TEAM

Site HSE Manager Commissioning Manager KPC


Enppi Enppi Commissioning / Operation
Planning / Vendor
Representative
Coordinator
Construction Commissioning
Support Team Coordinator Technical KPC KPC Discipline
Support Operation Engineer
Supervisor
Mechanical Inst. /Control Electrical Preservation / Process KPC Shift Instrumentation
Engineers (2) Engineers (3) Engineer (2) Maintenance Commissioning Supervisor
Engineer Engineer
Electrical

Mechanical Inst. /Control Electrical


Technicians (4) Technicians Technicians Mechanical
(6) (4)
Preservation
Technicians Plant Operators KPC Plant
(2) (DCS 2+ Field 4) Operators (8)

Work Permit Punch List


Coordinator Coordinator
Hand Over Coordinator Document Controller
(2)

Reports to QA/QC

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

INTEGRATED START-UP ORGANIZATION

Operation Manager (KPC)

Lead Operations Supervisor Commissioning Manager


(KPC) (Enppi)

Start-up &
Operation Lead Shift Supervisors (2) Commissioning Enppi Process Engineer
KPC Coordinator (Enppi) (Technical)

Senior Process Engineering


Operators (2) Supervisors (2) KPC
KPC Sr. Electrical Technicians
DCS Operators (2) KPC (2) KPC

Sr.Mechanical Technicians
Field Operators (6) (2) KPC
KPC

Sr.Instrument Technicians
(2) KPC

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DOCUMENT TITLE: COMMISSIONING MANUAL Rev No. A

4.4 Commissioning Schedule

A detailed Commissioning Schedule is developed identifying the sequence and duration of


the commissioning activities required to complete and make the systems ready for Start
up. The schedule is based on,

Commissioning the Utility Systems and putting into operation prior to Hydrocarbon
Feed Introduction and

Commissioning the Process Systems fully after Hydrocarbon Feed Introduction.

4.5 Resources

The qualified & competent manpower required for Commissioning activities is provided
jointly by Contractor and Company as shown in Site Commissioning Organization Chart on
page 11 of this manual.

The identified team shall carry out the operational activities in the process units
complying with the safety requirements during the Commissioning / Start up &
Stabilization / Performance Guarantee Test Run phases.

5.0 Commissioning Spares & Consumables


Contractor is responsible for making the required commissioning spares available on the
site as per the equipment specifications prior to commence the commissioning activities
and also for suitable storage of the same in accordance with the manufacturers / vendors
storage instructions. Commissioning spares left unused shall be handed over to Company at
the end of Initial Operation.

6.0 Lubrication Schedule

Lubrication Schedule showing the various kinds of lubricants used for the equipments and
lubricating locations & frequency is in place for follow up during commissioning.

7.0 Preservation & Maintenance

Preservation & Maintenance shall be carried out on the equipments supplied to site,
installed, tested and commissioned for normal operation. Contractor is responsible for
carrying out the pro-active preservation & maintenance by way of taking preventive
measures and the routine preservation & maintenance as specified in the respective
checklists and vendor requirements. This is also essential in maintaining warranties.

Preservation Records will be generated and forwarded to Turn over Coordinator.

8.0 Equipment & Instrumentation Commissioning

Commissioning of equipments & instruments shall be done after pre-commissioning


checks / Mechanical Completion with Companys clearance on Ready for Commissioning
(RFC).

Commissioning of Process equipments / systems shall be taken up after Utilities are


commissioned and put into operation.

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8.1 Static Equipment Commissioning

Static Equipments like Vessel, Tanks, Filters, and Heat Exchangers & Heaters shall be
commissioned in the following sequence;

a. Mechanical Completion, including installation of internals and external


instrumentation & piping as per P&ID/equipment drawing shall be verified.

b. Internal visual inspection for cleanliness shall be completed. Person carrying out
this cleanliness inspection shall witness the final closure of the equipment also.

c. Final inspection / closure (box up) of the equipment shall be done following the
completion of loading of packing, elements, etc. Respective Check Lists shall be
used for final inspection and closure of the Vessel /Tank.

d. Loading of packing, elements shall be carried out with vendor assistance as per the
procedure given in the vendor manual.

e. Leak Test / Inerting (purging) /Blanketing (where required), shall be done after
final closure of the static equipments.

Now the static equipment is ready for normal operation.

8.2 Rotating Equipment Commissioning

The following observations shall be recorded in the Commissioning Check List of the
specific Rotating Equipment.

a. Direction of rotation (DOR)


b. Bearing temperature.
c. Vibration and/or unusual noise.
d. Lubrication leaks around the equipment, piping and coolers, if applicable.
e. Excessive temperature at gland packing or seals and process fluid leaks.
f. Hot alignment of couplings, shafts and/or belts.

8.3 Instrumentation Commissioning

Instrumentation commissioning which comprises of


Functional Testing and operation of control loops,
Process Control (DCS) System,
Shutdown (ESD & OSD) System and
Fire and Gas (F&G) detection system
is part of the commissioning activities and it will be taken up parallel to pre-commissioning
activities.

9.0 Test Run of Rotating Equipments

9.1 General

Test run of the Rotating Equipment shall be carried out after completion of Commissioning
checks on it.

Testing of Rotating Equipments covers decoupled run (of drive motor) and coupled run of
pump, compressor, blower, fan, etc, for the test run.

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Ensure the inspection and calibration checks are completed for the associated
instrumentation prior to start the Test Run of Rotating Equipments.

9.2 Test Run of Electrical Motors

Electrical motors, wherever applicable, will undergo No Load Test run after de-coupling
from the driven equipment and a Test Run Sheet shall be filled up with data on following
parameters.
Direction of rotation (DOR)
Motor Vibration level
Bearing Temperature
Abnormal Noise & noise level
No Load current - amps (Compare it against specification of the motor)

During the subsequent coupled run, record the base line data in the Test run Sheet on
Current Load, Vibration Level and Bearing Temperature of the motor, as these data are
important for future reference while checking the motor performance.

9.3 Dynamic Run of Process Pumps

Dynamic Run of process pumps will be carried out as per the procedures where applicable,
with vendor clearance, to assess the operability of the pump against the intended use
before plant start up.

Install temporary screen (preferably 40 mesh) in the suction strainer or in the selected
flange joint between the suction strainer and the pump. Flag the strainers and keep a list
to prevent /identify a lost screen.

(Temporary screen shall be removed after completion of Dynamic Run and the original
strainer element installed).

Carry out the final alignment checks for the pump after the Dynamic Run (where
required), as per vendor guidance.

Caution: Temporary screens in the suction line / strainer may require cleaning during
dynamic run. Particular attention shall be given to any indications on surging when fine
mesh screens are installed. Indication will be, wild changes in pump discharge pressure
and sudden changes in amperage of the motor. These changes will indicate the blockage of
temporary screen in the suction line /strainer.

9.4 Test Run of Air Cooler Fan

Test Run of Air Cooler Fan shall be carried out after completing the Commissioning Check
Sheet.

Test Run shall be conducted preferably for all fans of the particular bank section
simultaneously in operation
Rotate Fan by hand to see if shaft, speed reducer, and driver turn freely.
Check and adjust for adequate fan blade tip clearance. The allowable clearance
range is 5 15 mm.
Kick start the fan and check direction of rotation (DOR) and it should be clockwise
when viewed into the discharge stream.
If the starting torque causes to trip vibration switch, adjust its sensitivity.

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Start the fan, check the motor current and adjust the fan blade pitch to load the
driver, if necessary.
Check for vibration levels on the drive end and on a specific point closer to fan
bearing.
Check for abnormal noise & noise level.
Check whether the belt/pulley engagement is over the full width, during test run.
Tighten HTD-belts as required in accordance with belt tensioning procedure for
banded belts (belts may continue to stretch during the first 30 days operation,
requiring re-tensioning.
Check for abnormal structural vibrations or loose bolts during the test run.
Test run will go for mutually agreed duration (normally four hours).
Record the data in Test Run Sheet for future reference.

9.5 Test Run of Blower / Fan

Test run shall be carried out for mutually agreed duration (normally four hours) after
completion of Commissioning Check Sheet. Record data on the following observations
during Test Run in the Test Run Sheet for future reference to review the blower / fan
performance:
Check suction filter for cleanliness (if applicable)
On belt drive fans, check sheave alignment and v-belt tension.
Ensure the bearings are properly aligned and lubricated with special attention to
the locking mechanisms, cleanliness, and possible corrosion. Bearings showing signs
of corrosion must be replaced prior to operation of the Blower / Fan.
Check the clearance of impeller to inlet cone and impeller to fan housing in order
to ensure that there is no interference. Turn the impeller by hand, and ensure it
rotates freely.
Impeller should be stationary prior to start up. Start up while fan impeller is
rotating backwards can cause damage.
When the fan is provided with damper or variable inlet vane, close the same to
minimize the starting load of the drive motor.
Kick start the blower / fan and see the direction of rotation (DOR).
Start and run the blower / fan for mutually agreed duration (normally four hours).
Suction damper can be operated to vary the load during the test run. Check and
record the readings on following data:
- Current load
- Bearing Temperature
- Vibration level
- Abnormal noise / noise levels

9.6 Test Run of Compressor

Centrifugal Compressors Test run will be carried out when process gas is available after
Hydrocarbon Feed Introduction.

Compressor Test Run Plan shall be jointly prepared with vendor assistance and it shall
consist of the following elements, as minimum:

Completion of chemical cleaning and oil flushing.


Completion of commissioning check list.
Test Run of compressors shall be carried out as per vendor instruction /
guidelines /procedure with vendor supervision.

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Tests of auxiliary systems in total seal system and fire protection shall be included
in the schedule well in advance of the compressor test run
All test results shall be recorded on specific test sheets.
All anti-surge equipments shall be tested for operability.

Following parameters shall be monitored during the Test Run:


Vibration levels (during start-up & operating speed)
Noise levels
Speed
Driver operating data (current load)
Start-up logic and any other relevant process data.

Following the test run, a hot alignment check of the coupling between the driver and
driven equipment is to be carried out as per vendor guidance.

10.0 Preparation for Plant Start up

The following activities shall be completed after the equipments / instrumentation


commissioning to prepare the plant ready for start up:

10.1 Installation of Orifice Plates

Instrument orifice plates and restriction orifices shall be installed in accordance with
vendor data sheets and the approved P&IDs, only after ensuring the corresponding pipe
runs are thoroughly cleaned.

Refer vendor data sheets to determine the orifice bore size, and refer approved P&IDs to
determine the flow direction & OD of orifice. Each Orifice bore shall be measured with
micrometer and any difference from the data sheets shall be noted down. Verify the piping
specification to use correct size gasket for orifice mounting.
Maintain a record of orifice plates to facilitate control over their installation in right
direction and to serve as a valuable reference, when any mismatch arises in requirement
vs. availability, etc.

10.2 (a) Removal of Spades:

Spade register shall be maintained as per the list of spades appearing on approved P&ID.
Data on spades installed in different location for hydro testing purpose shall be maintained
as a separate document by construction. Finally, it is the responsibility of the construction
team to remove these spades and hand over the document to Commissioning team so that
the removal of spades can be ensured prior to commissioning / start up.

(b) Checking Spectacle Blinds locations & Valves LO/LC position:

Spectacle blind register is compiled during the pre-commissioning and commissioning


preparation phase. This register serves as a basic reference document for physical
verification prior to commissioning and it contains the list of Spec blinds with their
locations that appear on approved P&IDs.
Valves LO / LC position (Lock Open / Lock Closed) register is compiled during the pre-
commissioning and commissioning preparation phase. This register serves as a basic
reference document for physical verification prior to commissioning and it contains the list
of Valves with their LO/LC position and their locations that appear on approved P&IDs.

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10.3 Water / Moisture Removal from Piping and Equipment:

Though the piping and equipment drying and inerting activity is completed at pre-
commissioning stage, it is imperative to check the water sensitive sections of the plant
These checks are necessary to prevent possible plugging of lines and equipment by hydrate
formation.

10.4 Relief Valve Calibration:

Prior to Hydrocarbon Feed Introduction, it must be ensured that all the relief valves have
been calibrated, tagged and certificate issued and installed in position as per the P&IDs.
The Calibration Certificate will remain valid as specified by the Vendor standards
(generally the validity would be from six months to one year). If a relief valve is installed
and the system becomes Live within the certificate valid time then the relief valve will
remain in situ otherwise it will have to be re-calibrated and re-certified again prior to use.

11.0 Commissioning / Start up Sequence

Commissioning of Common Utilities & Offsite systems and Process Systems is in the
following sequence:
1. Temporary Power.
2. Sub Station.
3. UPS.
4. HVAC.
5. Open Drain System.
6. EDG.
7. Telecommunication.
8. DCS, F&G, ESD Control Systems.
9. Fire Water System.
10. Potable / Fresh Water System.
11. Safety Systems:
a) Foam & Deluge System,
b) Safety Shower & Emergency Eye Wash Shower system &
c) FM 200 System.
12. Closed Drains System.
13. Utility Air / Instrument Air System.
14. Inert Gas Generation System.
15. GTG units (using Fuel Gas from( Temporary connection).
16. Cold Flare System.
17. Fuel Gas System.
18. Feed Gas (Hydrocarbon) Introduction.
19. Leak Test of process systems at operating pressure.
20. Process Start up & Stabilization.
21. Performance Guarantee Test Run.

After Gas-In, all the plant operation under Hydrocarbon will be managed by Company
Operations Team, on 24 hours basis, under Company Operating Procedures & PTW system,
and will be assisted by the Contractor Commissioning Team. This will ensure that all
operating interfaces & metering are under Company Operation & Control.

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12.0 Performance Guarantee Test Run

Following the Start up Plant Operation will be stabilized by maintaining process


parameters in the design

After establishing the stable operation for minimum 24 hours with Plant Throughput Rate
set at design or mutually agreed level, Performance Guarantee Test Run will be carried out
for consecutive 72 hours, as per the Performance Guarantee Test Procedure
The Contractor (Enppi) shall inform the Company (KPC) in advance on starting the
Performance Guarantee Test Run of the Plant.

Contractor (Enppi) is responsible for generating and maintaining the associated records
and log sheets on Process conditions and Plant Performance during the Performance
Guarantee Test Run.

13.0 Initial Operation

Within 24 hours following successful completion of Performance Guarantee Test Run,


Company (KPC) will issue Initial Acceptance Certificate and continue the Initial Operation
for Three months period.

Contractor (Enppi) shall assign a full time representative in the Control room along with
Company's Operation representative, and he will maintain a logbook on plant operation
during the Initial Operation period.

14.0 Hand Over

The plant will be handed over to Company (KPC) using the Handover Dossiers containing
the support documents for the pre commissioning, commissioning and performance
guarantee test run and also the mile stone certificates of these phases.

The formal handover will be achieved by signing off the Handover Dossier at the end of the
Initial Operation.

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Malcolm Vickers Page 18 of 18