IONE-AA00-PE-CM-0001 Precommissioning & Commissioning Execution Plan Rev.0

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DOC. NO. : IONE-AA00-PE-CM-0001
KARBALA REFINERY PROJECT Rev. 0 Page 1/48
Ref. FEED DOC. No. : 2342-AA00-JSM-901
PRECOMMISSIONING & COMMISSIONING Execution Plan
PROJECT : KARBALA REFINERY PROJECT
LOCATION : KARBALA, IRAQ
EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)
ISSUED FOR
0 30 SEP 14 K. Y. KO J. S. KIM Y.S.KIM B.H.SHIM H.S.HWANG
CONSTRUCTION
A 27 JUN 14 ISSUED FOR REVIEW K. Y. KO J. S. KIM Y.S.KIM B.H.SHIM H.S.HWANG
REVD REVD APPRD CONFD

REV. DATE DESCRIPTION PRPD CHKD
(PQM) (PM) (PD) (SCOP)
Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK Engineering
& Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,
Note :
a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made
b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by
HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

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REVISION HISTORY
Rev Date Description Page
A 27 JUN 14 Initial Issue -
0 30 SEP 14 Insert a page of Revision Hisory 2

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TABLE OF CONTENTS
1. GENERAL ...................................................................................................................................................6
1.1. Introduction ................................................................................................................................... 6
1.2. Purpose ......................................................................................................................................... 6
1.3. Scope of Application .................................................................................................................... 6
1.4. Objective & Strategy .................................................................................................................... 6
1.5. Definition ....................................................................................................................................... 7
2. REFERENCE ..............................................................................................................................................8
3. PHASES TO COMPLETION.......................................................................................................................8
3.1. MECHANICAL COMPLETION ...................................................................................................... 9
3.2. PRE-COMMISSIONING ................................................................................................................. 9
3.3. COMMISSIONING ........................................................................................................................10
3.4. START-UP .................................................................................................................................... 11
3.5. PERFORMANCE TEST ............................................................................................................... 11
3.5.1. PERFORMANCE TEST ......................................................................................................12
3.5.2. PROVISIONAL ACCEPTANCE ........................................................................................12
3.6. FINAL ACCEPTANCE .................................................................................................................12
4. SYSTEM METHODOLOGY ......................................................................................................................12

4.1. The ‘System Approach’ ..............................................................................................................13
4.2. Definition of System & Subsystem ...........................................................................................13
5. UNICCS .....................................................................................................................................................14
6. PRECOMMISSIONING METHODOLOGY ...............................................................................................14

6.1. Scope of Work and Activities ....................................................................................................14
6.2. Conformity Checks .....................................................................................................................15
6.3. Static/Dynamic Checks/Tests ....................................................................................................15
6.4. Piping and Equipment Preparation ..........................................................................................15
6.5. PUNCH LIST (during PRECOMMISSIONING) ...........................................................................15
6.6. PRECOMMISSIONING DOSSIERS ............................................................................................15

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7. COMMISSIONING METHODOLOGY.......................................................................................................16
7.1. Scope of Work and Activities ....................................................................................................16
7.2. Activating All Utilities .................................................................................................................16
7.3. Functional Test of Rotating Equipment / Electric Motors ......................................................16
7.4. Ready for Start-up & Start-up ....................................................................................................16
7.5. PUNCHLIST (during COMMISSIONING) ...................................................................................17
7.6. COMMISSIONING DOSSIER ......................................................................................................17
8. CONTROL OF SEQUENCE AND SCHEDULE ........................................................................................17
9. ROLES & RESPONSIBILITY ...................................................................................................................17

9.1. CONTRACTOR ............................................................................................................................17
9.2. EMPLOYER .................................................................................................................................18
10. ORGANIZATION ...............................................................................................................................18

10.1. CONTRACTOR’s PRECOMMISSIONING and COMMISSIONING Team ...............................18
10.2. Mobilization of PRECOMMISSIONING/COMMISSIONING Teams to Work Site ....................19
10.3. Job Description of CONTRACTOR’s Key Members ................................................................19
10.3.1. COMMISSIONING General Manager .................................................................................19
10.3.2. COMMISSIONING Area Manager .......................................................................................20
10.3.3. Maintenance Manager.........................................................................................................20
10.3.4. Planning Manager ...............................................................................................................20
10.3.5. Training Manager ................................................................................................................20
10.3.6. COMMISSIONING Area Engineer ......................................................................................20
10.3.7. Vendor’s Specialist ..............................................................................................................21
11. COMMISSIONING Documentation Methodology .........................................................................21

11.1. Category of Documents .............................................................................................................21
11.2. Document Control and Issue ....................................................................................................22
11.3. Schedule of COMMISSIONING Documents .............................................................................22
11.4. List of COMMISSIONING Documents .......................................................................................22
12. COMMUNICATIONS .........................................................................................................................24
13. SAFETY ............................................................................................................................................24

13.1. Introduction .................................................................................................................................24

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13.2. Work Permit.................................................................................................................................25

13.2.1. General ................................................................................................................................25
13.2.2. Precaution ...........................................................................................................................25
13.2.3. Closing out and filing the Permit .........................................................................................25
13.3. Personal Safety...........................................................................................................................25
13.3.1. Personal Protective Equipment ...........................................................................................26
13.3.2. Personal Coverage ..............................................................................................................27
13.3.3. House Keeping ....................................................................................................................27
ATTACHMENTS
#1. GENERAL WORK FLOW of PRECOMMISSIONING & COMMISSIONING ...........................................29
#2. CHECK LIST FOR MC..............................................................................................................................31

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1. GENERAL
1.1. Introduction
This document provides general guidelines for execution of PRECOMMISSIONING and
COMMISSIONING to be carried out by HDGSK JV(hereinafter “CONTRACTOR”). This document
was prepared to comply with the EPC Agreements between the STATE COMPANY FOR OIL
PROJECTS (SCOP) of the Ministry of Oil, Baghdad, Iraq (hereunder “EMPLOYER” or “SCOP”)
and CONTRACTOR for Karbala Refinery Project.
1.2. Purpose
The purpose of this document is to ensure that the PRECOMMISSIONING and
COMMISSIONING work are correctly planned, executed and controlled in accordance with
EMPLOYER requirements specified in the contract documents including Contract
Documents( Volume3 – Section1 – Para8, Volume5 – AA00 – JSM900, 901, 902, 903, 904).
To facilitate smooth and trouble-free completion of PRECOMMISSIONING and COMMISSIONING
followed by Initial Operation and PROVISIONAL/FINAL ACCEPTANCEs, CONTRACTOR will
develop necessary documents including PRECOMMISSIONING & COMMISSIONING schedules,
relevant plans and procedures. These documents will be used as the basic guidelines and tools to
obtain a smooth transfer of the installations from the Construction Team to
PRECOMMISSIONING & COMMISSIONING Team and then to the EMPLOYER, as quickly as
possible, in full confidence, and with all the required quality and safety requirements.
1.3. Scope of Application

This document will be applied to all PRECOMMISSIONING and COMMISSIONING activities to be
executed by CONTRACTOR.
1.4. Objective & Strategy

For the successful execution of project, the objective & strategy of COMMISSIONING team is that
follow faithfully the Project goals & Objectives mentioned 3.2 paragraph of ‘Project Execution
Plan’. Especially, the COMMISSIONING team, for EMPLOYER’s sustainable operation of Karbala
Refinery Plant, has two primary objectives as described below:
 Flawless Start up
 Faultless Operation
First, for the Flawless start up, COMMISSIONING team shall, without limitation:
 Involve COMMISSIONING staff in early stage of Project

 Make the reasonable COMMISSIONING & Start-up Schedule
 Review engineering data
 Reflect the real experience & lesson learned for operation
 Define the effective System & Sub-system definition
 Control the Project schedule from UNICCS
 Participate HAZOP / FAT / SAT / P&ID review / 3D review
 Study the Operability and Maintenability
Second, for the Faultless Operation, COMMISSIONING team shall, without limitation:

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 Provide the experienced staffs for the refinery plant

 Provide the effective training programs
 Organize OJT groups lead by supervisor staffs
 Hold frequently a schedule meeting with EMPLOYER and engineering department
 Hand over perfectly the COMMISSIONING & Operation documents
In order to accomplish COMMISSIONING team’s objectives mentioned above, the

CONTRACTOR’s COMMISSIONING team strongly needs the EMPLOYER’s full cooperation. And
all activities should first be based on the Safety for the successful execution of the Project.
1.5. Definition
Contract means the Contract Agreement, the Conditions, the Employ’s requirements, the Tender,
and the further documents (if any) which are listed in the Contract Agreement.
Party means the Employer or the Contractor, as the context requires.
Employer means the person named as Employer in the Contract Agreement and the legal
successors in title to this person. The “Employer” and reference to “Engineer” means the Director
General of SCOP or any person authorized by him.
Contractor means the person(s) named as contractor in the contract Agreement and the legal
successors in title to this person(s).
Employer’s Personnel means the Employer’s Representative, the assistants referred to in Sub-
Clause 3.2 [Other Employer’s Personnel] and all other staff, labor and other employees of the
Employer and of the Employer’s Representative; and any other personnel notified to the
Contractor, by the Employer or the Employer’s Representative, as Employer’s Personnel.
Contractor’s Personnel means the Contractor’s Representative and all personnel whom the
Contractor utilizes on Site, who may include the staff, labor and other employees of the
Contractor and of each Subcontractor; and any other personnel assisting the Contractor in the
execution of the Works.
Subcontractor means any person named in the Contract as a subcontractor, or any person
appointed as a subcontractor, for a part of the Works; and the legal successors in title to each of
these persons.
Commencement Date means the date of notification to the Contractor’s bank of the opening of
the activated L/C referred to in clause 14.16.1, unless otherwise defined in the Contract
Agreement (date upon which Letter of Credit is opened). “Contract Effective date” means the
date of signature of the Contract.
Materials means things of all kinds (other than Plant) intended to form or forming part of the
Permanent Works, including the supply-only materials (if any) to be supplied by the Contractor
under the Contract.
Plant means the apparatus, machinery and vehicles intended to form or forming part of the
Permanent Works.
Temporary Works means all temporary works of every kind (other than Contractor’s Equipment)

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required on Site for the execution and completion of the Permanent Works and the remedying of
any defects.
Works means the Permanent Works and the Temporary Works, or either of them as appropriate.
Contractor’s Documents means the calculations, computer programs and other software,
drawings, manuals, models and other documents of a technical nature supplied by the Contractor
under the Contract; as described In Sub-Clause 5.2 (Contractor’s Documents).
Country means the Republic of Iraq.
Site means the places where the Permanent Works are to be executed, including storage and
working areas, and to which Plant and Materials are to be delivered, and any other places as may
be specified in the Contract as forming part of the Site.
Variation means any change to the Employer’s Requirements or the Works, which is instructed or
approved as a variation under Clause 13 [Variation and Adjustment].
2. REFERENCE
Contractual documents referenced for preparing this PRECOMMISSIONING and COMMISSIONING

Execution Plan are as below.
st th
a) EPC Contract Finalization Meeting(Technical) 21 -24 Jan 2014 Amman, Jordan
b) CONTRACT DOCUMENTS Volume3. Contractor’s Scope of Work – Section1.8
Precommissioning / Commissioning and Start-up
c) 2342-AA00-JSM-900 OPERATION, MAINTENANCE AND PRESERVATION PHILOSOPHY
d) 2342-AA00-JSM-901 PRECOMMISSIONING & COMMISSIONING EXECUTION PLAN
e) 2342-AA00-JSM-902 KARBALA REFINERY TRAINING REQUIREMENTS FOR EPC
CONTRACTOR
f) 2342-AA00-JSM-903 CHECKLIST FOR PLANT COMPLETION PRE-COMMISSIONING AND
START-UP
g) 2342-AA00-JSM-904 GENERAL GUIDELINES FOR VEDOR MAINTENANCE MANUALS
3. PHASES TO COMPLETION
There are several major Phases to be passed by which leads to completion of the facilities during the
period after erection and before they are finally handed over to the EMPLOYER. These Phases include
MECHANICAL COMPLETION, PRECOMMISSIOING, COMMISSIONING and START-UP,
PERFORMANCE TEST, PROVISIONAL and FINAL ACCEPTANCE.
Especially, among these Phases, phase classification of detail activities related with phase of
PRECOMMISSIOING, COMMISSIONING and START-UP are made and developed clearly from “2342-
AA00-JSM-903 CHECKLIST FOR PLANT COMPLETION PRE-COMMISSIONING AND START-UP”
(See Attachment-2 CHECK LIST FOR MC). The developed contents of the Attachment-2 are

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expressed in inclined writing style as just behind example (examples  examples).
3.1. MECHANICAL COMPLETION

MECHANICAL COMPLETION is the stage when the construction and installation of equipment,
piping, instrumentation, cabling, electrical equipment, etc. have been demonstrated as
mechanically complete and all PRECOMMISSIONING activities including inspections, cleaning,
testing as well as documentation requirements have been fulfilled.
MECHANICAL COMPLETION of each component of Facility will be defined by signing off of the
MECHANICAL COMPLETION CERTIFICATE (MCC) for the individual System and/or Subsystem.
3.2. PRE-COMMISSIONING
PRECOMMISSIONING means all checks, cleaning and testing of Plant and its implementation
without introducing hydrocarbons or permanently energizing or pressuring said Plant.
PRECOMMISSIONING includes all activities implemented between the completion of construction
activities and Ready for COMMISSIOING. PRECOMMISSIONING is a series of activities
consisted of cleaning, checking, testing, adjustment, etc.
PRECOMMISSIONING activities will be started as soon as system installation works are
completed. But, category “A” punch list items should be rectified perfectly before starting the
PRECOMMISSIONING activities.
From the PRECOMMISSIONING phase, the EMPLOYER’s operators and maintenance personnel
shall be involved and work with the CONTARACTOR’s COMMISSIONING team under control of
CONTRACTOR’s COMMISSIONING manager.
CONTRACTOR will be responsible for all activities during PRECOMMISSIONING and shall work
in accordance with the PRECOMMISSIONING Procedures.
CONTRACTOR shall, without limitation:
 Provide PRECOMMISSIONING Procedures as well as activity schedule for safe and efficient
progression of PRECOMMISSIONING works.
 Provide suitably experienced personnel to undertake PRECOMMISSIONING activities and to
resolve any problems that may occur.
 Undertake PRECOMMISSIONING activities according to the approved
PRECOMMISSIONING Procedures.
 Provide and manage the Vendor services as necessary
 Promptly rectify any problems and/or defects found in the course of PRECOMMISSIONING
works.
 Provide all records including check and test sheets.
 Provide effective & strict training to manage trainee qualification for better training result and
operation and maintenance quality.
Major activities to be performed in PRECOMMISSIONING stage are as below:
 System check out :

 Cleaning of piping and equipment, as necessary (Flushing, blowing, chemical cleaning,
degreasing, etc.)
 Piping reinstatement & tightness test
 Lube oil/Seal oil system flushing/cleaning and first lubricants filling
 Rotation direction and run-in of machinery drivers
 Electrical :

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 Make trials and adjustments and functional tests on switchgear, control panels and motor
control centers
 Test-set switchgear relays for proper co-ordination
 Check phase sequence and polarity
 Energize the system after completion of all tests
 Instruments/automation :
 Calibration instruments with standard test equipment and make all required adjustments and
control point settings
 Check settings of all alarm and shutdown switches
 Check all shutdown systems
 Check all safety valves and settings, ensure that safety valves isolation valves are
locked/open or locked/closed as per drawings
 Check control panels for all signals
 Instrument loop checks
 Removal of temporary screens, strainers, and blinds and their replacement as necessary
 Loading of vessels internals
 Final equipment close-up
 Fire and safety system pre-commissioning
 Others as necessary
In case inspection and/or witnessing of activities by EMPLOYER are requested or specified,

CONTRACTOR shall give adequate notice to EMPLOYER of the time and date when he intends
to perform such activities and tests. No test shall be conducted unless EMPLOYER is present or
has specifically instructed CONTRACTOR to proceed without his presence. The
PRECOMMISSIONING activities will be supported by specific check sheets to be signed off by
concerned parties.
Procedures of PRECOMMISSIONING activities are to be the general & standard documents for
issuing Method statements of each PRECOMMISSIONING activities detailed, and to be prepared
and issued from the Home office. To facilitate proceeding with PRECOMMISSIONING activities
such as cleaning (water flushing, air/steam blowing, manual/chemical cleaning, etc.) and tightness
test, marked up P&ID will be issued as a part of the Method statements as well.
3.3. COMMISSIONING
COMMISSIONING is the testing and adjustment of an assemblies, system or subsystem, and will
mainly comprise of Operational Testing under real or simulated conditions to ensure that it meets
all applicable Rules, Regulations, Specifications, Codes and Standards, and fulfils its intended
duty.
COMMISSIONING covers all activities conducted from after MC to before READY FOR START-
UP. Subject to the terms and conditions of the Contract, the Plant or Subdivision of the Plant is to
be commissioned by CONTRACTOR, who will commence COMMISSIONING as soon as he
deems it possible, under approval by EMPLOYER that the Plant or Subdivision of the Plant is
ready for COMMISSIONING and any operational requirements of the EMPLOYER are fulfilled.
Check list for plant completion is to be used for the EMPLOYER to approve commencement of
COMMISSIONING.
CONTRACTOR shall be responsible for all activities during COMMISSIONING and shall work in
accordance with the COMMISSIONING Procedures.
CONTRACTOR shall, without limitation:
 Provide COMMISSIONING Plans and Procedure as well as activity schedule for safe and
deficient progression of COMMISSIONING works.

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 Provide suitably experienced personnel to undertake COMMISSIONING activities and to

resolve any problems that may occur.
 Undertake COMMISSIONING activities according to the approved COMMISSIONING
Procedures.
 Provide and manage the Vendor services as necessary
 Promptly rectify any problems and/or defects found in the course of COMMISSIONING works.
 Provide all records including check and test sheets.
 Retain care and custody of the Plant throughout COMMISSIONING through to
PROVISIONAL and FINAL ACCEPTANCEs.
Major activities to be performed in COMMISSIONING stage are as below:
 Rotating equipment run-in

 Piping/equipment leak testing, drying out, purging
 Catalyst loading / desiccants
 Refractory Dry-out
 Chemicals Loading
 Functional tests
 Hot bolting
 Lube oil/Seal oil system commissioning
 Blind installation
 Instrument fine tuning and analysers testing
 Others as per contractual requirements
The procedures for special PRECOMMISSIOING or COMMISSIONING activities such as heater

refractory drying out, chemical cleaning, catalyst loading, etc. to be received from Vendors or Sub-
contractors will be checked by CONTRACTOR and additionally provided to EMPLOYER for
approval.
3.4. START-UP
When COMMISSIONING activities are completed at EMPLOYER’s satisfaction, and all Punch List
items have been cleared, the status of the READY FOR START-UP shall be reached, and the
READY FOR START-UP CERTIFICATE shall be issued by EMPLOYER.
CONTRACTOR shall prepare procedures for units START-UP activities and perform START-UP
according to said approved procedures. START-UP procedures shall describe in step by step
manner the activities carried out by CONTRACT Commissioning team during START-UP.
Major activities to be performed in START-UP stage are as below:
 Feed stock introduction

 Start filling of process vessels
 Initiate circulation of liquids in oil system
 Increase of process fluids flow, temperature and pressure, as applicable
 Control of products quality and quantity
 Achievement of unit stable conditions
 Establish unit normal operating conditions
 Establish unit products on spec at design throughput
3.5. PERFORMANCE TEST

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3.5.1. PERFORMANCE TEST

PERFORMANCE TEST shall be carried out by CONTRACTOR, and will be witnessed by
EMPLOYER.
The official starting time of PERFORMANCE TEST shall be agreed upon by EMPLOYER and
CONTRACTOR. That means the Unit has thereafter achieved stable, safe, continuous
operation, free of leaks and defects for seventy-two (72) hours with operating conditions
recommended by CONTRACTOR and approved by EMPLOYER as specified in JSM 901.
Detailed PERFORMANCE TEST Procedure shall be provided by CONTRACTOR to
EMPLOYER for approval at least six (6) months prior to the commencement of the
COMMISSIONING activities as specified in Volume3 - Section1.8 and Volume2 – Section3.
3.5.2. PROVISIONAL ACCEPTANCE

At the end of the PERFORMANCE TEST the CONTRACTOR shall prepare and submit, for
EMPLOYER approval, a report to demonstrate the successful result of the PERFORMANCE
TEST.
As soon as said report is accepted by EMPLOYER, CONTRACTOR shall apply to the
EMPLOYER for the provisional acceptance certificate.
PROVISIONAL ACCEPTANCE of the Plant shall occur upon issuance of a certificate of
PROVISIONAL ACEPTANCE by EMPLOYER.
3.6. FINAL ACCEPTANCE

Upon a completion of guarantee period CONTRACTOR shall apply to EMPLOYER for the final
acceptance certificate. FINAL ACCEPTANCE of the Plant shall occur upon issuance of a
certificate of FINAL ACCEPTANCE by EMPLOYER.
4. SYSTEM METHODOLOGY
The PRECOMMISSIONING and COMMISSIONING activities are relatively sophisticated operations,

which have to be carried out in a limited span of period. Not all parts of the plant reach the same
degree of completion at the same time; hence some areas or units of a plant may be MECHANICALLY
COMPLETE while others are not. It would therefore be a waste of time to wait for the whole plant to be
MECHANICALLY COMPLETE before starting PRECOMMISSIONING activities.
On the other hand, the start-up sequence of a new plant is often affected by operational constraints. In
general, safety-related equipment or system is given the highest priority, then the utilities such as
electrical power, instrument air, steam, nitrogen, fuel gas and flare systems are required to be serviced
earlier than the main process side. Therefore, the PRECOMMISSIONING and COMMISSIONING
activities will be proceeded in a different way compared with construction work; while the latter is
essentially planned in a basis of sequential completion by discipline and/or areas, the
PRECOMMISSIONING and COMMISSIONING work are planned in a multi-discipline and multi-system
basis.
Project Execution Planning will therefore be optimized in terms of means and resources if the
Construction activities are organized in such a way to be proceeded with by system and/or subsystem
in accordance with the given MC priorities instead of the whole system being handled at the same time

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without priorities.
The transition of construction mode from ‘Area Basis’ to ‘System Basis’ usually starts from the point
when approximately 60% of piping work progress has been achieved. But considered from realistic
point of view, the sooner the transition could be started, the higher efficiency in execution of
PRECOMMISSIONING and COMMISSIONING works would be resulted.
4.1. The ‘System Approach’

The execution of the project as a whole will be optimized if the PRECOMMISSIONING and
COMMISSIONING activities could be performed by smaller parts, called ‘SYSTEM’ or
‘SUBSYSTEM.’
Hence, the most efficient way for achieving plant completion in a limited period of time will be to
carry out PRECOMMISSIONING and COMMISSIONING activities by Systems and/or
Subsystems according to the predetermined MC priorities.
Expected benefits obtainable by “System Approach” are illustrated in the Figure-1 below.
Figure-1: The merit of ‘System Approach’
4.2. Definition of System & Subsystem

Any Project facilities can be divided into smaller sections called ‘system’ or ‘subsystem’ according
to a certain criteria such as kind of fluids serviced in the facilities, operational conditions and/or
characteristics of the process.
A system is a subdivision of a plant unit, either process or utility, which performs a specific
operational role or function in the plant. It is a discrete and functionally independent section which
can be PRECOMMISSIONed and made “READY FOR COMMISSIONING” separately from the
adjoining systems.
A Sub-system is a further subdivision of a system, that performs a given operational function that
may have little or no interference with the other subsystems. The subsystem will be so defined as
to be as independent as possible, not too small, yet of manageable size which could be smoothly

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adapted to the start-up sequence as one unit.

Not only the piping works but also all of the associated equipment and instruments that allows the
Plant to operate will be included in the Systems and Subsystems. The boundary of these Systems
and/or Subsystems will be marked up on the P&IDs and submitted to the EMPLOYER.
These marked up P&IDs will be used as a basis for developing the flushing packages and
hydrostatic pressure test packages of the piping works.
Non-process facilities within the project such as electrical substations, buildings, etc., shall be
similarly identified as systems for the purpose of MECHANICAL COMPLETION acceptance and
making them ready for use. Non-process systems can be further identified as following:
 Non-operational systems such as civil concrete work, structural steel, buildings, roads,
painting, insulation, etc.
 Operational systems such as electrical substations, HVAC, plant lighting, cathodic protection,
etc.
The “System Definition” is one of the major engineering deliverables and may be subject to
revisions and updates until the PAC. PRECOMMISSIONING and COMMISSIONING operations
will be carried-out and reported by systems.
5. UNICCS
UNICCS is an “in-house” software solution and specially designed for the management of
COMMISSIONING activities, and available either as proprietary solutions. And UNICCS is a software
package that has been developed to manage the Preparation, Execution and Monitoring phases of
PRECOMMISSIONING, COMMISSIONING. CONTRACTOR will use the UNICCS to report a status of
MECHANICAL COMPLETION, PRECOMMISSIONING, COMMISSIONING activities. EMPLOYER also
can access to UNICCS for monitoring a various status and balanced actual work.
The definitions given below are applicable to a fundamental concept of UNICCS:
 System is a functional grouping of piping, equipment, and instruments, which are logically
related to each other according to the process and which can be isolated from other Systems
for the purposes of managing MECHANICAL COMPLETION, PRECOMMISSIONING,
COMMISSIONING, and HANDOVER.
 SUB-SYSTEM is a part of the SYSTEM that can be completed and commissioned as a
separate entity.
 ITEM GROUP is a group of the Mechanical equipment, piping, Electrical Circuits, Instrument
Loops and Test Packages that are contained within the project.
 ITEM is an Individual tagged items such as Equipment, Pipe lines, Valves, Vessels &
Instruments and may be a part of the ITEM GROUP.
6. PRECOMMISSIONING METHODOLOGY
6.1. Scope of Work and Activities

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The PRECOMMISSIONING activities will be organized by systems and/or subsystems, following

the approved sequences which optimize the PRECOMMISSIONING phase. Permanent electrical
power as well as a few necessary utilities should be serviced prior to these activities.
The physical scope of PRECOMMISSIONING work consists of:
 1st Conformity checks of piping and equipment

 2nd Static/dynamic checks/tests of electrical, instrument and equipment
 3rd Piping and equipment preparation
6.2. Conformity Checks

Conformity checks, the first type of work in the PRECOMMISSIONING phase including inspection
of vessel, column, etc, will be carried out with the Check Lists which define the exact scope of
work to be systematically performed on every item of equipment or on selected packages.
A set of standard Check List Forms will be developed as necessary, and will be used for each
item or package.
6.3. Static/Dynamic Checks/Tests

Static checks and tests, the second type of key PRECOMMISSIONING activity including
calibration and function test of instruments, cable continuity tests, alignment checks, PSV setting
test, etc. will be carried out in accordance with technical specifications, and reported by Test
Sheets.
6.4. Piping and Equipment Preparation

Cleaning such as water flushing, air blowing, steam blowing, manual cleaning, chemical cleaning,
tightness test, catalyst loading, readying of chemicals for use, drying out of heater refractories,
inerting, testing the performance of nitrogen vaporizer, etc., which can collectively be grouped as
the fourth type of key PRECOMMISSIONING activities will be carried out according to the
General and/or Detail Procedures prepared exclusively for this activities by the CONTRACTOR
and approved by EMPLOYER. For Special activities such as catalyst loading and catalyst
activation, refractory drying out, Vendors procedures and/or method statements, checked by
CONTRACTOR and approved by EMPLOYER, will be additionally referenced.
The packages for cleaning and tightness test will be defined and marked up on the PID prepared
as an attachment to the Procedures.
6.5. PUNCH LIST (during PRECOMMISSIONING)

The Master PUNCHLIST, once established at the READY FOR COMMISSIONING stage, is
continually updated during the subsequent PRECOMMISSIONING stage by adding all newly
discovered items and deleting cleared ones.
While the PRECOMMISSIONING checks and tests are being performed, all discrepancies,
damaged or missing parts, malfunctions, if not corrected immediately, will be enlisted in the
Master PUNCHLIST.
6.6. PRECOMMISSIONING DOSSIERS

All documentation pertaining to the PRECOMMISSIONING activities will be compiled in the MC
Dossier. Check sheets and test report for each system, subsystem and/or equipment will be the

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main documents.
7. COMMISSIONING METHODOLOGY
7.1. Scope of Work and Activities

The COMMISSIONING activities will be organized by systems and/or subsystems, following the
approved sequences which optimize the COMMISSIONING phase.
The physical scope of COMMISSIONING work consists of:
 1st Activating all utilities

 2nd Functional run test of rotating equipment
 3rd Ready for Start-up & Start-up
All operations are organized by system and/or subsystem, following a sequence, basically
identical to that of PRECOMMISSIONING, which optimizes the COMMISSIONING phase.
7.2. Activating All Utilities

Activating all utilities, the first stage of work in the COMMISSIONING phase, is to activate all of
the utilities such as air, water, steam and nitrogen as well as fuel gas and flare systems.
This will be started once MECHANICAL COMPLETION and READY FOR COMMISSIONING for
a specific system or subsystem has been achieved according to the sequences and/or priorities
complying with the COMMISSIONING schedule.
In some cases utilities such as fresh cooling water, instrument air, fuel gas and flare, etc. should
be available earlier to make the PRECOMMISSIONING activities such as Mechanical Running
Test (MRT) of large pumps and air compressor and refractory dry-out possible. In this case
special care and cooperation among concerned parties should be exercised to avoid any
occurrence of safety incident.
A set of standard Check List or Check Sheet Forms will be developed and used to avoid any
possible confusion.
7.3. Functional Test of Rotating Equipment / Electric Motors

Functional test of rotating equipment, the Second type of work in the PRECOMMISSIONING
phase, will mainly consists of mechanical run-in test of rotating machines such as Electric
motors, pumps, mixers, air fans, compressors, deluge system for fire protection, etc.
This test is preceded under the operating conditions as close to normal as possible with inert
fluids for the purpose of confirming possible mechanical or electrical faults (water tightness,
vibrations, overheating, overloading, etc.) which may occur during prolonged normal use.
A set of standard Test and Check and/or Test Sheet Forms will be developed and used as
necessary.
7.4. Ready for Start-up & Start-up

Ready for Start-up, the third stage of work in the COMMISSIONING phase, will virtually be the
starting up activity of the unit towards continuous operation. This activity mainly consists of line-up
for feeding, loading of chemical & catalyst, inert gas purging finally.
If a Unit or System is readied for introduction of feed, Start-up activities should immediately be

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conducted by CONTRACTOR with witness by EMPLOYER. Every activity should be conducted in

a very cautious manner in accordance with the technical specification and Operating Manual, and
under the witness of or cooperation with the EMPLOYER personnel.
A set of standard Check List, Test and/or Log Sheet Forms will be developed and used to
maintain records for operation and maintenance.
7.5. PUNCHLIST (during COMMISSIONING)

The Master PUNCHLIST, established before the READY FOR COMMISSIONING stage, is to be
continually updated during the COMMISSIONING period also by adding all newly discovered
items and deleting cleared ones. All of the discrepancies, damaged or missing parts, malfunctions,
if not corrected immediately, will be enlisted in the Master PUNCHLIST for continued handling.
7.6. COMMISSIONING DOSSIER

All documentation related to the COMMISSIONING activities will be compiled in the
PROVISIONAL ACCEPTANCE Dossier, which will be prepared in Electronic File. Check sheets,
test report and/or log sheet for each system, subsystem and/or equipment will be the main
documents.
8. CONTROL OF SEQUENCE AND SCHEDULE
To meet the Project Milestone agreed upon between the EMPLOYER and the CONTRACTOR, it is
mandatory to prepare a well organized schedule for PRECOMMISSIONING and COMMISSIONING
activities showing the right sequence and time for each Unit comprising the whole Karbala Refinery
Project (See IONE-AA00-PE-CM-0006 PRECOMMISSIONING and COMMISSIONING Schedule – to
be isseud)
But just preparing the schedule itself would not be sufficient. It will be even meaningless if a series of
managerial efforts to keep the schedule are not followed. Close coordination between the
PRECOMMISSIONING/COMMISSIONING and Construction Teams as well as expediting the lagged
activities and clarifying/adjusting the priorities of specific activities with potential problem based on the
analysis of critical path vs. overall progress status would have to be practiced on a daily basis.
9. ROLES & RESPONSIBILITY
In order to obtain satisfactory results with PRECOMMISSIONING and COMMISSIONING works, a very
close coordination between the EMPLOYER and the CONTRACTOR is utmost important. In addition to
this, clear-cut understanding regarding scope of roles and responsibilities for each concerned party is
also very important. A split of responsibilities between the CONTRACTOR and the EMPLOYER is
shown below:
9.1. CONTRACTOR

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 Mobilization of necessary Construction and PRECOMMISSIONING/ COMMISSIONING

teams that consist of discipline engineers, supervisors and labors
 Periodical reporting of PRECOMMISSIONING and COMMISSIONING progresses
 Preparation and submission of all PRECOMMISSIONING and COMMISSIONING Manuals
and Procedures as per CONTRACT DOCUMENTS Volume3 – Section1 – Para8
 Preparation of tools, material and equipment needed for efficient and successful execution of
PRECOMMISSIONING and COMMISSIONING works
 Arrange for Vendor and/or Licensor representatives as necessary for COMMISSIONING &
START-UP and on-the-job training
 Preparation of QC documents for any activity which requires witness/verification
 Any others agreed between the EMPLOYER and the CONTRACTOR
 Tracking progress of PRECOMMISSIONING and COMMISSIONING activities
 Taking the responsibility for training to EMPLOYER’s 700 operation and maintenance
personnel
 Control of EMPLOYER’s 700 operation and maintenance personnel for sustainable operation
of the Plant
9.2. EMPLOYER
 Verifying various kinds of check sheets and/or test records to be prepared for the
PRECOMMISSIONING, COMMISSIONING and Performance TEST RUN activities.
 Providing 700 operation and maintenance personnel from 2 month before the
PRECOMMISSIONING as per contractor’s request and they will work with CONTRACTOR’s
COMMISSIONING team under control of CONTRACTOR’s COMMISSIONING manager.
 In time approval of MECHANICAL COMPLETION, READY FOR TEST RUN, PROVISIONAL
and FINAL ACCEPTANCEs for each system, etc. as per CONTRACT DOCUMENTS
Volume3 – Section1 – Para8
 PRECOMMISSIONING and COMMISSIONING Procedures review
 Organizing Operations and Maintenance personnel
 Any others agreed between the EMPLOYER and the CONTRACTOR
10. ORGANIZATION
PRECOMMISSIONING work leading to MECHANICAL COMPLETION will be conducted by the site

organization consisted of Construction and PRECOMMISSIONING & COMMISSIONING Teams. Both
of the PRECOMMISSIONING & COMMISSIONING and Construction Teams will work in close
coordination in order to efficiently conduct all the activities associated with PRECOMMISSIONING and
COMMISSIONING work. Same close cooperation is also needed between the COMMISSIONING
personnel and operation & maintenance personnel provided by the EMPLOYER and those of
CONTRACTOR.
Vendor’s specialists will be assisted by each discipline supervisor in Construction and
COMMISSIONING Teams.
10.1. CONTRACTOR’s PRECOMMISSIONING and COMMISSIONING Team

CONTRACTOR will develop a PRECOMMISSIONING and COMMISSIONING Team of sufficient
size to accomplish the works within the time schedule based on milestone of Contract. In addition,
CONTRACTOR will maintain a Construction Support Group to be directed by

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PRECOMMISSIONING and COMMISSIONING Manager during the time of COMMISSIONING

works. (to be detailed in IONE-AA00-PE-CM-0005 PRECOMMISSIONING and
COMMISSIONING Plan)
CONTRACTOR personnel will have overall responsibilities for the PRECOMMISSIONING and
COMMISSIONING activities as well as for the cooperation with and training of the EMPLOYER
personnel engaged in the PRECOMMISSIONING and COMMISSIONING work.
The major works to be performed by PRECOMMISSIONING and COMMISSIONING Team are
summarized as below:
 To develop the systems/subsystems lists and boundary drawings (marked up P&ID’s)

 To develop detail PRECOMMISSIONING, COMMISSIONING and START-UP schedules
 To develop various kind of plans and procedures as per CONTRACT DOCUMENTS Volume3
– Section1 – Para8
 To develop PUNCHLIST and clearance processes.
 To develop Vendor support and call out plan in accordance with the PRECOMMISSIONING
and COMMISSIONING schedule
 To perform the PRECOMMISSIONING and COMMISSIONING works according to the
agreed schedule and ensure that the startup date is achieved.
 To perform testing and inspection with approval from EMPLOYER of all systems and
subsystems according to this PRECOMMISSIONING and COMMISSIONING plan.
 To perform PRECOMMISSIONING, COMMISSIONING, START-UP, PREFORMANCE TEST
and stable operation according to the approved procedures.
10.2. Mobilization of PRECOMMISSIONING/COMMISSIONING Teams to Work Site

CONTRACTOR will mobilize their PRECOMMISSIONING and COMMISSIONING team to Site as
the hydrostatic test on the first system or subsystem is approaching.
Prior to mobilizing their PRECOMMISSIONING and COMMISSIONING Team to the site location it
is CONTRACTOR’s intention to complete all PRECOMMISSIONING and COMMISSIONING
Plans in their home office. The major works among these are:
 To develop and submit all of Procedures including marked up P&ID’s requested by

EMPLOYER for EMPLOYER’s approval at least six (6) months prior to commence of
PRECOMMISSIONING activities at site.
 To develop detail PRECOMMISSIONING and COMMISSIONING Schedule fully integrated
with construction
 To review and secure all first fills, tools, temporary equipment and piping materials required
for PRECOMMISSIONING and COMMISSIONING activities.
 Any others regarded as necessary.
10.3. Job Description of CONTRACTOR’s Key Members
10.3.1. COMMISSIONING General Manager

 To report work status to the Project Manager
 To lead PRECOMMISSIONING/COMMISSIONING Area Managers & Staff
Organization(Planning, Training, Support Groups, Maintenance, Laboratory) for efficient and
successful execution of their duties
 To approve the PRECOMMISSIONING and COMMISSIONING Procedures
 To preside over the PRECOMMISSIONING and COMMISSIONING Meetings

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 To consult PRECOMMISSIONING and COMMISSIONING associated matters with

EMPLOYER
 To authorize the Vendor Specialists schedule, if necessary
 To lead the Construction Support Group for successful support and backup for the execution
of PRECOMMISSIONING and COMMISSIONING activities
 To closely cooperate with the EMPLOYER counterparts
 To control the overall manpower and schedule
 To control EMPLOYER’s 700 operation and maintenance personnel from
PRECOMMISSIONING phase
10.3.2. COMMISSIONING Area Manager

 To report work status to the COMMISSIONING General Manager
 To lead and guide the PRECOMMISSIONING & COMMISSIONING Engineers and/or
Supervisors in each area
 To proceed with PRECOMMISSIONING & COMMISSIONING works in accordance with the
existing Plan and Schedule
 To prepare Manuals and detail Procedures for PRECOMMISSIONING and
COMMISSIONING works to be executed
 To update the PRECOMMISSIONING Plan and Schedule
 To coordinate with construction team for completion of remedial works
 To sign and authorize Work Permit, if necessary
 To secure tools, materials and equipment as required
10.3.3. Maintenance Manager

 To lead and guide the maintenance Supervisors
 To take care of the equipment, instrument and piping on whole area
 To manage a site shop for maintenance and fabricating
 To prepare 1YEAR OPERATION & MAINTENANCE
 To Prepare tools, material and equipment needed for efficient and successful execution of
PRECOMMISSIONING and COMMISSIONING works
10.3.4. Planning Manager

 To make manpower schedule for execution of PRECOMMISSIONING and
COMMISSIONING activities
 To update the PRECOMMISSIONING and COMMISSIONING Schedule and Milestones
 To lead UNICCS team
10.3.5. Training Manager

 To report training status to the COMMISSIONING General Manager
 To make schedule for execution of training and revise
 To lead Training team
10.3.6. COMMISSIONING Area Engineer

 To report work status to the COMMISSIONING Area Manager

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 To implement PRECOMMISSIONING and COMMISSIONING Procedures relevant to his

discipline or system / unit
 To prepare PRECOMMISSIONING Procedure for a specified units or systems, if necessary
 To prepare the Work Permit for all field works
 To assemble drawing modification sketches
 To authorize the Sub-contractor time sheet, if necessary
 To support Vendor's work for package items
 To secure required tools and test equipment in advance
10.3.7. Vendor’s Specialist

 The PRECOMMISSIONING and COMMISSIONING activities such as witnessing and
approval of mechanical run-in of complicated rotating machinery, etc. may require the
Vendor’s assistance.
 CONTRACTOR will obtain required Vendor’s specialist at site for the appropriate time.
11. COMMISSIONING Documentation Methodology
11.1. Category of Documents

The category of COMMISSIONING Documents will be divided into 3(three) parts as below.
st
 1 part: PLAN
nd
 2 part: PROCEDURE
rd
 3 part: METHOD STATEMENT
The first category, included in ‘PLAN’, will, without limitation:
 Be The highest class on the COMMISSIONING documents

 Be made and issued from ‘Home office’
 Include the general contents as “Overview”, “Objective & strategy”, “Schedule”,
“Organization”, “Plan” etc.
 Schedule, check list will be attached
 Examples: Documentation Plan, Training Plan, PRECOMMISSIONING & COMMISSIONING
Execution Plan etc.
The Second category, included in ‘PROCEDURE’, will, without limitation:
 Be the general documents for PRECOMMISSIONING & COMMISSIONING activities

 Be the standard of “METHOD STATEMENT”
 Be made and issued from ‘Home office’
 Include the general contents as “Definition”, “Objective”, “Objects”, “Sequence of Activities”,
“Check list” etc.
 Schedule, check list will be attached
 Examples: Preservation Procedure, Turn-over Procedure, Air-blowing Procedure, Catalyst
Loading Procedure, Leak Test Procedure, Permit To COMMISSIONING Work Procedure etc.
The third category, included in ‘METHOD STATEMENT’, will, without limitation:
 Define and describe the detail activities and methods in step by step fashion all the activity

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 Be made and issued from ‘Site office’

 Include the general contents as “Definition of work”, “Standards and Objective”, “Detail
activities”, “Materials required” etc.
 Examples: Method statement of Air-blowing for PKG12 in Subsystem 05-1010 etc.
The whole list of COMMISSIONING Documents is listed in “11.4. List of COMMISSIONING

Documents” as below.
11.2. Document Control and Issue

All documents shall be submitted to EMPLOYER for approval before appointed due date on
Contract Document. And the each document issued by COMMISSIONING team will follow the
“IONE-AA00-PE-PM-0004 DOCUMENT CONTROL PROCEDURE”
11.3. Schedule of COMMISSIONING Documents

The Due-date of all COMMISSIONING Documents will be detailed in “11.4. List of COMMISSIONING
Documents” as below.
.
11.4. List of COMMISSIONING Documents
No Document No. DESCRIPTION Category Due Date
Pre-commissioning and
1 IONE-AA00-PE-CM-0001 PLAN CD+6M
Commissioning Execution Plan
2 IONE-AA00-PE-CM-0002 Training Plan PLAN CD+6M
Systems and Subsystem

3 IONE-AA00-PE-CM-0003 PLAN P-3M
subdivision(Marked-up P&ID)
1 year operation and maintenance
4 IONE-AA00-PE-CM-0004 PLAN MC-6M
execution plan
Commissioning Plan
Commissioning Schedule
7 IONE-AA00-PE-CM-0007 UNICCS control procedure PROCEDURE CD+6M
8 IONE-AA00-PE-CM-0008 Leak test & Vacuum test procedure PROCEDURE P-3M
9 IONE-AA00-PE-CM-0009 Inerting procedure PROCEDURE P-3M
10 IONE-AA00-PE-CM-0010 Amine system degreasing procedure PROCEDURE P-3M

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System and sub-system definition

11 IONE-AA00-PE-CM-0011 PROCEDURE P-3M
procedure
Commissioning work permit
procedure
13 IONE-AA00-PE-CM-0013 Punch management procedure PROCEDURE P-3M
14 IONE-AA00-PE-CM-0014 LOTO and Blind control procedure PROCEDURE P-3M
15 IONE-AA00-PE-CM-0015 Mechanical completion procedure PROCEDURE P-3M
16 IONE-AA00-PE-CM-0016 PSSR procedure PROCEDURE P-3M
17 IONE-AA00-PE-CM-0017 Air-blowing procedure PROCEDURE P-3M
18 IONE-AA00-PE-CM-0018 Water flushing procedure PROCEDURE P-3M
19 IONE-AA00-PE-CM-0019 Chemical cleaning procedure PROCEDURE P-3M
20 IONE-AA00-PE-CM-0020 Steam blowing procedure PROCEDURE P-3M
21 IONE-AA00-PE-CM-0021 Flange management procedure PROCEDURE P-3M
22 IONE-AA00-PE-CM-0022 Pig cleaning procedure PROCEDURE P-3M
Manual and power cleaning

procedure
24 IONE-AA00-PE-CM-0024 Cooling water passivation procedure PROCEDURE P-3M
25 IONE-AA00-PE-CM-0025 Fire water pressurization procedure PROCEDURE P-3M
26 IONE-AA00-PE-CM-0026 Preservation procedure PROCEDURE P-3M
27 IONE-AA00-PE-CM-0027 Mechanical alignment procedure PROCEDURE P-3M
28 IONE-AA00-PE-CM-0028 Lube oil flushing procedure PROCEDURE P-3M
29 IONE-AA00-PE-CM-0029 Mechanical run-in test procedure PROCEDURE P-3M
Catalyst loading & unloading

procedure
31 IONE-AA00-PE-CM-0031 Vessel final box-up procedure PROCEDURE P-3M
Chemical loading & unloading

procedure
33 IONE-AA00-PE-CM-0033 Boil-out and dry-out procedure PROCEDURE P-3M
34 IONE-AA00-PE-CM-0034 Cause and effect function test PROCEDURE P-3M

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procedure
Before
METHOD
35 Each activity (will be issued) commencement
STATEMENT
of each activity
※ CD : Commencement Date
P : Commencement of PRECOMMISSIONING
MC : Mechanical Completion
12. COMMUNICATIONS
Throughout the period of PRECOMMISSIONING and COMMISSIONING, coordination meetings

between EMPLOYER and CONTRACTOR are to be arranged periodically, weekly or even daily, to
maintain effective communication. After each meeting regular MOM will be signed off and distributed to
all of the participants to prevent any confusion or misunderstanding on what has been talked,
discussed, and/or concluded.
In addition to this, spot or random type of communication will also be practiced in the field or any other
place in the Plant Site depending on the situation and the necessities. Brief talks over the phone, face
to face talks, or exchanging email would be common means for this.
13. SAFETY
13.1. Introduction
It is impossible to formulate rules applicable to every conceivable circumstance or combination of
circumstances that may encounter during the daily working hours in the complex units. So
Safety might be said as an outcome which can only be secured through the cooperative effort
exerted by all of the parties and personnel involved in the PRECOMMISSIONING and
COMMISSIONING works.
This Safety Instruction is a general one in nature, offered only as a guideline, and does not, under
any circumstance, preclude any other instruction already issued for general use in the specific
field.
The purpose of this Safety Instructions is to prevent any possible accident in the plant or at least
minimize the possible damages on both the working personnel and the plant equipment. All
personnel must be familiar with these Safety Instructions and Procedures before starting any work
in the plant keeping in mind that ‘Safety is the First.’
Separate from this, Risk Assessment shall be carried out against PRECOMMISSIONING and
COMMISSIONING activities to reduce the possible risks of personal injuries and damages to the
equipment as well as to reduce the risks of negative impacts on the environment.

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13.2. Work Permit

13.2.1. General
EMPLOYER employs a robust Safety Policy and Plan. CONTRACTORs working within the
Karbala Refinery Project are expected to know and follow all of the requirements as stated in
EMPLOYER’S CONTRACTORs Safety Booklet.
After starting COMMISSIONING, the plant may be under operation or in fully or partially
pressurized condition. Therefore, any additional and/or modification works on the plant
facility should be reviewed and approved in advance by COMMISSIONING manager.
Before starting COMMISSIONING work, the COMMISSIONING team should announce and
notify all concerned parties to avoid any site work being proceeded without acquiring work
permit signed by COMMISSIONING the respective area supervisor.
The COMMISSIONING supervisor should visit the site to investigate possible hazards
associated with that particular job grant the work permit after reviewing all safety conditions.
The following types of Work Permits will be used as below, without limitation:
 Hot and/or cold work

 Vessel and/or vehicle entry
 Electrical isolation
 Excavation / road closure
 Radiography
13.2.2. Precaution
Each Permit contains in itself a checklist of precautions against common hazards. But this
list being not able to cover entire precautions against all kind of hazards, it should be
commonly understood as a duty for both of the issuer and the receiver to review the job and
its probable hazards and see that extra precautions have been specified on the Work Permit
before it is signed.
One common precaution applicable to all work is to clear the area of people not required for
the job so as to avoid their being exposed to potential hazards.
If people enter an area where they could be exposed to danger, the work should be stopped
until the people are cleared out of the area.
(1) If conditions become unsafe in the course of work, the COMMISSIONING Supervisor
must stop the work and withdraw the Work Permit.
(2) Any employee is responsible to stop the work at any time he finds the actual work
conditions of the job is not safe enough to meet the required safety conditions for the
Work.
13.2.3. Closing out and filing the Permit

Normally, Work Permit must be closed at the end of the working hours regardless of the work
having been completed or not. In case the work is not completed it should be continued on
the next day with new Work Permit.
The closed Work Permit will be filed and kept by the COMMISSIONING supervisor for one (1)
year.
13.3. Personal Safety

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13.3.1. Personal Protective Equipment

(1) Eye Protection
Eye protection should be practiced all the times while patroling or working in the operating
area. Proper eye protecting spectacles or face shield should be worn whenever handling
acid, caustic or other dangerous materials, or when using grinding or drilling tools which
will cause fine particles fly around.
(2) Respiratory Protection

Air mask, Dust mask and Gas Masks are to be used as situation and conditions dictate.
Extreme care must be taken in analyzing each condition to ensure the most effective and
reliable measure is adopted for the situation.
(3) Ear Protection

Long and repeated exposure to high level noise may have detrimental effect on the ears
causing hearing loss. Although the impact varies from person to person, it is
recommended to wear ear plugs all the time when working or patrolling around the noisy
area.
(4) Protective Clothing

Suitable rubber plastic coats, pant, boots and hoods should be worn when working on
lines or equipment that may contain hazardous materials. Gloves protect your hands from
cuts, burns, chemical burns, etc. and should therefore be worn at all times while operating.
Safety shoes should be worn at all times in the plant.
(5) Work Clothing

Clean and durable clothing, in good repair, prevents skin irritations that, if exposed to
chemical liquids or fumes, can cause harm. Avoid loose fitting clothes that can get
caught in moving machinery. Don’t expose large areas of bare skin.If clothes get
chemically soaked, strip them and take a shower immediately. Rings should not be worn
around rotating machinery or electrical gear.
(6) Hard Hats (Helmets)

Hard hats should be worn at all times while in the plant operating area where there is no
danger from falling objects and safety or “hard” hats are considered unnecessary.
(7) Foot Protection

Hard/metal toes safety shoes should be used for foot protection.
(8) Body, Skin and Hand Protection

Rubber or other protective gloves should be worn where any danger of contact with
hazardous material may occur. For the protection of skin, a cotton skirt, trousers and
underwear should be worn. In case of emergency, a rubber apron or rubber coat may
provide sufficient protection. For optimum protection of the body, the collar should be kept
buttoned, glove gauntlets should be turned inside of sleeves and trouser legs should be
left outside of boots.
(9) Personal Gas Monitoring Device

Personal Gas Monitoring Device should be used for detecting combustible gas, toxic gas
such as CO and H2S, oxygen deficiency, etc. before executing related work where any
gas surrounding working place may be dangerous condition to cause fire, expolusion,
asphyxiation, poisoning etc.

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13.3.2. Personal Coverage

Whenever possible, at least two men shall be present in a plant which is operating. Where
that is not possible, a system for periodical checking on the safety of the single man must be
initiated.
Two men should be mandatory when entering an closed area such as a vessel and a sump
where the possibility of a hazardous atmosphere is great enough to warrant the use of
respiratory protection. When one may enter a closed area, the other must watch the status
inside.
13.3.3. House Keeping

Good housekeeping goes hand in hand with safety. Good housekeeping can be maintained
by observing the following practices.
 Keep the work areas clean at all times.

 Keep aisles, stairs and platforms clear at all times.
 Use proper receptacles for disposal of all waste material
 Store tools, equipment and materials in a near and orderly way.
 Prevent or eliminate conditions that impair footing visibility, judgment, protection or
escape.

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ATTACHMENT LIST
1. GENERAL WORK FLOW of PRECOMMISSIONING & COMMISSIONING
2. CHECK LIST FOR MC

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ATTACHMENT #1
General Work Flow of PRECOMMISSIONING &
COMMISSIONING
(1 Sheet)

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#3. Attachment - General Work Flow of PRECOMMISSIONING & COMMISSIONING
Pressure Test - Motor Solo Run Test

- Loop Test
Punch Works CONSTRUCTION
Category ‘A’
completed
-Flushing/ Blowing - Lube oil flushing

- Reinstatement - Chemical cleaning
- Filling lubricants
Notice 2 Days Before - Cold alignment PRECOMMISSIONING
Notice 2 Days Before
MECHANICAL COMPLETION
Mechanical run-in test
Notice 2 Days Before

- Function test
(ESD / Interlock / Sequence)
Tightness Test - Catalyst /Adsorbent loading
- Refractory dry-out COMMISSIONING
- Final hot alignment
Drying - Safety equipment tests
Out - Fire protection system tests
- Service utilities as necessary
- Chemical charging
Inerting Punch works
category ‘B’
completed
READY FOR START-UP
Start-up -Operational leak test

-Introduction of feedstock
-Run-in & operational testing START-UP
-Dynamic functional test
-Stable & steady operation
READY FOR PERFORMANCE TEST
Performance Test
PERFORMANCE TEST
PROVISIONAL ACCEPTANCE
1 YEAROPERATION & MAINTENANCE

Final
Acceptance FINAL ACCEPTANCE

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ATTACHMENT #2
Check List for MECHANICAL COMPLETION
(17 Sheet)

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
#4. Attachment - Check List for MECHANICAL COMPLETION
pre-commissioning
Commissioning
start-up
1.1 manufacturer or vendor service assistance where
responsibility is not indicated in section 4:
a. obtain the assistance of the manufacturor vendor, as required,
X X X
for technical assistance
1.2 Permits
EPC Contractor shall prepare all documentation required by the
applicable provisions of the IRAQI law for the COMPANY to
X X
apply for, and obtain, all necessary permits by government and
regulatory agencies that are required for plant use and operation
1.3 Removal Of Rust Preventives
a. remove all rust preventives and oils used to protect the
equipment during the construction period whenever these X
protective materials will be detrimental to operation.
1.4 Lubricants
a. verify availability of all lubricants X
b. flush systems and install initial charge of all lubricants. dispose
X
of all flushing oil in accordance with the applicable regulations
c. maintain lubrication after initial charge X X X
1.5 Packing And Seals
a. install mechanical seals and accessories, as required X
b. install packing and accessories, as required X
c. adjust and replace mechanical seals, packing, and
X X
accessories, as necessary, during commissioning period
1.6 Removal Of Temporary Bracing
a. remove all temporary supports, bracing, or other foreign
objects that were installed in vessels, ducts, piping, transformers,
X
machinery, or other equipment to prevent damage during
shipping, storage, and erection and repair any damage sustained
1.7 Rotation And Alignment
a. check rotating machinery for correct direction of rotation
and for freedom of moving parts before connecting the X
driver

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
b. perform cold alignment to the manufacturer’s tolerances and
X
record
c. perform hot alignment X X
1.8 Leak Test
a. notify the owner of the schedule for leak tests X
b. provide any media for test purposes X
c. conduct all tests in accordance with applicable codes.
X
specifications, regulations, and the project instructions
d. dispose of all test media in accordance with the owner's
X
instructions
e. conduct all operational tightness tests X
f. system leak test before hydrocarbon feed-in X
1.9 Inspection
a. provide inspection of the plant to verify that erected facilities
conform to flow diagrams, construction drawings, vendor prints, X
and specifications
b. verify and approve the plant inspection. note any exceptions
X
on the punch list
c. provide for special inspections, such as those required by
insurance or governmental agencies
note: shop inspected equipment will not be reopened for X X X
inspection in the field except as specified by the owner or as
specifically noted in 4. 1.
1.10 Pressure/Vacuum Safety Relief Devices
a. transfer relief devices to and from the specified testing facility X
b. test and adjust all devices and seal wherever necessary or
X
desirable
c. install all devices after testing. adjusting, and tagging X
1.11 Flushing And Chemical/Mechanical Cleaning
a. except as specifically noted in the next section:
1. conduct all flushing. blowing, and mechanical(by hand tools)
cleaning operations where such operations can be accomplished
X
without using permanently installed equipment and providing
temporary equipment as necessary

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
2. conduct all flushing and blowing operations where
X(STEAM
permanently installed equipment must be used to obtain proper X
BLOWING)
line velocities
3. provide any media for flushing and for cleaning purposes X
4. dispose of all media X X
c. conduct chemical and special mechanical(e.g. hydro-jetting)
cleaning providing and disposing of all fluids used during X
execution
1.12 Temporary Screens, Strainers, And Blinds
a. provide and install all required temporary strainers X
b. clean strainers, as required, during circulation X X
c. remove temporary strainers when system is adequately
X
cleaned
d. provide, install, and remove all temporary blinds required for
X
flushing
X for
e. provide, install, and remove all temporary blinds require for process
X X
isolation fluids, as
necessary
1.13 Purging / Inerting
a. install purge/inerting connections X
b. provide purge materials and conduct necessary purging
X
operations
1.14 Drying Out
a. dry out facilities, as requested, to prevent contamination of
X
catalysts, operating materials, and/or product
b. dry out systems, refractories, and linings when this drying

X
operation is to be accomplished with temporary facilities
c. dry out systems, refractories and linings when this drying
operation is to be accomplished by means ofpermanently X
installed equipment
1.15 Vessel Packing And Fixed Beds
a. install all inert materials such as sand, gravel, balls, rings, and
X
saddles

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
b. install all materials, other than the materials specifically noted
X X
in section 4, such as chemicals, resins. Desiccants, Catalyst
c. inspect the vessel interior before and during loading to ensure
X(a) X(b)
proper installation
1.16 Housekeeping
a. at completion of construction, remove excess materials,
temporary facilities, and scaffolding; rough sweep or rake the
X
area: and pick up trash. erform washing or further cleanup, as
required
b. after mechanical completion maintain adequate housekeeping
X X
practices as required for safe operation
1.17 Maintenance, Spare Parts, And Special Tools
a. after pre-commissioning is complete protect equipment from
X
normal weather conditions, corrosion or damage
b. after pre-commissioning is complete provide adequate
maintenance for equipment, including the cleaning of strainers X
and the repairing of steam traps
c. after pre-commissioning is complete, maintain adequate spare
X X
parts and supplies
1.18 Noise Survey
a. conduct individual equipment noise surveys, as required X X
b. document all survey data X X

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
2.1 Vessels- Tower, Reactors and Drums
a. open the vessel and execute inspection of internals after
X
installation
b. open both internal and external man ways and execute final
X
inspection of the vessel, unless otherwise specified
c. mechanically clean the vessel internally, as required X
d. close after final inspection X
e. Check condition of equipment quality of installation and
cmpliance with Project drawings, manufacturer's instructions, X
safety rules and specifications and good practice.
f. Install all tower, reactor and drum internals and perform tray
X
leakage test and leveling adjustment as required
g. Issue to Contractor witten authority to close up each vessel X
h. Properly close up all vessel internal manways and openings
after final inspection or after loading of chemicals, catalystsm etc. X
is completed
i. Cure and dry out castable linings X
j. Inspect all towers and drums for cleanliness and dryness
X
before loading catalysts, etc.
k. Load all chemicals(including hot oil, amine, glycol, freon,
X
inhibitors), desiccants, catalysts, tower packings
l. Carry out air blowing if required X
m. Inspect after loading. Obtain samples of all catalysts loaded. X
n. Carry-out leak testing X
o. Conduct performance test X
2.2 Shell And Tube Exchangers
a. perform field inspection, if required, of exchangers X
2.3 Air-Cooled Exchangers
a. inspect exchangers to ensure that temporary shipping
X
supports and erection materials have been removed
b. adjust fan assemblies to obtain specified tip clearance and test X

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
c. install and adjust tensioning of belts X
d. Check operation of louvers and operating linkage X
e. Check satisfactory operation of louvres and variable pitch
X
assembly
f. Start up fans and check vibrations, motor loading, and proper
X
operation of auto-varialbe fans
g. Conduction performance test X
2.4 Fired Heaters
b. execute all non operating prefiring checks in accordance with
X
the manufacturer's instructions
c. blow fuel lines, check them for cleanliness and connect
X
burner piping
d. check operation of registers and dampers and verify position
X
of indicators
e. check operation of air preheaters, blowers and soot blowers X
f. dry refractory during initial firing by following the manufacturer's
X
temperature cycles
g. conduct boil out, chemical cleaning and flushing operations, as
X
required dispose of wastes and cleaning media
h. obtain and charge liquid heat transfer media, if required X
i. conduct light off, drying, and purging operations X
j. After drying out, clean stack and duct, open manholes and
other openings inspection. Check operation of dampers. Close X
stack and duct after inspection
2.5 Pumps, Compressors, And Drivers
a. chemically clean any completed lube and seal oil when
X
specified. Dispose of wastes and cleaning media
b. charge the lube oil, seal oil, and oil cooling systems with
flushing oil and circulate for cleaning purposes. dispose of any X
flushing oil
c. install coupling between driven and driver machines X
d. charge the lube oil, seal oil, and oilcooling systems with the
X
operating oil recommended by the manufacturer

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
e. operate equipment and make vibration, trip, governor, and
safety device checks and any operating tests and adjustments, X
as required
2.5.1 Pumps
a. Set and cold align pumps and drivers X
b. Couple pumps to drivers X
c. Install temporary strainers X
d. Check that piston seal packaging followers, if any, are
X
correctly tightened
e. If discharge flow dampers are fitted(normally nitrogen filled
X
bladder type) check these are correctly charged and installed
f. Check pump gear box oil levels X
g. Run-in pump in recycle, check pump and motor operation and
X
do any required dowelling of the pump driver
h. Check oil for presence of chips after no load run X
i. Check gears, bearings and parts for signs of wear and damage X
j. Make final hot alignment check X
k. Run unit after start-up conduct performance test X
4.5.2. Gas Turbines, Compressors and Expanders
a. Install all piping and make piping corrections as required by
X
manufacturer's tolerances. Set and cold align unit
b. Clean chemically suction and interstage piping and lube/seal
X
oil piping
c. Disassemble above piping for cleanliness inspection as
X
required
d. Fill lube and seal oil system X
e. Carry out lube and seal oil systems flushing, circulate oil uit
X
test patches are clean
f. Drain lube and seal oil systems then refill with new oil, if
X
required
g. Run in driver(uncoupled) excepted for expanders X
h. Couple driver and driven unit X

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
i. Run in compressor in recycle on air or inert gas, if possible
X
and/or suitable, on gas after gas-in otherwise. Check operation
j. Check hot alignment X
k. Carry out comprehensive vibration tests X
l. Check equipment noise levels X
m. Run unit on stream X
n. Check plant noise levels X
o. Conduct performance tests X
2.5.3. Diesel Engines
a. Set and cold align units X
b. Clean lube oil piping X
c. Fill lube oil system X
d. Drain lube oil system then refill with new oil, if no required X
e. Test run Diesel engines and their accessories uncoupled X
f. Couple diesel engines to driven equipment X
g. Test run coupled unit verify all operating parameters X
h. Check alignment after operational test X
i. Carry out noise measurement tests X
j. Conduct performance test X
2.6 Tanks
a. after erection and installation, inspect any internals which
X
required field installation
c. conduct flushing operations, as required. dispose of wastes
X
and cleaning media
d. close after final inspection X
e. Install appurtenances X
f. Strap tank and issue record X
g. Organize independent calibraion of product tanks for custody
X
transfer where required by government regulations
2.7 Piping Systems

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
a. flush and drain system and install orifice plates. X
b. drain system, remove blinds and perform gross leak tests, as
X
required
c. check pipe hangers, supports, guides, expansion joints, and
other pipe specialties for the removal of all shipping and erection
X
stops and far the correctness of cold settings far the design
service.
d. check pipe hangers, supports, guides, and pipe specialties for
X X
hot settings and make minor adjustments, as necessary
e. install permanent filter elements, as required X X
f. verify, to the extent required by the contractor, that specified
X
valve packing has been provided in valves installed in the plant
g. install car seals on valves, where necessary and check and
record the positions of all car-sealed valves; paint or identify X X
valves, as required
h. correct support, vibration, and thermal expansion problems
X
detected during commissioning
i. retorque all hot and cold service bolting during commissioning
X X
and start-up, as required
j. Carry out preliminary cleaning and hydrostatic testing of piping X
k. Alleviate any excess piping stresses that may be imposed on
X
pipes, compressores or pump flanges
l. Provide and install all temporary strainers, blinds and blanks X
m. Check packing and packing materials and lubrication of
X
valves : repack and lubricate if necessary
n. Supply and install line identification tags and signs, stencil
X
lines for identification
o. Install safty valves or temporart spool pieces during
X
construction
p. Remove as necessary and transport all safty valves to and
X
from test facilities
q. Test, set and tag all safty valves, then carry out safety valves
X
final installation
r. Carry out piping water or air flushing operations X
s. Perform chemical cleaning were applicable X
t. Fill in hydraulic unit and network with appropriate oil X

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
u. Perform drying out where applicable X
v. Carry out leak testing X
w. Carry out innerting X
x. Provide list and location of all blinds intalled X
y. Define, provide and install temporary blanks required for start
X
up
z. Install corrosion probes X
a'. Carry out oil and gas-in X
b'. Perform hot or cold bolting of piping and equipment during
X
initial plant start up
c'. Check spring hangers, pipe anchors and guides in hot
X
position
d'. Remove temporary strainers(normally after start-up) X
2.8 Electrical Power And Lighting Systems
a. perform trials and adjustments on all switchgear, motor control
X
equipment, and generators
b. test and set switchgear and circuit breaker relays for proper
X
coordination
c. obtain local inspector's approval, where required X
d. energize all substations with approval of the owner after
X
completion of all tests
e. check phase sequence, polarity, and motor rotation X
f. check installation of emergency power and lighting systems,
X
including light intensity
g. Perform preliminary tests with equipment de-energized,
including :
- Insulation resistance measurements
X
- Di-electric strength tests
- Loops and circuits continuity tests
- Earthing resistance measurements
h. Fill in transformers with oil X
i. Carry out breakdown test of oil samples X
j. Energize and test control power system X

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
k. Perform all functional tests, including :
- Adjstment and testing of protective devices
X
- Chec-out and adjustment of electrical instruments
- Operation of safety devices
l. Energize and test emergency and instrument power system X

m. Start up and test power plant X
n. Carry out preliminary load test(when possible) X
o. Fill in batteries with electrolyte X
p. Carry out batteries discharge test X
q. Test battery chargers, inverters, UPS X
r. Modify connections if wrong direction of rotation X
s. Perform motors 4 hours no load runs. Test motors ancillary
X
equipment
t. Check temperature rise of motors, bearings, transformaers,
X
relays, when loaded(if possible))
u. Check operation of manual and auto controls X
2.9 Instrument Systems (shared with mac)
a. conduct any non-operating checks to ensure instrument
operability, that is, remove all shipping stops: check pointer
travels; and verify instrument capability to measure, operate, and X
stroke in the direction and manner required by the process
application
b. clean all transmission and control tubing by blowing with
cooled and filtered clean air before connecting to instrument X
components
c. clean all air-supply headers by blowing with clean air and
X
check them for tightness
d. leak test pneumatic control circuits X
e. check piping from instruments to process piping for tightness X
f. for each instrument loop verify conformance to specifications
and design criteria for function and range using dummy X
transmission signals, as needed
g. identify orifice plates by tagging X
h. check and record bores of orifice plates and install after
X
completion of flushing operations

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
i. isolate or remove, if necessary, inline components such as
X
control valves, positive displacement meters, and turbine
j. flushing operations and reinstall them on the completion of
X
these operations
k. install any sealing fluids, as required X
l. fully pressurize and energize the transmitting and control signal
system(s) by opening process connections at primary sensors
and final regulators and by making control mode settings for X
automatic operation of equipment as the process unit is charged
and brought on stream
m. Remove in-line intruments before hydralic test(except control
X
valves)
n. Perform required pressure test on :

- Instrument take of piping
X
- Air piping
- Air tubing
o. Reinstall instruments after pressure tests and flushing of the

X
process lines
p. Calibration all instruments other than F&G detectors prior to
X
installation
q. Check continuity of transmission and identification of
indication, control and alarm signals.
X
- Perform continuity and insulation test for instrument cables
- Perform continuity and tightness test for pneumatic tubing
r. install sealing fluids where required X
s. calibrate all F&G detectors, synchronise with F&G panel X
t. Test marchalling relay boxes, programmable logic controllers,
X
sequential operators and all numeric control systems
u. Carry out loop testing X
v. Test shutdown systems, interlocks, and sequencers X
2.10 Boilers
a. inspect the boiler for completeness and correctness of
X
installation and make other non operating prefiring checks

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
b. check operation of air preheaters, dampers, soot blowers, and
X
other equipment for proper positioning and travel
c. dry refractory during initial firing by following the
X
manufacturer’s temperature cycles
d. purge, flush, and drain steam mains, as necessary X
e. obtain and charge treated water for boil out and initial
X
operation, as required
f. commission auxiliaries as detailed elsewhere under the
X
appropriate equipment type
g. conduct boil out, chemical cleaning, and flushing operations,
X
as required. dispose of wastes and cleaning media
h. conduct initial light off, making the associated checks and
X
adjustments
i. conduct all operating tests and obtain the required
X
certification
j. recheck and set pressure relief valves X
2.11 Water Treatment Plants
a. inspect for completeness and correctness of installations and
X
make any non operating checks that may be required
b. provide and install the initial charge of ion-exchange resins
X
and inert bed material
c. provide all water treatment chemicals except the initial charge
X
of ion- exchange resins
d. make the necessary operating tests and adjustments to water
X
treatment systems
e. purify potable water systems X
2.12 Water Systems (cooling towers, fire water systems,
and river water systems)
a. inspect for completeness and correctness of installations and
X
make any non operating checks that may be required
b. clean the cooling tower basin and install screens in the suction
X
pit before water circulation
c. flush, drain, and clean the cooling tower basins X
d. clean intake screens X
e. adjust cooling tower fans to obtain specified tip clearance and X

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
test
f. operate fire pumps to check performance of systems X
g. head up reservoirs vessels tanks, and other water system
equipment, as required, fill with water, check for leaks, and flush X
to clean
h. Provide insurance company inspection of the fire systems, as
X
required
i. obtain and install all required fire fighting chemicals and
portable equipment, such as hoses, fire extinguishers, and X
related equipment
2.13 Waste Disposal
a. inspect facilities for completeness and correctness of
installation and make any non operating checks to ensure their X
conformance to specifications
b. operate all equipment and supply all chemicals and agents
X
related to waste treatment
2.14 Buildings And Accessories
a. check installation of buildings and accessories. including all
heating, ventilating, and air conditioning equipment, to ensure X
their completeness and conformance to specifications
b. as required, obtain certification that all plumbing, electrical, fire
protection. elevator, and special materials handling installations X
comply with local government regulations
c. operate heating, ventilating, and air conditioning units and
X
make all performance
2.15 Miscellaneous Equipment (agitators, mixers, rotary
filters, weigh scales, and materials handling equipment)
a. fully assemble rotary filters except for final filter media (cloth,
X
precoat, or screen)
b. install all final filter media X
c. level and calibrate weigh scales with the assistance of the
manufacturer's representative and set tare weights wherever X
possible
d. manually check materials handling equipment for freedom and
X
direction of movement
e. check clearances on materials handling equipment X
f. make all final adjustments during run-in and conduct any
X
required performance tests

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
g. as required, obtain certification that all lifting and materials
handling installations and other items of equipment comply with X
government regulations
2.16 Living Quarters Equipment
a. Check condition of equipment quality of installation and
b. Pressurize water Pipes(hot and cold) and test taps, sinks,
X
toilets, Showers
c. Energize specific(kichen) electrical appliances and check
X
functions with reference to electrical procedures
d. Leak test Fresh Water Maker system X
e. Energize and test run unit X
f. Verify conformity to specifications of the water quality X
g. Conduct performance test X
2.17 Fire Fighting Equipment
a. Check storage locations of all extinguishers X
b. Function test CO2/Halan skids without actual release X
c. Carry out operational test of deluge System, Hydrants and
X
Monitors.
d. Carry out specific tests as required by local Authorities X
2.18 Telephones
a. Check condition of equipment, quality of installation, and
compliance with Project drawings, manufacturer instructions, X
safty rules, specifications and good practice
b. Check especially that EX equipment has been installed in
X
classified area
c. energize and carry out equipment functional tests X
d. Test actual operation of all equipment X
2.19 Public Address
b. Energize and carry out PA loops functional tests X

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
c. Test actual operation of loudspeakers and flushing beacons,
including check and adjustment of operational features on field X
such as : range/coverage, visibility, etc.
2.20 Radios
b. Check condition of antennas, feeders, radio transceivers and
X
associated equipment
c. Energize and carry out one in-station test per radio equipment X
d. Test radio systems operation X
2.21 Meteorological Equipment
b. Carry out the calibration of sensors X
c. Energize and test the operation of each loop X
d. Test the system test processing X
e. Test logging equipment X
2.22 Telemetry(MTU & RTU's)
b. Energize and test data transmission X
c. Carry out instrument inerface tests X
2.23 CCTV systems
b. Check free operation of cameras and pan-and-tilt equipment X
c. Energize and check proper functioning of equipment X
d. Test system test, scanning, sequencing, etc X
2.24 HVAC Equipment

PROJECT PROCEDURE
PRECOMMISSIONING &
PROJ. 2171
pre-commissioning
Commissioning
start-up
a. Check condition of equipment quality of installation and
b. Check alignment of motors/fans and drivers X
c. Check that tension on drivers is correct X
d. Check that fans and motors rotate manually and run freely X
e. Check that anti0vibration mountings are correctly installed X
f. Check that sealing compound of fire dampers is installed
X
correctly
g. Check that linkage and blades of dampers operate correctly
X
and freely
h. Check that dampers actuators operate correctly X
i. Check that airflow direction in pre-heaters is correct X
j. Carry out ductwork leak tests X
k. Energize and run unit. Test sequences and interlocks. Check
X
vibrations
l. Carry out airflow and balacing tests X
m. Control and adjust rooms temperature and pressurization X
n. Conduct Performance Test X

IONE-AA00-PE-CM-0001 Precommissioning & Commissioning Execution Plan Rev.0

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PROJECT PROCEDURE

PRECOMMISSIONING & COMMISSIONING Execution Plan

PROJECT : KARBALA REFINERY PROJECT

LOCATION : KARBALA, IRAQ

EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)

REVD REVD APPRD CONFD

& Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

Rev Date Description Page

A 27 JUN 14 Initial Issue -

0 30 SEP 14 Insert a page of Revision Hisory 2

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

4. SYSTEM METHODOLOGY ......................................................................................................................12

6. PRECOMMISSIONING METHODOLOGY ...............................................................................................14

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

8. CONTROL OF SEQUENCE AND SCHEDULE ........................................................................................17

9. ROLES & RESPONSIBILITY ...................................................................................................................17

10. ORGANIZATION ...............................................................................................................................18

11. COMMISSIONING Documentation Methodology .........................................................................21

12. COMMUNICATIONS .........................................................................................................................24

13. SAFETY ............................................................................................................................................24

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

13.2. Work Permit.................................................................................................................................25

#1. GENERAL WORK FLOW of PRECOMMISSIONING & COMMISSIONING ...........................................29

#2. CHECK LIST FOR MC..............................................................................................................................31

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

1.3. Scope of Application

1.4. Objective & Strategy

 Involve COMMISSIONING staff in early stage of Project

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 Provide the experienced staffs for the refinery plant

In order to accomplish COMMISSIONING team’s objectives mentioned above, the

Party means the Employer or the Contractor, as the context requires.

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

Country means the Republic of Iraq.

Contractual documents referenced for preparing this PRECOMMISSIONING and COMMISSIONING

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

expressed in inclined writing style as just behind example (examples  examples).

3.1. MECHANICAL COMPLETION

CONTRACTOR shall, without limitation:

Major activities to be performed in PRECOMMISSIONING stage are as below:

 System check out :

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

In case inspection and/or witnessing of activities by EMPLOYER are requested or specified,

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 Provide suitably experienced personnel to undertake COMMISSIONING activities and to

Major activities to be performed in COMMISSIONING stage are as below:

 Rotating equipment run-in

The procedures for special PRECOMMISSIOING or COMMISSIONING activities such as heater

Major activities to be performed in START-UP stage are as below:

 Feed stock introduction

3.5. PERFORMANCE TEST

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

3.5.1. PERFORMANCE TEST

3.5.2. PROVISIONAL ACCEPTANCE

3.6. FINAL ACCEPTANCE

The PRECOMMISSIONING and COMMISSIONING activities are relatively sophisticated operations,

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

4.1. The ‘System Approach’

Figure-1: The merit of ‘System Approach’

4.2. Definition of System & Subsystem

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

adapted to the start-up sequence as one unit.