COMPANY DOC. No. L290-AR-PEP-0001 REV.

JKC DOC. No. S-0290-1711-0001 2

COMPANY CONTRACT No. 800224 Review Class. 1

JGC JOB No. 0-6037-21 KBR JOB No. F034 CHIYODA JOB No. 11051
SHEET 1 OF 56

INPEX Operations Australia Pty Ltd

ICHTHYS ONSHORE LNG FACILITIES

COMMISSIONING EXECUTION PLAN

REV. DATE ISSUE PURPOSE PREPARED CHECKED APPROVED

A 04-Jul-11 IFA S. Sawamoto K. Harada T. Saito

0 09-Sep-11 IFC S. Sawamoto K. Harada T. Saito

1 18-Oct-11 IFC S. Sawamoto K. Harada T. Saito

2 28-Oct-13 IFC S. Sawamoto K. Harada T. Saito

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 INPEX Operations Australia Pty Ltd COMPANY Doc. No. L290-AR-PEP-0001
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Commissioning Execution Plan Sheet No. 2 of 56

Contents
1. INTRODUCTION............................................................................................... 4
1.1 Purpose ............................................................................................................. 4
1.2 Scope ................................................................................................................ 4
1.3 Definitions ......................................................................................................... 4
1.4 Applicable Specifications and Standards .......................................................... 5
1.5 Abbreviations .................................................................................................... 6
2. COMMISSIONING PROCESS.......................................................................... 8
2.1 Care, Control and Custody ................................................................................ 9
2.2 Pre-Commissioning ......................................................................................... 10
2.3 Commissioning Testing ................................................................................... 11
2.4 Operational Testing ......................................................................................... 12
2.5 Temporary Utilities for Commissioning and Operational Testing .................... 13
2.6 Ready for Start-Up .......................................................................................... 15
2.7 Handover Certificate ....................................................................................... 15
2.8 Start-up Procedures ........................................................................................ 15
2.9 Performance Test ............................................................................................ 15
3. GENERAL REQUIREMENT ........................................................................... 16
3.1 Deliverables during Home Office Engineering ................................................ 16
3.2 Pre-Commissioning ......................................................................................... 16
3.3 Commissioning ................................................................................................ 17
4. COMMISSIONING ORGANISATION AT DARWIN SITE............................... 17
4.1 Organisation .................................................................................................... 17
4.2 Manning Chart ................................................................................................. 17
4.3 Vendor Service Man Mobilisation .................................................................... 17
5. COMMISSIONING/ MODULE FABRICATION/ DARWIN
CONSTRUCTION INTERFACE...................................................................... 17
6. PROGRESS TRACKING & RECORDING DATABASE ................................ 18
6.1 Completion Management System ................................................................... 18
6.2 Information Management ................................................................................ 18
7. INVOLVEMENT OF COMPANY OPERATIONS START-UP TEAM.............. 18
8. PERMIT-TO-WORK (PTW) SYSTEM............................................................. 19
8.1 Construction Permits (Pre-Start-Up) ............................................................... 19
8.2 Commissioning Permits .................................................................................. 19
9. SIMOPS & HYDROCARBON INDTRODUCTION.......................................... 20
10. SEPARABLE PORTION HANDOVER TO COMPANY.................................. 20
11. RIGHT FIRST TIME ........................................................................................ 21
11.1 RFT Objective Areas ....................................................................................... 21
11.2 RFT Key Element Steps .................................................................................. 21

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Commissioning Execution Plan Sheet No. 3 of 56

Attachment 1 – List of Commissioning deliverables during Home Office Engineering

Attachment 2 – Block Sequence of Commissioning and Start-up
Attachment 3 – Commissioning Organisation Chart
Attachment 4 – Commissioning & Start-up Manning Chart
Attachment 5 – Vendor Service Man Mobilisation
Attachment 6 - Work Demarcation Plan for Building (LER/ Substation)
Attachment 7 – Temporary Generator Mobilisation Plan
Attachment 8 – Temporary Distribution Scheme
Attachment 9 – Use of Permanent Equipment prior to Handover

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Commissioning Execution Plan Sheet No. 4 of 56

1. INTRODUCTION

1.1 Purpose
The purpose of this document is to present the basic strategy for the site commissioning
activities and the handover of completed facilities to COMPANY.

1.2 Scope
This document is a plan, not a procedure, and should be reviewed as such.
This document addresses commissioning and handover activities at Site. Activities in
the fabrication yards will be addressed in a separate document.

This plan addresses:

 Commissioning Process
 Commissioning/ Module Fabrication/ Construction interface
 Turnover of systems/ units/ sections from Construction to Commissioning
 Progress tracking and recording database
 Involvement of the COMPANY Operations start-up team
 Commissioning by Systems
 Commissioning Permit to Work System
 Hydrocarbon introduction
 Operational testing
 Phased Handover of Facilities to COMPANY

1.3 Definitions
Agreement Contract with Articles and Annexes
Company INPEX Operations Australia Pty Ltd
Company Items Equipment and materials supplied to Contractor by
Company
Construction Everything necessary for the Works but not incorporated in
Equipment the Plant
Contractor JKC Australia LNG Pty Ltd
Contractor Items Everything to be incorporated into the Plant
Deliverables All documents by Contractor necessary for the Works
Design Dossier FEED Package
Final Documentation As-built documents, certificates, manuals and the like
Ichthys Project The Ichthys Gas Field Development Project
Project Gateway Web system to communicate business opportunities and to
register suppliers

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Site Location where the plant is to be constructed and the

vicinity thereof
Subcontractor Any company to whom Contractor has subcontracted any
part of the works
Vendor Supplier of Contractor’s items
Works All and any parts of the works and services by Contractor
Worksite Any location where work for the site is carried out
Work Time Schedule Schedule for the performance of the Work, specified in
Exhibit C, Contract
Pre-commissioning Pre-Commissioning is a subset activity of the
Commissioning process and is the term used to define the
tasks that – prior to any operational activities - ensure all
piping, vessels, exchangers, equipment are free of:
 Construction and fabrication debris
 Contaminants that could be deleterious to the process
 Rust, mill-scale and weld-slag
 Welding dams
 Preservatives, such as silica gel or other inhibitors or
coatings, free water
RFC Ready for Commissioning: the point at which a system
reaches the erected status defined in the relevant system
pack dossier and the system can be turned over from
CONTRACTOR Construction to CONTRACTOR
Commissioning. The target dates for each of these events
will be incorporated into the integrated project execution
schedule.
Turnover when a system transfers from CONTRACTOR Construction
to CONTRACTOR Commissioning
Handover the transfer of systems/ units/ areas from CONTRACTOR to
COMPANY
RFSU Ready for Start-Up certifies that all necessary dynamic
testing, competency training and familiarization has been
accomplished as per the requirements of the Contract and
that the Plant section satisfies the applicable statutory
codes and COMPANY procedures for Introduction of
Process Hydrocarbons.

1.4 Applicable Specifications and Standards

1.4.1 Contractor Documents

(1) L290-AB-PLN-10143: TURNOVER SYSTEM TRACKING AND REPORTS
(TOSTR) PLAN
(2) L290-AB-PRC-10090: TURNOVER SYSTEM TRACKING AND REPORTS
(TOSTER) PROCEDURE
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(3) L290-AR-PLN-0001: SIMULTANEOUS OPERATIONS STUDY PLAN

(4) L290-AR-PLN-10011: SYSTEM COMPLETION EXECUTION PLAN
(5) L290-AH-PER-0001: HEALTH, SAFETY, ENVIRONMENT AND SECURITY
CONSTRCUTION PERMIT TO WORK PROCEDURE
(6) L290-AR-LIS-10009: COMMISSIONING SUBSYSTEM AND SEPARABLE
PORTION DEFINITION LIST

1.4.2 Company Documents

(1) L290-AR-SPC-0001: COMPLETIONS MANAGEMENT SYTEM – FUNCTIONAL
SPECIFICATION (ONSHORE)
(2) L290-AR-SPC-0002: ONSHORE COMMISSIONING
(3) L290-AR-SPC-0003: PRECOMMISSIONING EXECUTION
(4) L683-AH-MAN-0001: SIMOPS MANUAL

1.4.3 Australian and International Codes and Standards

(1) Not applicable

1.5 Abbreviations
AIP Australian Industry Participation
AQIS Australian Quarantine Inspections Services
ATSI Aboriginal and Torres Strait Islander
EIS Environmental Impact Statement
EPC Engineering, Procurement and Construction
EPBS Enhanced Project By-law Scheme
HR Human Resources
IR Industrial Relations
ITP Inspection and Test Plan
IVB Independent Validation Body
NTG Northern Territory Government
ICNNT Industry Capability Network (NT)
POC Perth Operations Centre
PEC Production Engineering Centre
TCO Tariff Concession Order
TOC Tsurumi Operations Centre
YOC Yokohama Operations Centre
DOC Darwin Operations Centre

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Commissioning Execution Plan Sheet No. 7 of 56

SIMOPS Simultaneous Operations

GEP Gas Export Pipleline
PWC Power and Water Corporation
AGRU Acid Gas Removal Unit
CCPP Combined Cycle Power Plant

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2. COMMISSIONING PROCESS

The Commissioning process is a series of plant verification activities which are required
before operation of any systems or introduction of hydrocarbons to processing facilities.
The Commissioning process ensures that all equipment is installed and operates as per
design and meets functional intent. These verification activities include the last critical
review of the design before achieving a state of Ready for Start Up (RFSU)

The checking and testing of the facilities is, by necessity a detailed and complex
process which needs to be planned and managed in a manner that ensures safety and
efficiency while providing transparency and auditability. Commissioning execution is
fundamentally managed and driven by a systems based approach whereby the plant is
broken into small manageable sections which can be checked and tested independently
of other sections of the plant.

Figure 1 Precommissioning and Commissioning Site Activity Flow Chart

Pre-Commissioning checks for Civil, Architectural and Structural will be performed by

construction on an area by area basis and compiled into separate Pre-Commissioning Dossiers.

The commissioning process can be viewed as a series of stages and gates. Each stage
consists of specific checks and tests which must be completed prior to moving to the
next stage. The completion of all checks and tests results in the issue and acceptance
of a specific document certifying the completion of the stage. These documents can be
considered as gates which must be passed in order to move to the next stage.

DR20A
To enable the efficient use of resources and to allow commissioning testing to be
commenced while construction is still ongoing on nearby equipment, commissioning
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execution is managed and driven by a systems based approach. Construction, on the

other hand, is essentially planned and driven by areas. When construction is
approximately 80% complete a shift in prioritisation will occur from “area build” to
“system build”. At this point in the execution of the project, the workscope must become
back end driven by the commissioning schedule. This shift in execution methodology is
essential to the realisation of opportunities to accelerate the commissioning program,
and allows construction and commissioning activities to be carried out simultaneously.

The Commissioning process requires effective and efficient planning and execution to
ensure a successful project handover including:

 Identification of required activities;

 Identification of acceptance criteria;
 Identification of responsibilities regarding care control and custody
 Definition of responsibility for each activity;
 Identification of resources;
 Development of a Commissioning plan;
 Development of a Commissioning Risk Management plan;
 Development of a Commissioning Strategy;
 Incorporation of the above into an overall strategy which should form part of the
overall Project Quality Plan.
It is essential for planning, resourcing and procedure development that the
Commissioning personnel have a continuing two way dialogue with applicable
personnel responsible for Design, Procurement, Construction and the Operations
Group.

2.1 Care, Control and Custody

The responsibility for care control and custody of equipment will pass through several
functional groups prior to final handover of the plant. The following table is a basic
illustration of the group responsible for Care Control and Custody of equipment as it
passes through the various stages of completion from Construction to final handover.

Stage 1 Stage 2 Stage 3 Stage 4 Stage 5

Pre-Commission Commissioning Operational Performance
ing Testing Testing Start Up testing
Single Discipline Multi Discipline
Completion of stage Ready For Provisional Acceptance
Handover Certificate Certificate
Achieves Commissioning
Execution
Care CONTRACTOR
Construction CONTRACTOR Commissioning
Control Project Start Up Team
Custody
Documentation Completions

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2.2 Pre-Commissioning
Precommissioning, abbreviated and quoted as PC, is the last major activity and
milestone achieved by construction. Precommissioning includes all necessary
installation and fabrication checks to prove equipment has been constructed and
installed correctly and in accordance with drawings, specifications, applicable statutory
codes and practices.
Precommissioning includes all necessary documentation, certification, verification and
checks prior to declaring the system Ready for Commissioning.
Pre-Commissioning checks are assigned by completions in consultation with
Commissioning and Construction and are compiled by Functional System.
Pre-Commissioning checks are single discipline and non-energised / non pressurised,
except for strength testing and insulation testing.
Pre-Commissioning checks are performed by construction and witnessed by
Commissioning as required to ensure a high degree of confidence in the process and
facilitate simple and seamless handover.
Pre-Commissioning checks are of two types, Inspection Check Records which have
results recorded and Inspection Check Lists which do not record results. Completions,
in consultation with construction and Commissioning will assign Inspection Test Lists
and Inspection Check Records as required depending on the tag type and checks
required.
The Pre-Commissioning schedule is developed by Functional System to reflect the
Commissioning schedule and becomes an integral part of completions planning and
reporting. The completions schedule forms part of and is integrated into the overall
project schedule. Pre-Commissioning Inspection Check Records will be compiled by
Functional System into Dossiers. The content of PC Dossiers shall be as per
L290-AR-PLN-10011, System completion execution plan.

2.2.1 Inspection Test Records

Inspection Test Records define the exact scope of work that shall be systematically
performed on every pre-defined item of equipment including packages. Inspection Test
Records do not need to be filled in or returned to the COMPANY, however a fully
auditable system to demonstrate that checks have been completed in their entirety is to
be implemented.
Personnel performing Inspection checks as per Inspection Test Records shall complete
a daily work sheet detailing all checks performed. The work sheet shall record the
tagnumber for each piece of equipment inspected and the number of the check list
applied during Inspection. It shall indicate whether any Punchlist items were raised on
the equipment.
The Completions Management System (CMS) shall record the completion of each
Inspection Test Records and cross reference each piece of equipment to the daily work
sheet. The implementation of this system shall be such that an inspector can check
equipment from different subsystems on the same day and record the results on a
single daily work sheet.

2.2.2 Civil, Structural and Architectural

Although there are no commissioning activities to be performed on Civil, Structural or
Architectural works, Pre-Commissioning will still be performed at an area level, with PC
Dossiers produced to capture relevant documentation.

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2.2.3 Hazardous Area Certification (Ex Checks)

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Electrical equipment installed in hazardous areas needs to be designed, supplied,

installed and inspected to the requirements of COMPANY document. For the purpose of
this document, Initial inspections of Electrical equipment within Hazardous areas will be
referred to as Ex Checks. Ex Checks shall be completed during Pre-Commissioning
wherever possible, but Ex checks which are not able to be completed due to missing
documentation shall not hold up the issue of a Ready for Commissioning certificate.
Upon Completion of Ex Checks, the original check sheets shall be filed in a separate set
of Dossiers which shall contain all Ex checks listed by Tag Number of device checked.
Incomplete Ex Checks will stop the issue of an RFSU certificate for a system, unless the
equipment can be adequately isolated to prevent operation until Ex Checks are
completed. A system will be in place to track outstanding certification and will be
included in CONTRACTORs Commissioning documentation.
Project Hazardous Area check records shall be developed during the Detail Design
phase of the project.

2.2.4 Ready for Commissioning

When all Equipment in a Functional System is fitted, installed and checked as per the
allocated Inspection Test Records, the Functional System is ready to be turned over
from Construction to Commissioning.
To effect this transition, a Ready for Commissioning Certificate, which is an internal
certificate with COMPANY signature for endorsement, is generated from the CMS and
issued from CONTRACTOR Construction to CONTRACTOR Commissioning, complete
with a punchlist report of outstanding punchlist items in the Functional System.
Upon receipt of a Ready for Commissioning Certificate, Commissioning will review the
documentation and associated punchlist and if all is in order will accept the Ready for
Commissioning certificate.
Acceptance of the Ready for Commissioning Certificate indicates that Care Control and
Custody of all equipment in the Functional System has passed from construction to
Commissioning, and any further works performed by construction on the equipment,
including punchlist clearance shall be performed under the control of the commissioning
manager, and the CONTRACTOR’s Commissioning Permit to Work system.
The project philosophy of clearing all punch items prior to allowing equipment to
transition from one department or physical location shall be adhered to, unless material
delivery or similar constraints make such adherence impractical.

2.3 Commissioning Testing

Upon acceptance of a Functional System from Construction, Commissioning testing can
begin. The Commissioning Testing is the first time at which equipment becomes
energised or pressurised.
Commissioning test record sheets are generic in nature and are developed and
assigned to individual pieces of equipment by completions in consultation with
Commissioning. Commissioning Inspection Test Records
Commissioning Inspection Test Records shall be completed in the field during the time
of testing, with all test values, results and readings recorded on the original
Commissioning Inspection Test Record. Where practical the Commissioning Inspection
Test Records shall contain expected values and acceptance criteria prior to performing
the commissioning test.

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Commissioning Inspection Test Records will be compiled with all other commissioning
records by Functional System into Commissioning dossiers. The content of
Commissioning dossiers shall be as per L290-AR-PLN-10011, System Completion
Execution Plan.

2.4 Operational Testing

Once Commissioning testing is completed, Operational testing may commence.
Operational testing proves the functionality of utilities and process systems to the fullest
extent possible prior to the introduction of process hydrocarbons.
Operational tests are performed by Operational Test Procedure (OTP) with any
documentation generated being compiled into the Functional System Commissioning
Dossier.
Operational Test Procedures shall be developed in the Detail Design phase of the
project.
Where utilities hydrocarbons are introduced during Operational Testing, processes and
procedures will be in place to ensure safety, integrity and regulatory compliance.

2.4.1 Operating Test Procedures (OTP)

Operational Test Procedures are a detailed description of each operational test by
Functional System. As well as providing the test methodology, the operational Test
Procedures shall list the observations and readings to be recorded, the acceptance
criteria for the equipment under test and the expected result of each test.
Operational Test Procedures shall be developed such that the required results and
acceptance criteria are documented, with operating instructions coming from the
COMPANY operating manuals. These Operational Test Procedures are produced by
CONTRACTOR for approval by COMPANY. The only exceptions to this will be for
special operation methodology required to test a particular function. This allows test
procedures to be consistent with operating manuals while allowing the field practicality
of the operating manuals to be reviewed.
Operational test procedures shall be approved by COMPANY prior to use and all testing
performed under the Operational Test Procedures shall be witnessed by COMPANY
operations personnel.
Operational test procedures shall be completed in the field during the time of testing,
with all test values results and readings recorded on the original document. Results
shall be recorded for all testing performed.

Operational Test Procedures will be developed during the commissioning engineering

phase of the Project.
Operational Test Procedures will take utilities systems through to a fully functional state.
Final performance testing of utilities may need to be performed during startup when
operational loads and fluctuations are present. Where operational loads can be
simulated, the simulation shall be part of the Operational Test Procedure. Further
testing shall be itemised in the Operational Test Procedure and included in the Start-up
test procedures.
Operational Test Procedures will prove process systems as far as possible without
introduction of Process Hydrocarbons.

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2.4.2 Operational Test Certificate

Upon completion of the Operational Test Procedure, a certificate is presented to
COMPANY for acceptance signifying that the Functional System is complete and
operates as per design intent and Acceptance Criteria. This document is the
Operational Test Certificate. Acceptance of the Operational Test Certificate indicates
Acceptance of the Functional Systems condition, minus any accompanying punchlist
items.
This does not alleviate the CONTRACTOR’s responsibility if faults, shortfalls or
omissions are discovered during further testing under the Start-up scope.

2.5 Temporary Utilities for Commissioning and Operational Testing

Commissioning activities will be started by using temporary utilities before its permanent
systems are Ready for Start-up (RFSU) and are in operation, because no permanent
utilities are available at this time.
Commissioning activities and Construction work can be executed in parallel
simultaneously. When this is carried out, part of system in Commissioning activities will
be isolated from the part in Construction work and Commissioning activities. These will
be done using temporary facilities instead of the permanent facilities.
The following temporary utilities and facilities will be planned for this purpose.
 Temporary electric power
 Temporary air

2.5.1 Temporary Electric Power

Main substation and Local Electrical Room (LER) will be energised by temporary
electric power supplied from the temporary diesel engine generator until permanent
power from the gas turbine generator (GTG) is available. During this period,
Commissioning activities will be done by using temporary electric power.
Prior to permanent electrical power is available, emergency power generator (EDG)
system will support Commissioning and Operational Testing and achieves RFSU of the
systems that shall be completed before start of GTG operation. The permanent EDG
power will be used based on agreement with COMPANY so as to minimize the number
of temporary diesel generators and associated intensive maintenance man hour of
temporary facilities for supplemental power supply source for heating the HP fuel gas in
the Start-up Fuel Gas Electric Heater for GTG commissioning activities. This period will
be minimised and limited to 2 or 3 months at the GTG commissioning activities before
starting GTG operation.
Temporary power is progressively replaced by permanent power supplied by GTG.
Required Temporary Diesel Generator size was estimated based on following two
stages.
- Stage-1 : Upto end of Project Month 39 (Permanent EDG commissioned and
become Ready for Use)
- Stage-2 : Upto end of Project Month 48 (Two sets of permanent GTGs
commissioned and become Ready for Use)
(1) Stage-1 Supply Scheme
Purpose of Stage-1 temporary power distribution is mainly for permanent HVAC
energisation for each LER / LIR building. Temporary electrical supply will be fed by

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temporary power will be distributed through the temporary distribution board and
necessary temporary cablings which are prepared by AG&P Module Yard and delivered
to Darwin-site together with LER/LIR module. For Utility LER and Utilities Annex LER,
temporary diesel generators will be installed near the LER’s to supply power for Motor
No Load Run Test and required Mechanical Run-in Test.
(2) Stage-2 Supply Scheme
Purpose of Stage-2 temporary power distribution is mainly for Motor No Load Run Test
and required Mechanical Run-in Test at Train-2.
Power supply of other than Train-2 process LERs will be switched-over LER by LER to
permanent EDG distribution scheme once after the permanent EDG and associated
downstream distribution scheme were commissioned and became ready for use (i.e.,
Project Month 39).
In order to maximise the use of permanent EDG supply for commissioning purpose,
temporary bypass (i.e., jumper wire) will be used to allow simultaneous closure of
Normal and Emergency 400V switchgear tie-circuit breaker and Emergency 400V
Switchgear Incomer breaker. The bypass wire shall be removed prior to the permanent
GTG supply is fed to the Normal 400V Switchgear.
Train-2 permanent EDG distribution cannot feed the Train-2 Normal 400V Switchgears
due to a number of split normal switchgear distributions. In order to commence the
Motor No Load Run Test and critical part of Mechanical Run-in Test in Train-2 area,
larger size temporary diesel generators will be installed in Stage-2 period. Tie-in point of
the larger temporary generators will be equipped spare feeder circuit of Train-2 LER
6.6kV Switchgears.
Refer to Attachment-7 “Temporary Diesel Generator Mobilization Plan” and
Attachment-8 “Temporary electrical power distribution scheme for Stage-1 and
Stage-2”.
A 6.6kV Temporary Diesel Generator will be mobilised and connected to the emergency
6.6kV switchboard (in Main Substation) instead of one of the permanent Emergency
Diesel Generators. This temporary generator will be operated in lieu of the permanent
Emergency Diesel Generators when the total power demand is very low in order to
avoid light load operation of the permanent generators.

2.5.2 Temporary Air

Temporary dry air is required for Commissioning and Operational Testing and utility
systems operation before the permanent air system is in service. Temporary dry air will
be produced by portable oil-free air compressor package with air dryer package, and
used as temporary instrument air source and for cleaning of systems. For temporary
instrument air, two temporary air compressor packages (1 + 1s) are planned and are not
commonly used as dry air supply for cleaning of systems so as to secure the instrument
air supply. For dry air supply for cleaning, other temporary air compressor packages will
be planned.
Emergency air compressor package and emergency instrument air dryer package are
planned to be available when EDG power is available. Emergency instrument air
system may be used with COMPANY’s approval.
Permanent air system will be commissioned with EDG power by using temporary link
between normal and emergency bus and become in service. When permanent power
is available from GTG, this temporary link will be removed.

2.5.3 Temporary Vent System

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Temporary vents will not be used for early Utility area Commissioning in current plan.
Warm Flare will be used for initial venting of nitrogen from Gas Export Pipeline.
However, dispersion studies for the utilisation of Temporary Vents have been carried
out and confirmed that it’s safe.

2.5.4 Permanent Equipment Usage while Commissioning

Permanent equipment usage while commissioning has been discussed and COMPANY
has agreed to allow using the equipment under CONTRACTOR care and custody as
listed in attachment-9.

2.6 Ready for Start-Up

The Ready For Start-up Certificate is presented to COMPANY for acceptance signifying
that a discrete section of the Plant is ready for the introduction of Hydrocarbons.
Acceptance of the Ready for Start-up Certificate indicates acceptance of the condition
of all equipment covered by the RFSU certificate, minus any accompanying punchlist.
This does not alleviate the CONTRACTORs responsibility if faults, shortfalls or
omissions are discovered during further testing under the Start Up scope.

2.7 Handover Certificate

When all equipment in a Separable Portion is Ready for Start-up and all required
drawings, documents, data and permits have been handed to COMPANY, the
Separable Portion is ready to be handed over to the COMPANY Start-up Team. To
facilitate and document this milestone, a Handover Certificate will be presented to
COMPANY for acceptance. After acceptance of the Handover Certificate the care,
Custody and Control of the system is transferred to COMPANY.
The Acceptance of the Handover Certificate certifies that the COMPANY accepts that
the Separable Portion is ready for the introduction of Process Hydrocarbons and that
the Start Up procedures can commence.
When operation of commissioned equipment is required prior to handover,
CONTRACTOR takes the responsibility to operate it with agreement of COMPANY.

2.8 Start-up Procedures

CONTRACTOR Commissioning team will produce detailed Start-up procedures
outlining the steps to be taken and testing to be performed for cool down, introduction of
process hydrocarbons and bringing the plant to full operational status.
Readings to be recorded and testing to be performed shall be detailed in the Start-up
procedures. All recordings taken, and results of all tests performed during Start-up shall
be recorded in the relevant Start-up procedure.
All outstanding tests on utilities systems as detailed in the Operational Test Procedures
shall be included in the Start-up procedures. These tests shall be planned and
incorporated in the Start-up schedule with testing performed during the Start-up phase.
Process system functionality and performance shall be proven as far as possible during
the Start-up procedure execution.

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Once the plant is running and stable, output will be increased to the design nameplate
value which will be held for a predetermined period to prove the facility can perform to
the nameplate rating.
A set of performance testing procedures will be developed by CONTRACTOR with the
support of their VENDORS and Licensors outlining the steps to be taken and testing to
be performed to prove to COMPANY’s satisfaction the performance of the plant. All
readings recorded and testing performed shall be detailed in the performance testing
procedures. All recordings taken, and results of tests performed during performance
testing shall be recorded in the relevant performance testing procedure.
Upon completion of Performance Testing all utility and process systems will have been
tested and proven to perform to design intent and manufacturers specifications. The
ability of each system and system component to meet COMPANY acceptance criteria
will have been demonstrated by the conclusion of Performance Testing.

3. GENERAL REQUIREMENT

Like any project, a major key to successful field execution is the relationship between
the Construction and Commissioning teams – during the home office EPC period, the
fabrication yard activities and, finally, the site erection phase. Although Commissioning
is Construction’s “customer”, both of these field execution groups must have the same
objective – a smooth start-up leading to continuous commercial operation and a
satisfied client.

3.1 Deliverables during Home Office Engineering

The List of the Commissioning deliverables during Home Office Engineering is shown in
Attachment 1. Documents of Subsystem-wise commissioning procedures will be
prepared after the completion of subsystem definition during EPC phase.

3.2 Pre-Commissioning
Executing Pre-Commissioning tasks will involve one or more of the following
methodologies:
 water-flushing
 air-blowing
 mechanical cleaning
 chemical cleaning
 steam-blowing
The responsibility for a “clean-build” fabrication and construction approach rests with the
Construction group. It is CONTRACTOR’s intention to maximise the amount of
pre-commissioning work that is performed in the fabrication yards or supplier shops and
CONTRACTOR will assign Commissioning personnel to witness for these activities.
Philosophy for pre-commissioning in the fabrication yards is shown in
L290-AB-PLN-0151, CONSTRUCTION AND PRECOMMISSIONING EXECUTION
FOR MODULE FABRICATION.
That said, however, it has to be recognised that there are certain pre-commissioning
activities that require the major portions of the system to be physically connected and
essentially construction-complete, e.g.:

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 air-blow cleaning of distribution headers of systems such as instrument air &

nitrogen
 circulation, heat-up and cool-down of the heating medium system
 water-flush cleaning of systems such as fire-water, demineralised water, service
water and drinking water.
 circulation of the cooling medium system
 steam-blowing or aqua-milling of the HP & LP steam distribution systems
These activities can only be performed at site by Commissioning.

3.3 Commissioning
Commissioning is the phase of a project in which the facilities transition from an erected
(or partially construction-complete) status to an operational status. Commissioning
focuses on “subsystems” rather than geographical areas; on the place of each system
in the overall process; and the bringing of each subsystem to an “operational readiness”
condition in a logic-based sequence that aligns with the start-up sequence for the
complex.
Block commissioning & start up sequences, one for utility including CCPP and the other
for LNG train, have been developed.
These block sequences are showing:
 Interaction among units during commissioning & start up phases
 Major milestones of commissioning & start up
These sequences will be the basis of Commissioning & Start up Schedule.
Refer to Block Sequence of Commissioning and Start up in Attachment 2.

4. COMMISSIONING ORGANISATION AT DARWIN SITE

4.1 Organisation
As required, experienced commissioning personnel will be mobilised to the appropriate
Engineering Centre to assist with the development of deliverables. Refer to
Organisation Chart showing Commissioning Reporting System, in Attachment 3.

4.2 Manning Chart

Refer to Commissioning & Start up Manning Chart, including both for utility and process
train, in Attachment 4.

4.3 Vendor Service Man Mobilisation

Refer to Vendor Service Man Mobilisation which shows the mobilisation plan in regard
to the operational activities, in Attachment 5.

5. COMMISSIONING/ MODULE FABRICATION/ DARWIN CONSTRUCTION

INTERFACE

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Work demarcation matrix plan showing the split of works between commissioning,
module fabrication and Darwin construction has been developed and will be updated as
required. Basic philosophy of this plan is to minimise the workforce at Darwin site.
Refer to CONTRACTOR Document L290-AR-PLN-0002, Commissioning/ Module
Fabrication/ Darwin Construction work demarcation plan.
Work Demarcation Plan for Building in Attachment 6 shows the basic strategy for
Building (LER/ Substation) Commissioning.

6. PROGRESS TRACKING & RECORDING DATABASE

6.1 Completion Management System

The Ichthys Onshore LNG project will use the KBR system TOSTR as the completions
management system. This system will be used in all the Module Fabrication Yards and
at Darwin site. The full details of how TOSTR will be implemented are given in the
following documents
 L290-AB-PLN-10143, TOSTR Plan.
 L290-AB-PRC-10090, TOSTR Procedure.
TOSTR will be used to track the completion of Pre-commissioning and Commissioning
activities, TOSTR will not be used for the tracking of Construction QC forms and
activities.

6.2 Information Management

Equipment Information is vital to the efficient ongoing operations and maintenance of
the facility, and will be stored in a COMPANY database upon project completion. The
integrity of this information is key for ensuring COMPANY can manage the facilities
through their life cycle. A key benefit from the completions process is the ability to
confirm and augment the information produced during the design and procurement
stage of the project.
To facilitate this, basic engineering data such as manufacturer and model number as
per the design master engineering data warehouse shall be available for all equipment
prior to Pre-Commissioning checks being performed. This information shall be made
available to the technicians performing the inspection.
Any discrepancies found between the design data and the actual field data shall be
managed via a management of change process, to be implemented by the
CONTRACTOR. As a minimum these discrepancies shall be reviewed for equipment
compatibility and suitability by a competent engineer. If the actual installed equipment is
found to be suitable, the correct data shall be sent to the Engineering
Data Management group to propagate to all relevant design systems, the maintenance
system and spare parts system.
Included within the management of change process, shall be a methodology for
occasions when equipment is found to be unsuitable for the intended application, thus
ensuring equipment is replaced prior to handover.
A procedure shall be developed by CONTRACTOR outlining all aspects of the interface
between Completions / Commissioning and Information management

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To assist in the seamless handover of systems and to provide full buy-in to the
completions and commissioning process, a COMPANY Commissioning group has been
established to work with the CONTRACTOR Commissioning team. The COMPANY
Commissioning group will work together with the CONTRACTOR Commissioning group
to facilitate information flow and to give the end users of the facility valuable exposure to
the design, build and commissioning methods applied.
COMPANY input to the Project at FAT level, during Pre-Commissioning and during
function testing alleviates many problems due to a greater understanding of the
reasoning behind certain methodologies and decisions.
The COMPANY Commissioning group will provide input from FEED through detailed
design, Construction and Commissioning and will represent the COMPANY during all
project phases.
The COMPANY Commissioning team will support the CONTRACTOR to safely manage
and execute each phase of the project. Responsibility remains with the CONTRACTOR
to manage Project Controls.
The Contractor will provide facilities to accommodate the logistics requirements
required to allow integration of the COMPANY Commissioning team with the
CONTRACTOR Commissioning team.
The CONTRACTOR will develop Commissioning Team, consisting of but not limited to:
 CONTRACTOR Design Engineers
 CONTRACTOR Commissioning Engineers/Supervisors
 CONTRACTOR Commissioning Support
 Specialist Vendor Representatives.

8. PERMIT-TO-WORK (PTW) SYSTEM

8.1 Construction Permits (Pre-Start-Up)

Permit to work system prior to Ready For Commissioning has been identified in
L290-AH-PER-0001, Health, Safety Environment and Security Construction Permit to
Work Procedure.

8.2 Commissioning Permits

Once a “subsystem” has been turned over from Construction to Commissioning, the
subsystem will be identified as “under commissioning” and will be segregated from other
subsystems still under construction by suitable barricading, line tagging, notice boards,
etc.
The site workforces will be notified through daily safety talks “tool-box talks” and by
published and distributed copies of marked-up plot plans showing which areas of the
plot will now have commissioning activities occurring and therefore will have access and
work restrictions and will require a Commissioning work permit.
These notices will be issued in advance of anticipated turnovers of subsystems to allow
the information to be disseminated to all site personnel.
All mechanical, instrument and electrical intervention or testing-type activities on
subsystems designated as “under commissioning” will require a commissioning work
permit. Construction activities after turnover such as clearing of minor punch-list items,
touch-up painting, joint insulation, etc., will also require a commissioning work permit.

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The commissioning group’s intention is to model the Commissioning PTW system on

the intended COMPANY Operations’ PTW format so that the workforce does not have
to adapt to a totally different system as the facilities progressively come under the
control of COMPANY Operations.

9. SIMOPS & HYDROCARBON INDTRODUCTION

Please refer to L290-AR-PLN-0001, Simultaneous Operations Study Plan and

L683-AH-MAN-0001, COMPANY’s SIMOPS Manual showing detailed SIMOPS Plan.
Ichthys LNG facilities will be commissioned and brought into operation in a staged
process. This means that certain areas of the plant will become live whilst other areas
are still in varying degrees of construction completion. This introduces the risk of
accident hazard during SIMOPS, namely that systems, which have been completed and
are Ready for Start-up are brought into operation whilst construction work continues
elsewhere on the facility.
The main additional risks incurred during this SIMOPS phase are:
 Exposure of a larger than normal population to the risks of major accident hazards
due to the presence of considerable numbers of construction workers.
 The presence of additional ignition sources during construction work.
 The risks associated with pre-commissioning activities such as steam blowing.
 The risks associated with start-up and commissioning activities prior to steady state
operations being achieved.
 Additional complexity associated with the need to manage interfaces between
various parties.
 The risk of inadvertent breaking the containment envelope of an energized or
operating system.
 The risk of physical damage caused as a consequence of fault, failure, or mis-use
of construction and construction support equipment in close proximity to energised
systems.
 The risks associated with human errors and noncompliance with the rule of
operational area control.
The risks resulting from SIMOPS are managed to be as low as reasonably practicable.

10. SEPARABLE PORTION HANDOVER TO COMPANY

Handover of the facilities from CONTRACTOR to COMPANY shall be structured to

occur in logical steps. This approach has following advantages:
 Gradual transfer of technical documentation packages to COMPANY library
 Transition of responsibility from CONTRACTOR to COMPANY Operations group
happens progressively
 COMPANY maintenance and technical groups workload ramps up smoothly
 Punch-list items are dealt with more efficiently
 SIMOPS events are reduced

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The definition and composition of the subsystems or areas that comprise the separable
portion has been defined, refer to L290-AR-LIS-10009, Commissioning Subsystem and
Separable Portion Definition List.

11. RIGHT FIRST TIME

CONTRACTOR shall lead and direct the Right First Time program up to Acceptance of
Handover Certificate for each Separable Portion.

11.1 RFT Objective Areas

 SAFE
 CLEAN
 TIGHT
 OPERABLE
 RESOUCED
 COMPLETE
 TESTED
 SIMPLE/ PROVEN
 DOCUMENTED
 INTEGRATED
 SIMOPS

11.2 RFT Key Element Steps

The key elements of the Right First Time Program shall be as follows:
STEP 1 – Stakeholder Engagement / Formation of Steering Group (SG)
STEP 2 – Preliminary Lessons Learnt Database Development
STEP 3 – Right First Time Champions Selection
STEP 4 – Objective Champion Workshop (Develop Lead KPI’s / KPI’s)
STEP 5 – Review Lessons Learnt
STEP 6 – Risk Ranking
STEP 7 – Develop Achievable Actions
STEP 8 – Working Group Review of Ranked Action & Interim LI’s & KPI’s
STEP 9 – Conduct Brainstorm Sessions with Discipline Teams
STEP 10 – ICHTHYS LNG RFT and Lesson Learned Register with tracking and
reporting facilities.
STEP 11 – Maintain Currency and Track Actions
STEP 12 – Drive RFT into Design and Construction Contracts
STEP 13 – Integrate LI’s, KPI’s and RFT into Fabrication & Construction Yards
STEP 14 – Maintain Focus and Drive for Success
STEP 15 – Health Checks

DR20A
STEP 16 – Post Project Review

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