11050146-CM-PRO-000-5017_RA
Short Description
Commissioning Plan...
Description
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
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REVISION SUMMARY REV.
DATE
A
22 Nov. 2013
DESCRIPTION Issued for Approval
PAGE
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
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TABLE OF CONTENTS
1.
COMMISSIONING PHILOSOPHY .................................................................................................. 4 1.1
EXECUTION PLAN FOR THE COMMISSIONING PROGRAM ...............................................................4
2.
COMMISSIONING ORGANIZATION............................................................................................... 5
3.
COMMISSIONING SCHEDULES ................................................................................................... 5 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10
4.
SYSTEM COMPLETION PRIORITIES .......................................................................................... 22 4.1 4.2 4.3
5.
HOME OFFICE PLANNING & PREPARATION PHASE ..................................................................... 22 SITE COMMISSIONING PHASE ................................................................................................... 26 SYSTEM TURNOVER ................................................................................................................ 27 COORDINATION ...................................................................................................................... 29
HEALTH SAFETY & ENVIRONMENT (HSE) ................................................................................ 29 6.1 6.2 6.3
7.
EARLY ACCEPTANCE UTILITIES ................................................................................................ 22 SUPPORTING FACILITIES (TANKAGE & UTILITIES) ...................................................................... 22 PROCESS FACILITIES .............................................................................................................. 22
EXECUTION PLAN ....................................................................................................................... 22 5.1 5.2 5.3 5.4
6.
COMPLETION PROGRAM ............................................................................................................5 COMMISSIONING .......................................................................................................................7 COMMISSIONING EXECUTION .....................................................................................................8 TESTING OF ROTATING EQUIPMENT ............................................................................................9 TIGHTNESS TESTS .................................................................................................................. 13 INSTRUMENTS AND SAFETY CONTROL ...................................................................................... 14 OPERATIONAL FUNCTION TEST ................................................................................................ 14 PREPARATION FOR START-UP .................................................................................................. 16 CONSTRUCTION COMPLETION (CC) AND READY FOR COMMISSIONING (RFC)................................ 20 AFTER CONSTRUCTION COMPLETION (CC) ................................................................................ 20
HOME OFFICE PREPARATION ................................................................................................... 29 COMMISSIONING SITE SAFETY ................................................................................................. 29 ENVIRONMENT & HARMFUL EMISSIONS .................................................................................... 30
ATTACHMENTS............................................................................................................................ 31 ATTACHMENT 1: TABLE–SPLIT OF WORK FOR CONSTRUCTION, PRE-COMM. & COMMISSIONING ............. 32 ATTACHMENT 2: PRE-COMMISSIONING/COMMISSIONING ORGANIZATION .............................................. 63
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
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COMMISSIONING PHILOSOPHY A successful Commissioning for WARA PRESSURE MAINTENANCE PROJECT will require attention to detail and close coordination between COMPANY and CONTRACTOR to successfully produce a safe and reliable operating facility on schedule. CONTRACTOR’s approach to a successful Commissioning for WARA PRESSURE MAINTENANCE PROJECT is based on the fully integrated involvement of all concerned parties in all aspects, and in each phase, of the project as described below. This assures that all parties are fully familiar with their respective duties, are fully informed and trained to safely carry out their duties and fully supported by the Team for the successful Start-up and operation of WARA PRESSURE MAINTENANCE PROJECT. CONTRACTOR will make use of the most experienced and specialized personnel in the execution of the Commissioning. Key members of this Team will be assigned as early as possible during the Engineering Stage and preparations for the following work.
1.1
Establish an Organization. Develop schedules and progress measurement tools for commissioning phases of the works. Be responsible for the management and direction of all vendor representatives, specialists and technical service providers Manage, supervise, direct and control the Commissioning activities for the safe and assist operation and test activities of the facility for successful turnover to COMPANY
Execution Plan for the Commissioning Program The Commissioning program plan is a two distinct-phased approach to Commissioning – the Initial Home Office Planning & Preparation phase and the Site execution phase which is defined as follows: Phase-1 of the Commissioning program plan will be conducted / developed in CONTRACTOR’s home office and will include, but not be limited to, the following activities:
Coordination with Engineering and Precommissioning on Commissioning requirement Development of site specific Commissioning administrative and technical procedures Incorporation of COMPANY procedures and testing requirements Preliminary Operations and Maintenance Manuals of the area not provided by Licensor will be prepared by process design team for review by COMPANY. Preparation of "Scoped" drawings / databases for turnover package development Development of Commissioning schedule with input from COMPANY’s project management Development of the budget for all Commissioning activities.
Phase -2 of the Commissioning program plan will be conducted on-site and will include, but not be limited to, the following activities:
Mobilization of the Commissioning Team Administration system turnovers from Precommissioning to Commissioning Team. Coordinate with precommissioning the completion of system punch lists in preparation for turnover to the Commissioning Team. Coordinate and conduct the equipment and systems Commissioning testing program. Administration systems turnover to COMPANY’s Commissioning Team.
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
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COMMISSIONING ORGANIZATION CONTRACTOR will provide Commissioning personnel in the applicable disciplines as needed with extensive experience to complete specified / identified Commissioning activities. Commissioning Manager will have overall responsibility for coordination of all project Commissioning activities. Commissioning Manager reports directly to the Site Manager and to the Project Manager. The discipline test engineers, equipment vendor representatives, precommissioning craft, contract support and Contractor’s Commissioning personnel assisting in the Commissioning effort will work under the direction of the Commissioning Manager as a single Team. Every effort will be made to maintain the continuity of all Commissioning Team members including assigned support craft and COMPANY’s personnel throughout the duration of all Commissioning activities. This continuity of personnel will aid greatly in the effectiveness and efficiency of the Commissioning Team. Refer to detailed Commissioning Organization.
3.
COMMISSIONING SCHEDULES The schedules for all Commissioning activities will be developed as early as possible at detail engineering stage. This will include an overview of the sequencing of system preparations and the critical path for these activities.
3.1
Completion Program The completion of the facility, the preparation of the facility for operation, the Start-up of the facility and the operation of the facility for proof of performance involves several steps or specific sets of activities which are typically referred to as:
Facility Construction Completion (End of Pre-commissioning) System Commissioning Facility Initial Start Up Facility Turnover (End of Commissioning) Performance Test Provisional Acceptance Final Acceptance
These various steps, and the sequence of execution, are represented below:
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CONTRACTOR is responsible for Construction, Pre-commissioning and Commissioning of the Facility including test run. However, COMPANY’s operation team will work hand to hand, gaining experience in plant Commissioning and Start up and ensure seamless transfer of responsibilities during take over of the new facilities on completion of test run.
3.1.1
End of Pre-commissioning and Handover to Commissioning End of Pre-commissioning is the 2
nd
key step in the process of overall completion.
This is the stage where the basic pre-commissioning work has been completed and the precommissioning quality control inspections and tests have been completed (and duly recorded) for all the elements that make up a particular system within a unit or plant area. This is attested by the various QA/QC Reports associated with each discipline and item of equipment. These Tests and Records represent volumes of records and, in order to readily determine the status of completion; these records shall be collated on a system- by -system or unit basis. Pre-commissioning is achieved when the pre-commissioning work for a defined scope of piping, electrical, instrumentation, civil/structural facilities buildings, underground, structural steelwork, and miscellaneous items have been completed. CONTRACTOR remedy or resolve to the satisfaction of COMPANY all pre-commissioning punch list items classified as needed before starting Commissioning.
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Commissioning As soon as a System has been pre-commissioned and completed in accordance with the Contract and is in compliance with the Scope of Work (excluding such minor items as finishing of insulation and painting, and other items not materially affecting the operation or safety of the System) and has passed any tests required on that System, the system is on ready for Commissioning. Commissioning is the term used for the final tests, inspections and checks carried out by the commissioning team to confirm that the equipment and systems within the unit and plant are precommissioned in accordance with the approved design and specifications and will function to specified operational requirements. It is at this stage that the final preparations, checks and line out of the equipment and plant (commissioning of the particular items or systems) can be carried out in preparation for introduction of hydrocarbons and start-up of the facilities. CONTRACTOR will confirm to COMPANY that all commissioning activities have been successfully carried out. This is reflected by the Commissioning Checklists and “Test Record” Sheets, which record the action taken by the Commissioning Team in the preparation of the systems for Turn-over. It is typically at this stage, having confirmed for COMPANY that all End of Commissioning activities have been successfully completed, that Turnover Certification for the plant will be issued for performance test..
3.2.1
Scope Commissioning involves the preparation of systems to achieve ready for Performance test status. In this phase between system end of commissioning and the commencement of Performance test, a considerable amount of operation work is required. This Commissioning work is be carefully planned and executed by CONTRACTOR in close consultation with COMPANY and Manufacturer representatives. Throughout the Commissioning phase the CONTRACTOR maintain and update the formalized system punch list. At this time the punch list will record any material items which remain outstanding for Turnover (Commissioning Completion) status, and any corrective work which has become evident during commissioning. On successful completion of all of the required Commissioning work, CONTRACTOR will notify COMPANY a system is Turnover (Commissioning Completion). Upon successful completion of Commissioning, CONTRACTOR will apply for Turnover Certificate, signifies the end of the commissioning phase.
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
3.2.2
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Commissioning Responsibilities All tools and equipment, all consumable materials, fuels and all services necessary to complete Commissioning shall be planned and furnished by CONTRACTOR. Certain utilities, such as water and power may be sourced from COMPANY’s utility distribution system. Demineralized(or potable) water for Commissioning flushing and dynamic testing shall be provided by CONTRACTOR. CONTRACTOR will organize testing and water use to minimize waste of water. CONTRACTOR will provide the plant air and instrument air used during the Commissioning of instruments.
3.3
Commissioning Execution Detail and specific commissioning procedures will be prepared for the project and presented for COMPANY’s review and approval. The following Basic Guidelines are provided only as a “typical” guide to the commissioning activities which are normally involved in the preparation of a plant for operation. It is important to note that fixed procedures for the execution of every commissioning activity cannot always be applied in the same manner in each and every case. This is due to the nature of the work and conditions of the facility that can vary from case to case. It is not practical to cover all possible contingencies or emergencies conditions. Therefore, some of the procedures and operating conditions stated herein may be require modification to meet unusual or emergency conditions. The intent is to ensure that the quality and integrity of plant preparations is maintained; regardless of procedural methods. The purpose of the Commissioning Guidelines will be to familiarize COMPANY’s operation group with some of the basic aspects of Commissioning activities. Detail procedures specific to the individual systems and equipment items on this project will be prepared prior to the beginning of commissioning for the project. All COMPANY’s operating and operations maintenance personnel will become familiar with all details of the Commissioning activities, and the function of all operating equipment, during the course of the On-The-Job training that will be given as they participate in each of the following activities.
3.3.1
P&ID Checks The following Check List Procedure is intended as a guide to operators to assist in P&ID checking. However, it does not in anyway suggest that the P&ID check is limited to the following list. It is essential when carrying out the P&ID check the very latest revisions of the P&ID are checked. It is important that items on the Check List are clearly defined and the item number entered on the P&ID.
3.3.2
Check Procedure When P&ID checks are being carried out, and the persons checking are unsure of the validity of any
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item, they should immediately contact a member of the site engineering team. This will save future confusion and help to speed up the P&ID check. (a) List all items, e.g. temperature indicators, pressure indicators, etc. are not installed or incomplete. (b) Check instrument tag numbers to ensue the correct instrument is mounted in the correct location, note any deviation. (c) Note whether vents at high point or drains at low point are omitted. (d) Note dead legs and question drainage, purging etc. (e) Note any obvious materials faults, e.g. carbon steel bolts on stainless steel flanges. (f) Check (note deviation) of orifice plate orientation and tag number. (g) Note tapping point orientation. (h) Note if in line strainers are in place, check tag numbers. (i) Visually check (note deviation) piping runs for abnormality. Ensure exchangers, vessels etc. process/utility piping is routed to the correct nozzle. (j) Note installation of relief valves, check seals, bolts, gaskets and tag numbers. (k) Note all safety items, trip hazards, head room hazards, missing gratings, manholes, fire hazards, poor access to emergency equipment etc. 3.3.3
P&ID Check List Control To ensure that P&ID check results are properly recorded and subsequently acted on the following method is suggested; (a) P&ID check teams to mark up the P&ID with a highlighter, line by line, to reflect which portions of the system have been checked, (b) Faulty items are given a check number, this number is marked on the P&ID and corresponding number entered on the Check List with a description of the fault. (c) Make two photocopies of the Check List. (d) Make two copies of marked up P&ID. (e) Attach Check List to P&ID. (f) One copy of Check List and P&ID is used as the operations work copy. (g) One copy of Check List and marked up P&ID is the operating master copy and is kept in the central work area. (h) The work copy is used for rechecking purposes. The status of all items is noted on the work copy and find out entered into the master copy. (i) One copy of Check List and marked up P&ID is transmitted to COMPANY’s team who will inform Contractor of any further defective / missing items noted by the COMPANY’s team. (j) Operations will recheck the items to ascertain whether or not the item has been corrected. If not, a note is made in the Check List. (k) When Contractor has acted on the items he will inform COMPANY that the work is complete.
3.3.4
Check completion of Pre-commissioning Activities Please refer to the Pre-commissioning Procedures.
3.4
Testing of Rotating Equipment Before start of test runs on rotating equipment, the following personnel should be informed. (a)
Commissioning and start-up team.
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(b) COMPANY’s start-up rotating equipment engineers. (c) COMPANY’s operation group. (d) Vendor service engineer for package items Contractor maintenance specialists will instruct COMPANY’s team on how to carry out the testing of rotating equipment. They will keep a continuous watch on the rotating equipment and monitor performance. Where practical, machinery will be operated, performance tested and systems operated prior to startup of the Plant. For package systems, Operational performance of instruments and systems will be carried out. Instrument inspection and calibration must be completed prior to this run-in-period. Before the actual test is carried out, all inspection requirements and preparations, inclusive of manufacturer's vendor representative requirements must be completed. Inspection on any item of running equipment that could involve personnel coming into contact with moving parts requires the power supply to be isolated and locked off. Any internal inspection of running equipment, which involves opening of parts, which may contain pressure, requires the suction and discharge to be isolated and the casing vent to be opened. The casing must be at atmospheric pressure before any attempt is made to open the equipment. If there is any doubt as to the security of the isolation, then blind flanges should be installed on the equipment side of the suction and discharge valves. Equipment should be isolated using blinds if hydrocarbons are present in the system during the test run. 3.4.1
Electric Motors Electric motors will be subject to a no-load testing i.e.: the motor is uncoupled from the driven equipment. During the no-load test, the following items should be recorded: (a) (b) (c) (d)
Check direction of rotation. Motor vibration levels. Bearing temperatures. Abnormal noises
Using the subsequent test with the driven equipment connected to the electric motor the following items are to be measured and recorded: (a) (b) (c) (d) 3.4.2
Electric motor current. Motor vibration levels. Bearing temperatures. The start-up current, and time for fin fan motors.
Pump Test Run Preparation
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The following steps will be taken for the Pump Test Run Preparation: Pump suction line should be fully flushed before Test Run (a) The pump should still be uncoupled from the driver. (b) Install strainers with (20~40) mesh size temporary start-up screens before aligning pumps. Mark all strainers and keep a list similar to the blind list, so as to prevent a 'lost' screen. Connect the suction and discharge flanges to the pumps and simultaneously (c) Remove pipe stresses. (d) Connect the pump to the driver and check alignments (cold alignment check). (e) Rotate the shaft manually to check for freedom of movement. (f) When a test run with water has been planned, carefully isolate the loop system from the rest of the sections. The water should be sufficient to fill the whole loop and provide sufficient head available to the pumps. (g) A final check should be carried out that correct lubricating oil and grease have been put into the pump, and that the oil glass shows proper level. (h) Open the suction valve. (i) Check that the seal does not leak and that seal flushing and cooling water connections are correctly made. (j) Rotate the centrifugal pump shaft by hand to test for free rotation. (k) Flush water from the pump drain and the suction drain to remove scale (if possible). (l) Check that the coupling guard is secure. (m) Start lube oil system (if applicable). (n) Switch the pump on and off as a final check for correct shaft rotation. (o) Ensure that the pump is liquid full. 3.4.3
Centrifugal Pump Test Run During the pump test the following items should be checked: (a) (b) (c) (d) (e) (f) (g)
3.4.4
Bearing temperatures. Vibrations. Abnormal noises, noise levels. Pump discharge pressure at shut off head and normal flow (if possible). Leaks identified and listed for repair if not pulled up. A test sheet is to be completed. The test duration is for a minimum of 30 minutes (if applicable).
Positive Displacement Pump Test Run During the Initial run, the following items must be confirmed or checked: (a) Confirm the liquid has sufficient lubricating properties. (b) Supply cooling water where necessary. (c) Start the pump with open suction and discharge valve. Check the mechanical performance of the pump and watch bearing temperature, if applicable. (d) Check flushing supply to seals, if applicable. (e) When discharge pressure drops, stop the pump, inspect and clean the strainer in the suction line. (f) Check for excessive vibration. (g) Check motor amperage, if applicable. (h) Check for noise levels in excess of specifications.
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(i) Check pump for leaks. (j) A test sheet is to be completed. (k) The test duration should be for a minimum of 2 hours. 3.4.5
Centrifugal Compressor Test Run Before test runs on Centrifugal Compressors are carried out, a detail plan of action must be reviewed with the Vendor specialists to confirm readiness. The plan of action should consist of the following elements, as a minimum: (a) Vendor’s commissioning instructions for review (b) Detailed schedule of action with actual dates and milestones reached. (c) All individual equipment tests, lube oil pumps, motors, filters, etc. should be specified separately. In general the criteria for testing and inspection to be described individually for such equipment items. (d) Tests of all auxiliary systems lube oil, seal oil and cooling water etc. should be included and scheduled well in advance of compressor test run. (e) Anti surge control system to be tested and line up checked. (f) In case the test run is carried out with a medium different than the design process gas, restrictions on speed, discharge temperatures, pressures, etc. should be clearly specified. (g) The compressor test run should be scheduled at the end of the test run series of the driver (steam/gas turbine): however, it is to be carried out as a separate activity. (h) All test results should be recorded on specified test sheets that are part of the test program. As a minimum, the following parameters should be included: (a) (b) (c) (d) (e) (f)
3.4.6
Oil pressures, temperatures, flows. Gas pressures, temperatures, flows. Vibration signals (during start-up and at operating speed). Noise levels. Speeds. Driver operating data.
Reciprocating Compressor Start-Up Preparations The following steps will be taken for the Compressor Start-Up Preparations: (a) Check that the inlet filter and fine mesh screen element is installed and that there is no space between the filter element and the filter casing. (b) Check that correct lubricating oil has been put in the compressor and oil glass is full. (c) Check that all lines are connected properly to the machine. (d) Bar the crankshaft over for at least one revolution to make sure that all-moving parts of the compressor run freely. (e) Check that the shaft guard is installed. (f) The lubricator settings should be in excess of normal operating settings. Remove suction and discharge compression valves, if required.
3.4.7
Reciprocating Compressor Test Run In case a test run on a gas that is different from the design process gas is carried out, specific
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attention should be paid to restrictions on power demand and discharge temperatures. Restrictions should be clearly specified in the procedure. The plan of action should consist of the following elements, (a) Operate the compressor on a start-up procedure while the lube oil pump operates for about five minutes. (b) After bringing the unit to a standstill, check all bearings and other friction parts for temperature rise. If no excessive temperature is observed and once all items have been verified on tightness, start the compressor again and let it run for available hours. (c) Regular observations should be made during available hours. (d) After the mechanical run-in period, the suction and discharge compression valves should be refitted in their respective places and the compressor started again on no-load e.g.: by means of the application of valve unloaders. (e) Increase to full load gradually and run for specified period, unless observations indicate the presence of a defect. (f) Check the oil pressures and temperatures of all bearings and seals and check proper functioning of lubricator regularly. (g) Check the gas pressures and temperatures regularly. (h) Check for any gas leakage, vibration of machine and piping. (i) Check the automatic loading and unloading device, if installed, for smooth operation. (j) Check for noise levels in excess of specified requirements. (k) A test sheet is to be completed.
3.4.8
Air Cooler/Condenser Fan Test Run A test run to be carried out with preferably all fans of the particular bank section simultaneously in operation. The following checks will be made: (a) (b) (c) (d) (e)
3.5
Check for vibration levels on electric motor and one point of the structure. Record electric motor amperage. Check for abnormal noises. Check whether belt/pulley engagement is over the full width during operation. Check for abnormal structural vibrations or loose bolts during operation.
Tightness Tests This is normally the final stage before inerting the Plant prior to the introduction of hydrocarbons. Although the various items of equipment will be “boxed-up” and the piping system lined up for start-up a final “tightness” or leak test must be carried out. A tightness test is a final check for leaks before the inert/purging step and the introduction of hazardous materials into the plant. It is essential when preplanning this stage that particular attention is paid to pressure breaks in the various sections of the plant, in order to prevent damage to equipment by over pressurizing. A leak of hydrocarbons during start-up poses a safety risk. It can also prove costly. The opening of equipment after the introduction of hydrocarbons will require gas freeing and will also cause delays. The equipment has to be isolated, drained, depressurized and purged with nitrogen to remove the
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contents. Then, after repairs are completed, the system is again tightness tested and purged with nitrogen to remove the air. These delays can be costly. The following procedure is recommended to ensure that the unit is absolutely tight. When correctly done, the chances of equipment having to be opened for leak repairs later will be minimal. Mark-up the system to be tested on the P&ID, highlighting any pressure breaks within the system and the isolation points for the system. Isolate the system being tested at its extremities by block valves or blinds, closing all vents and drains. Line up valves within system ready for test. Where block valves are used for isolation, open a vent, drain, or instrument connection to atmosphere downstream of block valve. This will allow checks to be made as to whether block valves are passing and also prevent pressuring of downstream systems. Tape flanges in the system if required and make a pinhole on the tape at the top, mark clearly the location of the pinhole. During the test, the system must be protected against over pressuring by putting in service safety relief valves, which have been calibrated and set. In the event that the flare system is operational, the relief valves should be installed with the exhaust turned to atmosphere. Identify the instruments which will be used to monitor the pressure. Use of control room instruments to monitor the pressure is encouraged at this time, as it proves the output of instrument systems.
Pressure should be monitored and ambient temperatures taken into account for reasonable pressure losses due to ambient temperature reductions. It is useful to set the relevant DCS instruments on ’trend’ to record pressure variations. Pressurize the system in stages up to the defined pressure by using of plant/instrument air or nitrogen. Ensure soap solution being used is compatible with all metal and gasket materials etc. As each desired pressure step is reached, spray a small amount of soap solution on the point of the joints. Formation of soap bubbles will indicate a leak. When the required pressure is reached, shut off the main air/nitrogen supply and monitor the pressure over a fixed period of time. The standard set depends on the process being tested. 3.6
Instruments And Safety Control The objectives of the instrument section of the Start-Up Team are as follows: (a) (b) (c) (d)
3.7
To confirm that the instruments and safeguarding systems function as designed. To confirm that the instruments installation is according to design standards. To confirm that the instrument documentation reflects the as built status of the Plant. To advise and assist Production on a smooth transition of Plant from Precommissioning to Operational status.
Operational Function Test Operational Function Testing is to be developed in conjunction with and COMPANY’s commissioning team to prove the instrument and safety control systems and the associated operability of equipment.
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Operational Function Testing is to include the following requirements: (a) To prove the operation and calibration of each instrument loop from its process connection to final element. (b) To prove that for all input conditions, the corresponding output actions occur as designed. (c) To ensure the integrity of all safeguarding of equipment. (d) To ensure that all systems are fully commissioned and ready for Start-Up. Operational Function Testing Documentation is to be developed as follows: (a) Standard calibration sheets for all instruments incorporating an in-situ calibration procedure. (b) Supporting documents such as loop diagrams, and/or, marked-up logic diagrams. (c) A cover sheet for documentation approval. In addition to the above, complex procedures shall include the following: (a) A planning sheet showing test equipment and manpower required and involvement from other disciplines. (b) A summary sheet showing a list of all instrument tag numbers involved, supported with drawing numbers. (c) A functional description of the system. (d) A detailed step-by-step test procedure typically in the form of an input test condition versus output action matrix. (e) A diagram showing any independent relationships between test procedures. The Operational Function Testing is to be witnessed by the COMPANY to ensure that all testing is correctly executed and report sheets made and signed by both parties. If necessary, recommendations are to be made to improve or remedy problems discovered during testing. Testing is to be conducted so as to demonstrate to Operations that the systems operate as designed.
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SAFETY: During the commissioning phase, the instrument system and operation teams will work very closely, as part of the plant may be under pressure, people will be working in different areas, etc. It is important to stress that function testing of instruments may only be carried out under a Work Permit System, in order to prevent accidental discharge of air, etc. 3.8
Preparation For Start-Up
3.8.1
Introduction The final activities to make the unit ready for initial start-up are described in this section. These activities include: (a) (b) (c) (d) (e) (f)
3.8.2
Filter media in filters. Loading of chemicals. Installation of orifice plates. Removal of blinds. Nitrogen purge. Dry-out of lines and equipment.(if required)
Packing (Air Dryer) Confirm that the correct height of packing is installed, that the different layers of stacked packing are crossed in order that the joints are not in line, but there is an overlapping. Support grids and retaining grids should also be checked.
3.8.3
Filter Media Filling Before filter medias are loaded in filters, they must have been thoroughly cleaned. They should be free of debris. No excessive rust should be present. General guidelines for loading include: (a) Check that all nozzles and supports in and outside are as specification (vessel drawing). (b) Ensure that clearances between screen layers and screen and vessel walls have been checked and adjusted to prevent filter media falling below the support grid. (c) Inspect the filter media before loading to ensure that drums have not sustained damage in shipping or storage at site. (d) Do not load filter media or dryer desiccant in rainy or humid weather. (e) Only break filter media drum shipping seals as required to steadily supply the loading operation. (f) Provide loading personnel working inside a vessel with suitable protective equipment, such as dust or mesh air masks. Refer to supplier’s safety recommendations. (g) Mark in the same way the specified height of the filter media layer. (h) Use a hopper with flexible height for loading. (i) The sock attachment should be long enough to distribute the material without free fall Otherwise, filter media breakage could occur and too many fines will be produced. (j) Fill up with specified supporting material until the first mark. (k) Check the layer in the middle with a dipstick and ensure level is uniform
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Fill up with filter media until the second mark from the screen.
Loading Of Chemicals Prior to loading of any chemicals, vessels and lines should have been thoroughly cleaned and all equipment and upstream piping work should be free of rust and debris. If any chemicals are prone to oxidation, the applicable vessel should be inert and isolated as soon as possible after loading is complete. Safety precautions and procedures must be strictly adhered to (safety equipment used) during all handling and all loading of chemicals.
3.8.5
Installation Of Orifice Plates Install instrument orifice plates and restriction orifices (R.O's) in accordance with data sheets and P&ID. (a) Instrument orifice plates and R.O's must not be installed before piping runs have been thoroughly cleaned. (b) Consult orifice data sheets to determine bore size, use P&ID to determine the direction of flow and plate O.D. size. (c) Maintain an installation record of orifice plates and restriction orifices, to facilitate control over the installation of the plates and to serve as a reference should problems occur later. (d) Record the following information in the documentation pack for hand-over to COMPANY:
• • • • •
Date of installation. Plate tag number. Bore size. Line number. Signatures of witnesses for correct installation.
(e) All orifice plate to be installed with the inscription stamp on the upstream side of the tab. (f)
Flow orifice plates to have the counter sunk side facing downstream, except conical orifices which have the counter sunk side facing upstream (g) If vent holes in the orifice plate are specified, locate during installation top or bottom of the pipe dependant on liquid or gas service.
3.8.6
Plant Blinds Check Inspect all plant equipment and piping for the removal of test blinds. Make a Blind Control list of all operational blinds and spectacle blinds that should be installed. Indicate their operational position clearly. Check that blinds and spectacle blinds are installed in correct positions ready for plant start-up. The Blind Control list shall be checked and confirmed by the field operators or each shift.
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O2 Freeing Before hydrocarbons are introduced into the unit, the O2 content must be reduced to avoid an explosive mixture being created. Nitrogen can be introduced by hose connections or with fixed injection points, hoses are better connected at low points.
• • • • • •
Pressure up unit being purged with nitrogen to utility service pressure. Then depress as rapidly as possible. Carry out this procedure three more times Ensuring that you purge out all high point vents and low point drains. Commence checking O2 content at several points to ensure the whole unit is virtually O2 free. Continue pressure purging with nitrogen until O2 content of less than 2 % vol. is achieved. The unit should be left under a slight positive pressure of nitrogen until the introduction of hydrocarbons during normal startup.
NOTE: No entry into equipment permitted after introduction of nitrogen. After this step the flare header and stack can be commissioned, if not already in operation. 3.8.8
Dry-out Of Lines And Equipment Dry-out is necessary in Nitrogen Package units to avoid blocking lines and equipment by ice formation. Drying out is finished when the water content measured with portable moisture analysis is at the levels determined by vendor’s specification. Drying out of systems can be speeded up by using dry air during commissioning and the use of nitrogen during the purging phase.
The early Commissioning work focus on a sequence of activities performed on individual systems. Activities such as followings; these activities may be carried out in a simultaneous manner by individual disciplines.
Air blowing Water flushing Leak test Filter Media Loading Piping reinstatement Final instrumentation and electrical hook up Vessel inspection and closure Instrument loop / function tests Preservation
During the stages of Commissioning, systems are combined to enable wider functionality checks to be carried out, such as trial dynamic operation of pumps and compressors, containment / tightness testing, flow route and flow rate testing, control sequence testing, process initiated trip tests, and others. The stages of Commissioning therefore require that several interfacing systems are brought to an equivalent status to allow such testing to be carried out. At an appropriate point in the progress of Commissioning, systems shall therefore be combined and integrated to enable multidiscipline dynamic test activities to commence.
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The tests may simultaneously involve many systems and supporting utility distribution systems. Dynamic testing work is multidiscipline and sequential in nature, and CONTRACTOR will carefully plan and prepare for the activities to ensure all systems, personnel and material are made available when required. After dynamic testing, all systems within a part of the Plant it is brought to an equivalent state of readiness for commissioning operations to commence. CONTRACTOR will include for Manufacturer specialists if required at site for Commissioning work and advice. This will include, but not limited to the following:
Nut-shell Filter Package Media Filter Package Horizontal Induced Gas Floating Vessel(HIGF Vessel) Package Air Compressors Package including operations Chemical Dosing Package Large multistage pumps Critical Metering Systems Safety Systems High Voltage Switchgear Uninterruptible Power Supply (UPS) system Online Analyzers/Sampling system Fire and gas monitoring system Distributed Control System (DCS) and Safety Instrumented System (SIS) Emergency Vent Systems Critical HVAC Vibration monitoring of rotating equipment Flare
Throughout the Commissioning phase, CONTRACTOR provides evidence of the following:
Test, witness, and certification documentation. Systems Package records. All appropriate procedures and method statements. All safety plans/permit to work/safety procedures.
Check sheets, record sheets and certificates or documents to support ready for Commissioning are signed as complete by CONTRACTOR and witnessed by COMPANY. They also are recorded in the System Manual. 3.8.9
Equipment and Process Dynamic Testing Process and equipment dynamic testing have to be carried out during Commissioning in this Project. These activities are to confirm, as much as possible, that equipment will be capable of safe and secure operation when committed to the Start up sequence leading to operational service. Tests will be conducted using relatively safe fluids (e.g. air, water, inert gas) to allow run-in and functionality testing of individual equipment items and parts of the process. This functionality testing involves activities such as followings;
Water circulation at pressure Air circulation Control system serviceability Containment and valve integrity testing
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Blow down and depressurization tests
CONTRACTOR will develop specific method statements for these activities and address issues of area access and control, and the safety at interfaces. A safety risk analysis will be carried out prior to commencing each activity. CONTRACTOR will arrange for Manufacturer specialists as appropriate to direct, conduct or witness this dynamic testing, if required. CONTRACTOR will notify to COMPANY in writing to start the dynamic testing in advance. During this phase the Commissioning Team will confirm that the equipment and systems within the unit and facility are pre-commissioned in accordance with the approved design and specifications and will function to specified operational requirements. The Commissioning will be carried out in a system base methodology. At this stage the final preparations, checks and line out of the equipment and facility (Commissioning of the particular items or systems) will be carried out in preparation for introduction of hydrocarbons and start-up of the facilities. 3.9
Construction Completion (CC) and Ready For Commissioning (RFC) Once the Pre-commissioning has been completed in accordance with the Contract and has passed any tests required on that System, CONTRACTOR will notify the COMPANY in writing to issue the certificate for “Construction Completion” (CC). When CONTRACTOR submits a notice of system Construction Completion, There is a COMPANY check of the following before agreement that the system is Construction Completion and then COMPANY signs an accepted Construction Completion certificate for the system: a) The resolved punch list for the system with all items required for Pre-commissioning is completed. b) Check list of all pre-commissioning items for the system completed c) Non-destructive Testing (NDT) records and QA/QC documentation for all Materials to confirm checked/inspected/tested/calibrated to the requirements of the Project Standard and the Subcontractor’s instructions and Standards for each separate System. d) Confirmation of flow direction for all elements including control valves and flow elements. e) Isolation and/or blinding are correct f) Line by line check of system P&IDs g) Rotational, alignment and other mechanical consideration are completed Ready for Commissioning for a system is upon satisfactory completion of pre-commissioning activities, Construction Completion Certificate, a system pre-commissioning review and a Certification of Construction. COMPANY’s approval of CC status will be governed by the effective administration, resolution of outstanding punch list items, a system Commissioning plan and joint CONTRACTOR / COMPANY safety review. All inspection instructions, witness and documentation for the system will be completed and signed by COMPANY and CONTRACTOR as Construction Completion. Commissioning safety review for a system (or joint CONTRACTOR / COMPANY safety review) will be carried out based on PSSR (Pre Start up Safety Review) procedure. Following Completion of Commissioning safety review, CONTRACTOR will commence the Commissioning of the System.
3.10
After Construction Completion (CC) After the Pre-commissioning Completion of a system/sub-system, the preparation of the facility for
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operation, the Start-up of the facility and the operation of the facility for proof of performance involves several steps or specific sets of activities which are typically referred to as: 3.10.1
System Commissioning Facility Initial Start Up Performance Test Provisional Acceptance
System Base Commissioning Methodology The tests to be carried out during Commissioning activities will be exhaustive, according to the methodology described below. No equipment or part of the installation will be accepted without associated check and tests prior to energization and Start-Up.
3.10.2
System Base Completion Approach The checking and testing phase of a new facility is by necessity a relatively detailed and sophisticated process. Not all parts of the facility reach the same degree of completion at the same time, hence some areas or units may be mechanically completed while others are not. It would therefore be a waste of time to wait for the whole facility to reach End of Pre-commissioning before starting Commissioning activities. The Commissioning activities can start even if all the Pre-commissioning activities are not completed, provided that the system or subsystem concerned is in safe condition for doing the Commissioning activities As examples, the Commissioning activities, such as Mechanical running test for the each rotating equipment can start even if the Pre-commissioning of other piping or instrument portion in the same system or subsystem are not completed, provided that the system or subsystem concerned is in the safe condition for doing the Commissioning activities. Since HVAC systems and Firefighting equipment inside/outside buildings are independent from the process systems, these systems will be Pre-commissioned and Commissioned separately from the process systems.
3.10.3
System / Subsystem definition This specific partition of a facility into systems and subsystems for completions activities takes place as early as possible, at Basic Engineering phase and will always be submitted for approval to the COMPANY. The partition of a facility is a key preparation activity that has a major impact on all aspects of completion operation. The subsystems must be defined so as to be as independent as possible, not too small, but of manageable size, and exactly adapted to the Start-Up sequence. Refer to “11050146-CM-PRO-000-5013 System Definition Procedure” for system list.
3.10.4
Hand-Over Tool. A software application tool, called, UNICCS (Unified Construction to Commissioning System), CONTRACTOR In-house system, will be used as hand-over tool in order to cover the aspects of project completion activities and to obtain a smooth transfer of the facilities from CONTRACTOR to COMPANY, as quickly as possible and with the required safety. The UNICCS functions are follows;
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UNICCS is a database that tracks the completion progress of all tagged item, marked on the P&ID, installed on the project. Within UNICCS are links to the item which is fundamental to the requirements of inspection, test and commissioning at each stage of the project.
4.
Manage QC document Manage Commissioning job check / Test sheet Manage punch list Handle output progress reports and the status Import / Export data by using MS Excel.
SYSTEM COMPLETION PRIORITIES In general, except Early Acceptance Utilities, the facilities will be commissioned and completed to the following priorities to accommodate the staged Commissioning of the plant. Testing and handover will be completed “system–by–system” (service-by service) basis.
4.1
Early Acceptance Utilities Some specific facilities, requested by COMPANY, such as Utility Water, Site office complex, interconnecting piping, interconnecting pipe racks will be available to run in advance until fixed schedule.
4.2
Supporting Facilities (Tankage & Utilities) The Utilities Systems will be commissioned and put onto service first and used for the Commissioning and preparation of the rest of the plant. This generally applies to the water, air, nitrogen etc. services required to prepare the other plants for operation. The Commissioning of the Tankage Systems involves the final line up of the systems for introduction of feedstock for start-up.
4.3
Process Facilities The Commissioning and Start-up of the Process facilities involves a number of process steps, with the primary operations/process procedures being outlined in the Operations Manuals. A system comprises the equipment, piping and all support facilities within defined battery limit, required for carrying out a specific function or service. The objective of defining systems and subsystems is to facilitate sequential End of Precommissioning, Commissioning and Turnover to COMPANY for Initial Start-up and Performance Test. System may comprise a verity of subsystems such as mechanical items, piping, electrical and control systems.
5.
EXECUTION PLAN
5.1
Home Office Planning & Preparation Phase CONTRACTOR will commence the detail planning for the Commissioning of the facility.
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This will include participation in the Process Safety Reviews, HAZOP Study and Constructability Reviews to ensure that operational issues are fully anticipated in the design, construction and precommissioning of the facility. This involvement in the early basic design and engineering stage will assure the facility’s ability to be properly commissioned and assist the Team in the development of the Commissioning Execution Plan. During this initial stage, CONTRACTOR’s Commissioning Manager and his planning team will work with COMPANY’s Commissioning Manager and Operating representative to commence basic planning and development of the key execution tools. These Key Execution Tools include;
The basic Start-up Plan defining the sequential preparation and commissioning plan for the primary processes, units and systems. This sets the overall priorities for Engineering, Procurement and Commissioning.
The outline of the System Packages that will be used to define and record the completion and readiness of the facilities for commencement of operations. These packages (or System Dossiers) commence with the definition of the basic “systems” and “sub-systems” that will be required for detailed planning for End of Pre-commissioning of the facilities.
Commencement of preparation of the Commissioning Procedures to be used for the specific facility; in preparation for receipt of specific vendor and licensor data for the specific equipment items and processes.
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Commencement of preparation of the Operations Manuals that will include all data and procedures necessary for the safe and efficient start-up and operation of the facility.
Detailed planning and preparation for Commissioning activities will start in CONTRACTOR’s Home Office as early as possible at the Engineering stage. 5.1.1
Participation in Project Meeting & Design Input CONTRACTOR's Commissioning Manager or his designee will attend daily / weekly engineering meetings, as well as, regular project review meetings held by the Project Team during the home office engineering phase of the project. The Home Office phase will begin early in the design period of the project when key members of the Commissioning Team will be on hand to input specific requirements for Commissioning and Start-up procedures into the design phase. CONTRACTOR's Commissioning Manager or his designee will participate in the Constructability, Process Safety and HAZOP reviews if required with the other multi-discipline review Teams to ensure that all operability and operations safety issues are addressed. As the information becomes available, they will begin to review the basic process and utility system designs with engineering and the design operating parameters for major equipment items and packages.
5.1.2
Review of Project Drawing and Scope During the engineering phase, the Commissioning Manager or his designee will review project drawings for issues such as; system operability, lessons learned from previous projects to ensure better productivity and system reliability, incorporation of Commissioning flushing connections (If flushing is required), adequate system vents / drains and instrument taps for system Performance Testing. Electrical single lines and P&ID's will be used to "scope" the systems for development of turnover packages. These scoped drawings will specifically define the system turnover boundaries for precommissioning as bulk pre-commissioning finishes and the emphasis turns to system completion. Once the system boundaries are finalized, the scoping boundaries will be included as a development level in each electronically created drawing and maintained as the drawings are revised. A turnover package numbering system will be developed during the scoping effort. The scoped drawings will be assigned specific turnover package numbers for ease of identification. Engineering databases, which are developed, will incorporate these specific turnover package numbers by adding a turnover package number field to the database list. These databases include the project's major equipment list, valve list, motor load list, instrument list, cable and I/O lists. These lists will be sorted by turnover package number for inclusion into the individual turnover packages. The combination of scoped drawings and the scoped databases will give a detailed description of each system.
5.1.3
Development of Commissioning Documents A detailed Commissioning strategy document will be developed for the COMPANY, which includes execution plan for work at the project site with the first objective of optimizing the activities and schedule of the Commissioning phase.
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It will define the safe working practices, project site organization, responsibilities for the facilities and the interfaces within the CONTRACTOR’s team, the phased MC and RFSU completion objectives by system and Unit, the detailed method statements to be generated, and the completion documentation to be prepared by CONTRACTOR. The strategy document will also address the sequence and objectives of the Commissioning phase, including outline manpower plans for operations, supervisory, safety, and maintenance functions and technical support until the plant is released to COMPANY. CONTRACTOR will work closely with COMPANY on these items. Each system turnover from Pre-commissioning to Commissioning will be noted as a turnover milestone activity to begin major testing for the specific system. CONTRACTOR’s Commissioning Manager, in conjunction with COMPANY Operations, will develop, revise and maintain the Commissioning schedule and will coordinate / schedule activities with CONTRACTOR’s Project Scheduling Group to ensure timely Commissioning updates. The Commissioning Schedule will identify, by system, the preferred sequence in which commissioning should prepare and complete the scoped project systems. It will also identify walk-down dates for each system, commissioning release dates by system, and specific Commissioning activities required to test and pre-commission individual systems. The schedule will include, and be used to track system turnover dates and Completion Plan showing, individual commissioning target dates, Commissioning and RFSU targets and activities. CONTRACTOR will develop a commissioning plan and performance test plan in close consultation with COMPANY and ensure the commissioning and RFSU sequence for the Plant is consistent with the Commissioning plan The sequence and duration for commissioning work leading to RFSU of each system shall be prepared in a system Completion Plan showing, individual commissioning target dates, Commissioning and RFSU targets and activities. CONTRACTOR shall ensure the commissioning and RFSU sequence for the Plant is consistent with the Commissioning plan. 5.1.4
Development of System Manuals The Commissioning of the facilities will be carried out on a “system-by- system”. Each operating facility, and the specific units involved, is divided into logical process and/or piping and equipment “systems”. A System Manual will be prepared for each system. COMPANY shall be furnished updated copy. System Manual “CONTENTS” page will show the following minimum sections: a.) System Name b.) Contents Sheet (Index) c.) System and Sub-system identification d.) System summary sheet The documentation in each System Manual record the inspection, checking and testing activities required to achieve RFC and RFSU status. The System Manual will only be complete when all the records of inspections, checks and tests acceptance have been appropriately signed off as approved and summary certifications completed in the System Manual.
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System/Sub-System Division CONTRACTOR will divide the Facility into system as a basic approach to Facility Commissioning activities. Systems will be developed such that the individual systems can provide a practical, safe and secure subdivision of the facilities on which to base completion. The subdivision of the Facility into system provides a workable method to Schedule Commissioning work according to a logical sequence of Commissioning and/or Commissioning activities;
Conduct Commissioning and/or Commissioning activities of some Facility systems while others are still under pre-commissioning;
Complete the part on a system-by-system basis and in a systematic and controlled manner.
The approach takes full advantage of the fact that any given moment in the Facility, some areas (i.e. systems) are already under Commissioning, while others are under construction or still under precommissioning. The overall result of this approach is the earliest start-up date of the Facility as a whole. A defined subdivision of the Facility into system shall also be used by pre-commissioning staff as the basis of its pressure test program (hydraulic, pneumatic). Systems are first defined on the Facility P&I Diagrams; these are marked up using a clear identification method to show each system and boundaries between systems and ensure that any requirements for additional isolation for systems and operational areas will be included in the design.
5.2
Site Commissioning Phase
5.2.1
Site Mobilization Plan Site mobilization of the Commissioning Team will occur to support system turnovers from precommissioning and to ensure that subsequent testing will coincide with project schedule requirements. Additional Commissioning Test Personnel will be scheduled onsite, as needed, until full staffing levels are obtained. The Commissioning Manager will relocate to site after completion of the home office planning and preparations. This plan will be developed at the beginning of site mobilization for Commissioning team considering the actual progress of Commissioning activities and be reviewed with COMPANY’s Commissioning Team.
5.2.2
Equipment Vendor Support Plan Contractor will provide Vendor representatives for installation, Commissioning, and Commissioning services. CONTRACTOR will advise the COMPANY Representative when Vendor representatives are ready to mobilize to the Commissioning Site. For all Vendor representatives providing Commissioning assistance and Training for Company Employee before/after Mechanical Completion, CONTRACTOR will keep a daily time sheet for each Vendor representative.
5.2.3
Punch Control Plan
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Punch items are tasks not yet completed or tasks that do not meet project design and specifications and can be related but not limited to
Equipment that is damaged, defective, inoperable, incomplete or not yet installed. Any part of work, including documentation, which does not conform to project scope, specifications, documentation, recognized engineering practices, relevant codes or statutory requirements. Any situation that can have HSE impact.
This Punch will not include any approved facility modification which has been implemented but not reported on the master document, but incomplete facility modifications will be included on the Punch. Punch list items will be categorized by priority as shown below. A. B. C.
5.3
Must be completed prior to Mechanical Completion Must be completed prior to Start-up and Commissioning Can be completed after Start-up but prior to Turnover
System Turnover CONTRACTOR’s Commissioning Personnel will work with “COMPANY” prior to turnover of system to assist Performance Test in the identification and correction of deficiencies that require resolution prior to turnover. Prior to the system turnover process will consist of system walk-downs by COMPANY’s Commissioning personnel. The walk-down will result in the generation of a "System punch list". The items on this list will be addressed by CONTRACTOR’s Commissioning Team and prior to system turnover and acceptance by COMPANY’s Commissioning Team. CONTRACTOR’s Commissioning Group will identify components or system activities / tests that will be completed by commissioning prior to turnover. As pre-commissioning progresses to the point of 65% ~ 70% of End of Precommissioning, where various systems begin to reach mechanical, as well as, electrical completion, precommissioning begins to switch over from a bulk pre-commissioning mode to a systems completion mode. Turnover packages that define system boundaries using drawings and databases are developed and issued to commissioning well in advance of the first scheduled system turnover dates. The aim of the turnover packages is to provide commissioning with the necessary information to complete systems or portions of systems (subsystems) in the required sequence for successful project Commissioning. Each turnover package will contain mechanical, electrical, and instrumentation components that represent a usable part of a system or the entire system depending on system size. As each of the system / subsystem packages near mechanical and electrical completion, the Commissioning Team will coordinate with pre-commissioning to identify any deficiencies or incomplete items that would prevent the orderly and systematic testing for the turnover package equipment. The format, content, and detail of the Turnover Packages is usually defined through contract
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definitions and requirements or can be discussed and agreed to in meetings during the EPC portion of the project. 5.3.1
Turnover Documentation & Records The following Commissioning documentation and records will be maintained by CONTRACTOR to enable all parties to review the scope of the Commissioning works, the status of that work and the confirmation that each element of the work has been satisfactorily completed.
5.3.2
System Manuals The Commissioning of the facilities will be carried out on a “system-by-system” basis. Each operating facility, and the specific units involved, is divided into logical process and /or piping and equipment “systems”. These systems are generally defined by and incorporate equipment required for, a particular service or portion of the operation.
5.3.3
Documentation for Commissioning The following document related with Commissioning activities will be included in the system packages (dossier) for each system.
5.3.4
Notification of Readiness for Commissioning Commissioning “Punch” Status Report Check Lists & Reports Turnover Certificate Request
Commissioning QA/QC Records The confirmation of completion of commissioning works suitable for Commissioning to commence is represented by QA/QC Inspection Test Reports for the various elements of the facility. The records are collated on a discipline basis for each area of the facility. A QA/QC Status Register will be prepared that reflects the status of commissioning QA/QC documentation relating to specific facility (by Unit) and systems (by Service). CONTRACTOR’s QA/QC representatives will sign this Register as certification that the required items have been completed and registered with COMPANY. The QA/QC Status Register will be kept current and available for COMPANY and CONTRACTOR’s Commissioning Team to confirm that all commissioning QA/QC releases have been made for a particular facility or system prior to Start-up. This Register will also reflect the issue status of all such QA/QC records such that COMPANY can confirm readiness for Start-up.
5.3.5
Operating Manual CONTRACTOR will prepare plant specific draft-operating manual of the unit. The Operating Manual include procedure related with package items if any and will be submitted to COMPANY for review at least 90 days prior to Commissioning. Review of operating manuals shall be done by COMPANY within 30 days after receipt of draft operating manuals. All the changes, additions, deletion required by the COMPANY will be discussed
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with the CONTRACTOR and will be incorporated in the final operating manuals by the CONTRACTOR. The 10(Ten) copies of final operating manual in English, (along with 1 CD of the same) will be submitted to COMPANY. The manuals shall be submitted to COMPANY at least 60 days prior to Commissioning. 5.4
Coordination
5.4.1
Correspondence with COMPANY The Commissioning of the facilities will be carried out on a “system-by-system” basis. As soon as a System has been pre-commissioned and completed for each Commissioning activities in accordance with the Contract and has passed any tests required on that System, CONTRACTOR will issue “Request for inspection” to notify the COMPANY in writing. Company shall witness, finish his inspection and complete the Commissioning activities by sign off on the relevant check sheet/test record sheet.
6.
HEALTH SAFETY & ENVIRONMENT (HSE)
6.1
Home Office Preparation All Commissioning activities are planned and implemented in accordance with the COMPANY and Contractor’s HSE Guide Lines Procedure. Any accident or impairment to the health of personnel is avoidable. Commissioning team shall maintain a safe working environment and ensure that injury and harm to the health of personnel is mitigated.
6.2
Commissioning Site Safety To meet the schedule & target, End of Pre-commissioning, Commissioning activities will have schedule overlaps. Commissioning activities will begin early and will take place parallel with precommissioning activities. The management of hazards shall identify the possibilities of commissioning personnel being exposed to hazards associated with the activities of the other. The potential for exposure to hazardous situations increases with the large number of site personnel overlapping independent multiple work phases. Commissioning works is essentially the bridge activity between pre-commissioning and start-up. It must directly interface with Facility Completion. Therefore, toolbox talks will have to be conducted prior to starting any activity and will be repeated at each shift that will continue with the same activity to ensure that the work force is familiar with the hazards involved:
6.2.1
Work scheduled to be carried out Health, Safety, and Environmental requirements related to those activities Familiar with the Incident Reporting System
Effective Communication Effective communications is essential in conveying vital information to commissioning and operation
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personnel for ensuring their safety and the efficiency of the project. All communication should be clear, accurate, concise, and well planned to avoid ambiguities, confusion and/or misunderstandings. Following methods for conveying the information should be utilized as applicable: 6.2.2
Commissioning meetings Project site notices and placards Banners and warning signs Regular tool box talks Handover log books and shift reports Project daily progress reports
Isolations During Commissioning activities, it is necessary to protect personnel from sources of energy associated with the works by following a safe isolation procedure. Isolation procedures are designed to protect the crew from unexpected energization, start-up, or release of energy, while working on equipment or a unit. Contractor will clear all equipment that will be affected by the equipment isolation. Cleaning of equipment will be performed as outlines in unit/area specific procedure. Any chemicals or chemical residual expected to be remaining in the equipment must be documented for each affected work group.
6.2.3
Safe Use of Nitrogen Nitrogen is used during Commissioning for leak check and inerting purposes. Nitrogen is an inert gas that causes asphyxiation, if it is released in a space where it can lower the oxygen levels below required to sustain life. The nitrogen hazards, consequences on uncontrolled release, protective measures to be taken, shall be clearly specified in the procedures where nitrogen is used and shall be discussed with working team prior to start using nitrogen at site.
6.3
Environment & Harmful Emissions
6.3.1
Piping Dewatering Water used to test pipe work and the pipeline may contain chemical additives to prevent corrosion and microbiological growth, if required, and where applicable a marker for leak detection. These fluids shall be discharged in compliance with the Local Environmental Regulations and the Environmental Management Plan. The medium selection shall take into consideration the environment and compatibility with the final process fluids without compromising other testing criteria and requirements.
6.3.2
Venting and Flaring Start-up procedures shall include provisions to minimize flaring and venting; however, flaring and venting may occur as a result of testing and while bringing the facility up to specifications.
6.3.3
Waste Disposal Waste disposal shall be in accordance with the COMPANY’s Waste Management guidelines and wherever it is possible, the re-use or recycling of any solid or liquid waste shall be considered. The commissioning manager, jointly with the COMPANY, will make a plan for the control of waste
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generated during water flushing. The plan shall include permitting, means for storing and disposing contaminated fluids and material. 6.3.4
Noise Management Although every effort has been made in the design to minimize noise, the design still has to be tested to ensure noise levels are within the acceptable range. The Commissioning Team shall make possible recommendations for improvements, where noise levels do not meet the acceptance criteria. Potential for excessive noise increases during Commissioning activities. Therefore, Commissioning strategy shall be evaluated to minimize noise; e.g., consider the use of water versus air blowing, or reducing the noise level by using silencers or other means. To minimize the exposure against noise, air blowing will be considered to be done during night time or shift change as possible. The personal Noise Dose (a function of noise level and exposure time) shall not exceed 85 dB on a continuous basis over an eight-hour day. Proper ear protection shall be worn in areas where the noise level exceeds 85 dB.
7.
ATTACHMENTS
Attachment 1: Table – Split of Work for Construction, Pre-commissioning and Commissioning Attachment 2: Pre-Commissioning/Commissioning Organization
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Attachment 1: Table–Split of Work for Construction, Pre-Comm. & Commissioning
Section
Description
1.
General
2.
Electrical
3.
Instrumentation
4.
Buildings
5.
Air Conditioning
6.
Communications Equipment
7.
Tie-ins to Existing Facilities
8.
Safety & Fire Protection Equipment
9.
Civil/Structural
10.
Piping and Accessories
11.
Flare System
12.
Vessels
13.
Columns
14.
Tanks
15.
Exchangers
16.
Pumps
17.
Compressors
18.
Gas Turbines
19.
Heaters
20.
Miscellaneous
21.
Chemicals
22.
Package Units
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
Rev.A
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LEGEND: Cy = Company, Ctr = Contractor, X = Perform the work, A = Assist as required, W = Witness and sign off, R = Review and Approve, I = Inspect and Approve.
1.0 GENERAL
Construction Phase Ctr
a) Obtain vendor assistance where necessary for Mechanical Completion, Pre-commissioning and Commissioning.
Cy
X
Precommissioning Phase Ctr
Cy
X
X
A
X
A
c) Make application to the Company for all necessary permits issued in the Company’s name that are required for the Work.
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R
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d) Maintain an adequate vendor instruction file so that information may be readily reviewed through the Work.
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R
X
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W/I
g) Provide a list and the lubricants of Approved Manufacturer recommended for use in the Facility.
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h) Prepare detailed flushing and testing procedures for the specific systems.
X
R
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W/I
f) Remove all rust preventatives, oils, greases and paints used to preserve equipment during transportation and construction whenever these protective materials will be detrimental to operation.
i) Flush systems and perform initial charge of all lubricants. Dispose of all flushing oil in accordance with the Company’s instructions. j) Maintain lubrication after initial charge to achieve Precommissioning. [텍스트 입력]
X
Phase Ctr
Cy
X
b) Obtain any permits and approvals from government and regulatory agencies required in the name of the Contractor.
e) Transmit to the Company all ’As Built’ Records, Operation and Maintenance Manuals, spare parts lists and all other documentation required to obtain Turnover.
Commissioning
X
R
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
1.0 GENERAL (Contd.)
Rev.A
Construction Phase
k) Remove all temporary supports, bracing or other foreign objects that were installed in vessels, ducts, piping, transformers, machinery, or other equipment to prevent damage during shipment, storage, and erection and repair any damage sustained. l) Inspect and check Work during construction stage and perform such non-operational test as are necessary to assure the integrity of the installation in accordance with the Issued for Construction drawings and specifications. m) Complete all necessary insulation, painting, grating, fencing, paving, touch-up concrete and grouting, and items of like nature.
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X
q) Document all inspections, test and other Precommissioning activities. Document all deficiencies discovered during the course of the activities along with corrective actions taken. X
R/I
s) Check all items of equipment for adequate, safe and functional access per Project specifications. t) Provide, install, slip and/or remove all temporary and permanent blinds and spectacle plates required to isolate new systems from existing systems.
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u) Thirty (30) days prior to expected Mechanical Completion, the Contractor is to send a notification of impending Mechanical Completion to the Company.
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v) Completion of fire-proofing and insulation to limit heat loss during Commissioning and for protection of [텍스트 입력] personnel. w) Removal of scaffolding and other temporary works, debris, tools, and extraneous material from areas to be turned over.
Commissioning Phase
W
p) Verify that the Work, or portion thereof, is complete and that all required inspections, tests, reviews and approvals are complete and recorded.
r) Prepare punchlists, by system, of deficiencies between as-built plant and latest P&ID, specifications and vendor instructions. Correct deficiencies.
Precommissionin g Phase X
n) Make initial charge of non-production materials, such as desiccants and transformer oil. o) Make check of lighting intensities in buildings and plant areas in accordance with Project Specifications.
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
1.0 GENERAL (Contd.) x) Ten (10) days prior to expected Mechanical Completion, the Contractor is to send request for the Company punchlist, with copy of master punchlist status. y) Prepare and submit notification of Mechanical Completion when all Work items identified by the Contractor and the Company as required for Commissioning are completed. Each notification shall identify plant system(s) submitted for acceptance, copy of master punchlist for those system(s), list of uncompleted (“exception”) items with the reason for their late completion and estimated completion date, inspection and test and check-out reports, and copies of marked-up `As Built’ P&ID’s and one line diagrams and logic diagrams and list of start-up spare parts on site. z) Verify all instruments and electrical panels and local instruments and valves are accessible for operation and maintenance.
Rev.A
Construction Phase
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aa) Conduct all flushing, blowing and chemical/mechanical cleaning operations where such operations can be accomplished without using permanent installed equipment.
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Precommissioning Phase
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ac) Provide any special media for flushing and/or cleaning purposes.
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ad) Maintain flushing and/or blowing records as required.
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ae) Conduct all operational tightness tests.
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W/I
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ag) Maintain tightness test records, as required.
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ah) Install inerting connections.
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ai) Provide inerting materials and introduce where specified.
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W/I
ab) Conduct all flushing and blowing operations where permanently installed equipment must be used to obtain proper line velocities.
af) Prepare detailed purge procedure for specific system.
aj) Submit application for Turnover Certificate when all activities identified by the Contractor and the Company are completed. Each notification shall identify plant system(s) submitted for acceptance [텍스트 입력] and copy of signed-off report forms for Commissioning activities.
X
R
Commissioning Phase
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R
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
1.0 GENERAL (Contd.)
Construction Phase
Rev.A Precommissioning Phase
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Commissioning Phase
ak) Provide raw materials, such as reservoir crude Feed, brackish water, utilities etc. al) Check the integrity of system shutdown and prove the reliability before Commissioning.
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am) Proceed to Commissioning as per operating manual instructions.
A
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an) Conduct individual equipment noise surveys, as required by the Company’s specifications documents results.
A
X
ao) Prepare and submit Performance Testing procedures.
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ap) Notify when the system(s) are on stream, at design conditions and steady for the Performance Tests.
A
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[텍스트 입력]
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
2.0 ELECTRICAL
Rev.A
Construction Phase Ctr
Cy
2.1 TRANSFORMERS a) Check physically for damage, oil leaks, etc.
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b) Check insulation resistance between primary to earth, secondary to earth and primary to secondary.
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W
c) Perform oil dielectric strength tests. Provide samples to Company for independent check. Perform oil filtration, if required.
X
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d) Perform operation of Buchholz relay.
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e) Check alarm and trip contacts for actuation.
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f) Check off-load changer for proper mechanical operation.
X
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g) Check polarity of terminals and the phase sequence.
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h) Perform High Voltage DC Test in accordance with the Project specification.
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2.2 H.V. SWITCHBOARDS a) Check physically for damage, missing parts, moving parts, clearance, etc.
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b) Measure the insulation resistance of each bus from phase to phase and phase to earth with all circuit breakers in service position, but with the circuit breakers open. c) Draw out each circuit breaker and starter out of the panel and push it back to ensure that the operation is smooth. d) Draw out each circuit breaker and starter to the isolated position, close them manually and measure the insulation resistance from phase to earth. e) Draw out each potential transformer to the isolated position and measure the insulation resistance from phase to earth. [텍스트 입력] f) Check all current transformers by Primary injection testing.
Precommissioning Phase Ctr
Cy
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Commissioning Phase Ctr
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
2.0 ELECTRICAL (Contd.)
Rev.A
Construction Phase Ctr
Cy
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j) Check castell key interlocking between the circuit breaker and other devices as applicable.
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k) Check the phase sequence.
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l) Check the characteristics and operation of each relay by secondary injection testing.
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g) Close and open each circuit breaker and starter in test position, electrically using the control switch/push buttons at the H.V. switchboard. Check tripping of the circuit breaker and starter with its emergency mechanical trip device at the H.V. switchboard. h) Check all interlocking between earthing switches and circuit breakers/starters. Close and open the earthing switches and check for correct operation. i) Check the control circuit of each circuit breaker and starter with all the interlocks and check for correct operation. Check remote start/stop controls for starters.
m) Simulate the operation of each of the protective relays, trip receive and auxiliary relays, and ensure energising of the lock-out relays and tripping of the respective circuit breakers. n) Simulate and ensure correct operation of pilot wire feeder protective relay. o) Check the automatic change over from mains supply to stand-by supply and vice versa and ensure correct operation. Check the manual change over scheme mode. p) Set all protective relays to their correct setting. q) The Contractor shall establish a Tag and Lock-out Procedure, including a Work Permit Procedure for the construction, Precommissioning and Commissioning (The Company Work Permit Procedure shall be followed to energize circuits for powered checks/tests and start-ups). [텍스트 입력] r) Energize all circuits required for the Contractor’s Work responsibilities.
Precommissioning Phase Ctr
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Commissioning Phase Ctr
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R
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
2.0 ELECTRICAL (Contd.)
Rev.A
Construction Phase Ctr
Cy
X
W
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f) Check the control circuit of each circuit breaker with all interlocks and check for correct operation.
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g) Draw out each starter feeder to isolated position and check the insulation resistance from phase to phase and phase to earth on the load side with the starter open, for power and control circuits.
X
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i) Close and open switchfuse feeders and ensure correct operation.
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j) Check the current transformers by Primary Injection Testing. 입력] [텍스트
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k) Check the characteristics and operation of each relay by secondary injection.
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s) Check High Voltage DC Test as per Project Specifications 2.3 440V SWITCHBOARDS a) Check physically for damage, missing parts, moving parts clearance. b) Measure the insulation resistance of each bus from phase to phase and phase to earth with all circuit breakers, starters, and switchfuse feeders in service position but open. c) Draw out each circuit breaker, starter and switchfuse feeder, and push it back to ensure that the operation is smooth. d) Draw out each circuit breaker and switchfuse feeder to the isolated position, close them manually and measure the resistance from phase to phase and phase to earth. e) Close and open each breaker is test position and service position electrically. Check tripping of the circuit breaker with its emergency mechanical trip device.
h) Draw out each starter feeder to the test position, use the test control supply and check the starter for correct operation with all the interlocks from remote start and local/remote stop.
Precommissioning Phase Ctr
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Commissioning Phase Ctr
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
2.0 ELECTRICAL (Contd.)
Construction Phase Ctr
l) Simulate the operation of each of the protective relays and auxiliary relays and ensure energizing of the lockout relays and tripping of the respective circuit breakers.
Rev.A
Cy
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m) Set all the protective relays to their correct setting.
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n) Set all the thermal overload relays to their correct setting.
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o) The Contractor shall establish a Tag and Lock-out Procedure including a Work Permit Procedure for the construction, Precommissioning and Commissioning (Company Work Permit Procedure shall be followed to energize circuits for powered checks/tests and startups). p) Energise all circuits required for the Contractors’ Work responsibilities.
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Precommissioning Phase Ctr
Cy
Ctr
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W
2.4 MOTORS a) Check physically for damage, free rotation of fan and movement of parts. b) Check the insulation resistance value and dry out the machine if the value is: - less than 50 megohms for 3.3KV motors - less than 5 megohms for 440V motors. The method of drying out and retesting shall be in accordance with Approved Manufacturers’ instructions c) Check condition of grease in grease lubricated motor bearings and lubricate the bearings if necessary.
X
W
d) Check and ensure that all electrical connections are tight.
X
W
e) Check the direction of rotation running the motor momentarily. Run the motor uncoupled for four (4) hours and check for any abnormalities. The temperature rise of motor shall be recorded at the end of this period. 2.5 BATTERIES AND CHARGERS a) Check physically for damage. [텍스트 입력] b) Check the control circuit of charger for correct operation. Ensure that current limiting circuits, autochangover circuits from float to boost mode and vice versa are functioning correctly.
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Commissioning Phase Cy
R
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
2.0 ELECTRICAL (Contd.)
c) Top up the electrolyte level in the batteries as required.
Rev.A
Construction Phase Ctr
Cy
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Precommissioning Phase Ctr
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d) Boost charge the batteries.
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e) Energize the charger and keep batteries on float charge.
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f) Perform battery acceptance tests on batteries
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2.6 CABLES a) All high voltage (above 1KV grade) cables shall be
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subjected to high voltage DC test before termination. Insulation resistance value from phase to phase and phase to earth shall be measured before and after H.V.D.C test. b) Before making the H.V. cable joint at each location, the insulation resistance shall be measured from phase to phase and phase to earth. After completion of all joints and before termination, the entire cable shall be subjected to high voltage D.C. test followed by insulation resistance check. c) For all low voltage cables (up to 1KV grade), the insulation resistance value from phase to phase and phase to earth shall be measured before termination. Cable conductor continuity shall be checked for each and every cable. d) For any existing control cable which requires any joint, the insulation resistance shall be measured between conductors to earth before and after completion of the joint. For such cable the voltage at which the insulation resistance check is carried out shall be determined by the Company. e) Phase sequence and matching checks shall be conducted before connection of each and every high voltage cable. f) The insulation resistance checks for 11KV system shall be done with 5KV Megger, and 3.3KV system with 2.5KV Meggars and for LT system with 1000V [텍스트 Meggar.입력]
Page 41of 63
Commissioning Phase Ctr
Cy
WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
2.0 ELECTRICAL (Contd.)
Rev.A
Construction Phase Ctr
Cy
X
W
b) Check the continuity of the earthing system.
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c) Ensure that the earth resistance value of the complete earthing system does not exceed 4 ohms.
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W/R
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Precommissioning Phase Ctr
Cy
2.7 EARTHING a) Measure and record the earth resistance value of each electrode.
2.8 LIGHTING AND SMALL POWER a) Install lamps (incandescent, bulbs, mercury vapour lamps, fluorescent tubes, etc.) required to fill the fixtures, verify all lights and switches operate properly. Test photo cells for proper operation. b) Verify that all lights are operational using normal and emergency power.
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c) Test small power systems for correct operation.
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c) Check and ensure correct operation of the Variable Speed Drive Control Panel.
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d) Check and ensure correct operation of the annunciator.
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2.9 CONTROL PANELS FOR 11KV AND 3.3KV SWITCHBOARDS
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a) Check physically for damage. b) Close and open each circuit breaker and starter from control panel and ensure correct operation.
2.10 UNINTERRUPTIBLE POWER SUPPLY SYSTEM
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[텍스트 c) Check the 입력] bypass transformer and associated AVR circuits.
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d) Check the static switch circuits.
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a) Carry out checks and tests for the battery and charger of UPS as in Clause 2.6 (a) to (f) above. b) Check circuits of inverter for correct operation. Check the output waveforms including harmonic distortion. Verify the current limiting circuit.
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
2.0 ELECTRICAL (Contd.)
Construction Phase Ctr
e) Initiate transfer from one source to another, verify the transfer timings, transient voltage dips. recovery times, etc.
Rev.A
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f) Check all alarms and signalling circuits.
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g) Energize all circuits required for the Contractors’ Work responsibilities.
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2.11 MISCELLANEOUS a) Check out cathodic protection system. b) Paint or tag all electrical apparatus (switchboards, breakers, push button boxes, connecting boxes, etc.) according to the Company’s colour code or regulation.
[텍스트 입력]
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Doc. No. : 11050146-CM-PRO-000-5017
3.0 INSTRUMENTATION
Rev.A
Construction Phase Ctr
Cy
a) Check instruments and tag data supplied against specifications sheet (type, range, material).
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b) Install instruments and make all specified connections.
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c) Perform required pressure tests on instrument takeoff piping and air piping and tubing.
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d) Blow-out instrument air piping with dry air reconnecting after pressure tests, and site instrument air regulators.
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e) Check continuity and identification of transmission and control system for each instrument to ensure proper hook up and compliance with Project specifications. This applies both to pneumatic and electrical, analog and digital-systems. Perform insulation test with instruments isolated or removed for instrument electrical wiring. f) Check pneumatic and electrical instrument systems for proper installation including tagging, supports, accessibility, correct material, ratings and calibrated fittings. Synchronise transmitter and receiver readings for each instrument. g) Remove control valves, flowmeters, venturis, orifice plates, and other in-line instruments prior to pipe cleaning/flushing and hydrotesting. h) Leak-test `tight shutoff’ rates safety and control valves at grade before installation. i) Install instrument after line flushing/cleaning and hydrotesting. j) Perform all instrument calibrations at site before installation.
[텍스트 입력]
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
3.0 INSTRUMENTATION (Contd.)
Rev.A
Construction Phase Ctr
Cy
k) Prepare calibration sheets for each calibration, showing as a minimum the following: - date of calibration - instrument tag number - instrument spec. sheet number - reading before and after calibration, problems noted and corrected - description of calibration, method/equipment - name of person doing calibration, and indication of acceptance when achieved - reference to other instruments calibrated simultaneously. These sheets shall be submitted as part of the loop check data package.
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l) Inspect all flow elements. Micrometer check at grade.
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m) Check all emergency and safety systems for operability, by simulation, including bypass switches/lights and resets. n) Perform site acceptance tests on computerised Distributed Control System (DCS) in accordance with Approved Manufacturers test procedures. The DCS may not be powered up until the UPS is completely checked out and operable. (item 2.11 & a) o) Perform site acceptance tests on computerised Integrated Control System/Distributed Control System (ICS/DCS) in accordance with approved Manufacturers test procedures. The ICS/DCS may not be powered up until the UPS is completely checked out and operable. (Item 2.11 & a) p) Provide sealing fluids (for example, manometers, gauges, etc.) where required.
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q) Test annunciators and individual alarms by simulating alarm conditions where possible.
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r) Stroke control valves, solenoid valves and emergency isolation/shutdown valves, adjust the valve movements, limit switch and air operation/air [텍스트 입력] as required. failure actions
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
3.0 INSTRUMENTATION (Contd.)
s) Operate and adjust as necessary timers, switches, relays, push buttons, interlocks and other instrumentation components. t) Confirm that all elements in each instrument loop have been checked and tested for compliance with the drawings and specifications, after the loop elements are all complete and correct, install sealing compound in seals where required. u) Prepare and submit to the Company loop check packages for the Company approval prior to full loop checking by the Contractor. Data package shall contain (as applicable to each loop) installation check sheets, wire and tubing test sheets, instrumentation check sheets, with copy of the respective loop diagram and P&ID and instrumentation specification sheets. v) Perform full loop checks. Identify and log any problems for the Contractor Resolution.
[텍스트 입력]
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
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Rev.A
Construction Phase Ctr
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4.0 BUILDINGS a) Operate electrical and mechanical equipment such as lighting, fans, and air conditioning systems to the extent required to verify its operability. All Work necessary to properly safeguard the equipment must be complete. b) Install furniture, if any. c) Conduct test on HVAC systems, building pressurisation system, emergency switching system, and safety equipment (refer to sections 3,5 and 6). d) Clean toilets, basins, sewers and water systems.
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e) Operate and adjust doors, windows. Buildings shall be tested for leak tightness and maintenance of internal positive pressure.
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f) Perform roof leak test.
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g) Commission air conditioning, building pressurisation system, gas detection and fire control/halon systems h) Check the slope of roofing in order to ensure runoff of rainwater.
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5.0 AIR CONDITIONING a) Air conditioning air handling units, and individual components thereof, appurtenances, piping and wiring connected to the units and instrumentation controlling the units shall be Pre-commissioned per requirements, of the Company’s specifications and Approved Manufacturers instructions and sections 2 & 3 of this document. b) Provide all Freon or other cooling medium required to charge/recharge the air conditioning units.
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c) Charge or recharge the units as required. 6.0 COMMUNICATIONS EQUIPMENT a) Install checkout, calibrate and test PABX, telephone communication, internal TV system, all cabling and associated equipment included in Work, as per [텍스트 입력] Approved Manufacturer’s instructions.
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7.0 TIE-INS TO EXISTING FACILITIES a) The Contractor to perform all tie-in work including the
Commissioning Phase Ctr
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WARA PRESSURE MAINTENANCE PROJECT COMMISSIONING PROCEDURE Class 1
Doc. No. : 11050146-CM-PRO-000-5017
Rev.A
Construction Phase Ctr
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preparation of hot tap forms. (See Note 1). b) Prior to starting the Work, Contractor to obtain Work Permit approval for tie-in and carry out the Work, as required by specifications and as directed by the Company. c) Isolate, Drain and Depressure Process Equipment/Piping to which Tie-in is being made.
X
d) Provide and Install Temporary Blinds as required.
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e) If necessary, purge existing Equipment with N2 to make existing Equipment/Piping safe for Hot Work.
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f) Remove blinds, reinstate Piping as required.
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NOTE 1: The Contractor shall be provided with minimal shutdown period for the existing facilities during the tie-in work. In order to obtain necessary work permits, it would be the Contractors’ responsibility to give adequate prior notice to the Company to obtain the necessary `shutdown’. 8.0 SAFETY & FIRE PROTECTION EQUIPMENT a) Install relief valves or dummy spools during construction. b) Submit complete PSV (Pressure Safety Valve) and/or VSV (Vacuum Safety Valve) test authorisation package (testform, PSV or VSV specification sheet, P&ID) with PSV or VSV. c) Install all protective shields. d) Arrange for on-Site testing and calibration of all PSVs (Pressure Safety Valves) and VSVs (Vacuum Safety Valves). Provide new tags showing the Company serial numbering system. Paint all valve bodies per the Company specifications.
[텍스트 입력]
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8.0 SAFETY & FIRE PROTECTION EQUIPMENT (Contd.)
Rev.A
Construction Phase Ctr
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f) Inspect and tag all portable fire extinguishers.
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g) Install portable extinguishers, first aid kits and similar fire and safety equipment. Locations shall be approved by Company based on Fire & Safety Equipment Location Plan.
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e) Paint and/or tag all PSVs (Pressure safety valves) and/or VSVs (Vacuum safety valves), car sealed (i.e. locked open or locked close) valves, and safety equipment as approved by the Company. Provide and lock all valves per P&ID positions.
h) Remove, prior to equipment testing, all safety devices such as rupture discs and safety valves. Deliver safety devices to KOC workshop for testing.
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i) Retrieve safety devices delivered to KOC Workshop for testing and replace after equipment testing all safety devices such as rupture discs and safety valves in accordance with P&ID.
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j) Check the operability of sudden lighting shut-off switch, if any.
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k) Commission all new fire protection equipment. Conduct system capacity tests. l) Test safety showers for proper installation, flow rate, and water temperature. m) Testing, Commissioning and start-up operation of the fire pumps, diesel engine drive, flow measurement, pressure check, performance test, etc.
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b) All installations shall be checked for invert elevation using the mirror and light test.
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c) Operate and inspect plumbing systems to confirm proper functioning and leak tightness.
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d) Check that all required areas are fireproofed.
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e) Check the working areas around equipment such as turbines, heat exchangers etc. are free of any obstacles and properly compacted/paved per specification. f) Check the area under suction filters of turbines is paved, cleaned and protected against sand drift. 10.0 PIPING AND ACCESSORIES a) Clean piping and hydrostatically or pneumatically pressure test, as required by codes, specifications and the Company’s instructions.
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d) Remove blanks and install spectacle blinds to required positions after pressure testing.
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e) Check piping 입력] for correct slope and, for process [텍스트 gas lines, that no `pocketed’ sections exist upstream of flare. Correct as required.
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b) Before flushing/cleaning or pressure testing, remove any control valve, orifice plate and the like which might be damaged, and re-install after that Work is completed. c) Coordinate the flushing, cleaning, pressure testing and corrosion prevention requirements with all other Pre-commissioning activities, such as vessel/exchanger internal inspections, oil system cleaning and flushing and run-in, tightness testing and all other Work activities.
f) Provide and install all line vents, drums, strainers - both temporary and permanent,
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9.0 CIVIL / STRUCTURAL a) Sewer and drain lines shall be flushed and gravity tested, for leaks, then the sewers cleaned and all clean-outs, seal pots and service connections shall be checked for proper installation and functioning.
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blinds and non return valves called for on relevant drawings and specifications.
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10.0 PIPING AND ACCESSORIES (Cont.)
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g) Provide and install other temporary blinds and bypasses required for Commissioning and start-up as specified by the Company. h) Check packing and packing materials and lubrication of valves, repack and lubricate as required.
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i) Supply and install line identification tags, signs and flow arrows. To be coordinated with Company.
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j) Provide list and location of all blinds installed.
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l) Check piping to be free of bulges and imperfections.
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m) Check piping is properly resting on support and installed in accordance with drawings to provide thermal movements where applicable.
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k) Check spring hangers, supports, guides, expansion joints, and other pipe specialities for the removal of all shipping and erection stops and for the correctness of cold settings for the design service.
n) Provide all replacement gaskets, spool pieces, hoses, temporary connections, riggings/hoistings, and blind required for cleaning, treating, flushing and inerting activities. Supply supervised labour and necessary tools/equipment for air and/or water flushing, oil flushing, chemical and/or steam treating and flushing, as required. This will include removing control valves, check valves/flappers, flow elements, installation of temporary spool pieces, and replacement of those items when the cleaning/flushing activities are completed. o) Perform flushing operations as foreseen, after Mechanical Completion. p) Perform operational tightness tests of the process systems, using pressurised instrument quality air to bring the process systems to their adequate pressure. q) After operational tightness tests completion, purge process piping and equipment with nitrogen per purging procedures. [텍스트 입력]
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10.0 PIPING AND ACCESSORIES (Cont.)
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r) Adjust spring hangers, supports, etc. in `Hot’ conditions. s) Prepare detailed flushing procedure for the specific system. t) Visually check the overall system to be Commissioned to confirm its integrity. u) Prepare purging procedure for specific system and ensure oxygen limit to be 2% or less.
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10.1 SPECIAL PROCEDURES FOR PIPE LINES a) Verify that all components, piping, pigging facilities
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are installed in accordance with the design drawing/specification and vendor instructions. b) Prepare flushing procedure including purging. c) Perform cleaning and flushing operations, after Mechanical Completion, using storage tanks, transfer pumps and pigging facilities. d) Perform gauging of pipeline before hydrotesting and record the gauging results.
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e) Conduct functional tests on pigging facilities. f) Hydrostatically pressure test pipeline, as required by codes, specifications and the Company’s instructions.
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g) Undertake all elec. & inst. tests as per the relevant sub-section of sections 2 & 3 of this document (refer to sub-section for responsibilities). h) De-water, dry, purge and Commissioning of pipeline as required by codes, specifications and the Company’s instructions.
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d) Verify the flare lines are continuously sloping towards ground flare, burn pit and/or stack at a specified rate of inclination.
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e) Pneumatically test flare lines and service lines.
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11.0 FLARE SYSTEM a) Verify that all components, piping, electrical and instrumentation are installed in accordance with the Project drawings/specification. b) All system lines shall be checked during construction to be free of dirt and debris. c) Verify that pipe guides and anchors on flare line allow for thermal expansion and that saddle supports rest fully on concrete supports/slide plates. Correct as required.
f) Conduct functional test on ignition system utilising propane.
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e) Prepare purge procedure as per code of practice (pressure cycle procedure) and repeat the cycle until safe limits of oxygen (2% or less) are obtained.
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f) Dry out, if required, and install materials such as desiccants, catalysts, resins, chemicals etc.
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12.0 VESSELS a) Check the nameplates data for correctness, per P&ID and specification sheets. Resolve any differences.
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b) Clean out all vessels, open manholes and openings for inspection.
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c) Inspect internals and coatings, signify complete and ready for final closure.
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d) Witness inspections to extent desired.
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g) Issue to the Contractor, in writing, instructions to close- up each vessel.
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h) Properly close-up all vessels, manways, and openings after final inspection (items c and d). [텍스트 입력]
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i) Check ladders and platforms with the Company for required access, per specification.
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a) Check the nameplates data for correctness, per P&ID and Project specification. Resolve any differences.
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b) Clean out all columns, open manholes and manhole trays for inspection.
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c) Inspect internals, trays as per Approved Manufacturer’s drawings, signify complete and ready for final closure.
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j) Calibrate/test and designate the Company numbering system for all safety valves including tank pressure vacuum valves.
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13.0 COLUMNS
d) Witness inspection to the extent desired.
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e) Prepare purge procedure as per code of practice (pressure cycle procedure) and repeat until the safe limits of oxygen (2% or less) are obtained.
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f) Issue to the Contractor, in writing, instructions to close- up each column. g) Properly close-up all vessels, manways, and openings after final inspection (items c and d).
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a) Open manholes for cleaning and inspection.
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b) Inspect internal distributor/collectors and coating, signify complete and ready for final closure.
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c) Perform hydrostatic test of tank and internal piping, if any. Clean tank after testing.
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d) Perform settlement survey prior to, during and after hydrostatic test. [텍스트 입력] e) Inspect tank internals and gauging equipment, painting/coating, P.V. valves and foam pourers, signify as complete and ready for final closure.
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h) Check ladders and platforms with the Company for required access, per specification. i) Calibrate/test and designate the Company numbering system for all safety valves including tank pressure vacuum valves. 14.0 TANKS
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14.0 TANKS (Contd.)
f) Check tank for required access, with the Company, per Project specification.
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g) Calibration measurements, calculations and tables. (Tank Strapping) h) Calibrate/test and designate the Company numbering system for all safety valves all over the Facility including tankage pressure vacuum valves.
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b) Adjust fan assemblies to obtain specified tip clearance and test.
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c) Check operation of louvres, if any, and operating linkage.
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d) Open ten (10) plugs at each bundle of the exchangers that have been tested with water at the shop.
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a) Perform internal inspection or testing in field, if required, of exchangers that have previously been shop inspected. (To be done only if specially called in Specifications or Drawings.) b) Open channel heads on covers of exchangers that have been tested with water at the shop. 15.2 AIR COOLED EXCHANGERS a) Inspect exchangers to ensure that temporary shipping supports and erection materials have been removed.
15.3 PLATE HEAT EXCHANGERS a) Open inlet and outlet connections for inspection. Remove any temporary shipping supports. GENERAL: Calibrate/test and designate Company numbering system for all safety valves all over the Facility including tankage pressure vacuum valves. [텍스트 입력]
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i) N2 purging of tanks.
15.1 SHELL AND TUBE EXCHANGERS
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16.0 PUMPS a) Rotate pumps by hand to ascertain that they turn freely.
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e) Install proper lubricants prior to Commissioning after review by Company.
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f) If the pump is to be used for flushing, install temporary packing if permanent packing or mechanical seal is not suitable for flushing.
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g) Install temporary strainers in suction piping.
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h) Re-install permanent packing if permanent packing or mechanical seal on any pump used for flushing, if required.
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k) When necessary, clean pump strainers and remove temporary suction strainers after pumps have been in operation for a reasonable period.
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l) Check the general compatibility of the pumps with respect to any cavitation problem, discharge head, undue or excessive vibrations, excessive noise etc. which may hint at the abnormal operation of the pump.
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b) Check motor for rotation, run-in four (4) hours uncoupled and check bearings. Submerged oil pump/motor may be run-in coupled after oil flushing activities are completed. Recouple pump to motor. c) Align pump with driver after motor run-in and coupling installation. d) Check for and eliminate any loads imposed on the pumps by piping connections (to be done simultaneously to alignment operation).
i) Make final cold alignment on any pump used for flushing (items f and h). j) Check and run-in pumps, maintain them after Mechanical Completion; make final alignment check, and do any required dowelling of the pumps and drivers.
m) Obtain the assistance of the Approved Manufacturers if required. [텍스트 입력]
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a) Ensure suction and discharge piping has been correctly installed according to Approved Manufacturer requirements or recommendations.
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b) Check that the cold alignment and grouting have been carried out satisfactorily and that documentary evidence of this is to hand.
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17.0 COMPRESSORS
c) Chemically clean any completed lube and seal oil system, when specified. Disposal of wastes and cleaning media in accordance with the Company’s instructions. d) Charge the lube oil, control oil, and oil cooling systems with the flushing oil and circulate for cleaning purposes. Dispose of any flushing oil on accordance with the Company’s instructions. e) Charge the lube oil, control oil, and oil cooling systems with the operating oil recommended by the Approved Manufacturer in accordance with the Company’s specifications. f) Operate the autochange over of the oil coolers and oil filters.
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g) Operate equipment and carry out vibration, trip, governor and safety device checks and any operating tests and adjustments, as required.
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i) Perform all the tests as specified in the relevant data sheets and specifications.
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17.1 SPECIAL TEST FOR RECIPROCATING COMPRESSORS a) Check fit and clearance of bearings, connecting rod, crankshaft and cross-head slides.
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b) Check run-out of piston rod and cross-head slide.
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c) Check valve lift.
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d) Check rod seal assembly.
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e) Check that vent lines from seals and distance housings are free from obstruction and routed to safe location. [텍스트 입력] f) Obtain the assistance of Approved Manufacturer to perform the specified test.
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17.0 COMPRESSORS (Contd.)
17.2 SPECIAL TESTS COMPRESSORS
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a) Check carefully compatibility of operating oil recommended by Approved Manufacturer with process product in order to avoid problems during run-in. b) Obtain the assistance of Approved Manufacturer and perform all the tests as per the relevant specifications and data sheets.
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18.0 GAS TURBINES a) Check physically for any damage, defects on the surface, mountings and leakage etc.
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b) Remove all rust preventatives, oils, paints and blinds used to protect the equipment during shipment and construction period whenever these protective materials will be detrimental to operation.
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c) Check that the cold alignment and grouting have been carried out satisfactorily with the documentary evidence. As the gas turbine is to drive compressor and/or pump, the suction and discharge should have been aligned and freed of stresses.
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d) Inspect the combustion chamber/plenum chamber and the enclosure. e) Check and prepare starting system in accordance with the Approved Manufacturer’s recommendations.
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f) Check and prepare burner system in accordance with the Approved Manufacturer’s recommendation.
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g) Prepare and charge lube oil and control oil systems in accordance with the Approved Manufacturer’s recommendations. (Operating oil shall be in accordance with Company’s Specifications.) Check the control and the oil system. h) Check and conduct all blowing operations on gas lines. i) Operate equipment and carry out vibration, trip, governor and safety checks and any operating tests and adjustments, as required, in accordance with Approved Manufacturer’s instructions. [텍스트 입력]
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18.0 GAS TURBINES (Contd.)
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j) Check and run turbines, maintain them after Mechanical Completion in accordance with Approved Manufacturer’s operating manual instructions. k) Obtain the assistance of Approved Manufacturer and perform all the tests and checks as per data sheets and specifications
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19.0 HEATERS a) Check physically for any damage, leakage etc. b) Remove all temporary support, bracing or other foreign objects that were installed in heaters to prevent damage during shipping, storage and erection, and repair any damage sustained. c) Inspect the heater for completeness and correctness of installation and perform all nonoperating pre-firing check in accordance with the Approved Manufacturer’s instructions.
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d) Blow fuel lines, check them for cleanliness, and connect burner piping. Internally inspect oil bath heaters to ensure all dirt and debris is removed.
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e) Obtain and charge liquid heat transfer media, if required in accordance with the Approved Manufacturer’s instructions.
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f) Precommission and Commission auxiliaries as detailed elsewhere under the appropriate equipment type.
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g) Conduct refractory dry out with necessary adjustments to firing to establish temperature profiles in accordance with refractory Approved Manufacturer’s instructions.
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h) Conduct all operating tests and obtain the certification, if required, in accordance with the Approved Manufacturer’s instructions. i) Obtain the assistance of Manufacturer, if required.
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20.0 MISCELLANEOUS a) Install all miscellaneous mechanical equipment such as cranes, hoists, etc., carry out all the required site tests including based test and [텍스트 입력] provide test certificate from testing and certifying authority (e.g. Lloyds, Bureau Veritas, ABS etc.).
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b) Install, lubricate as required, perform mechanical check and adjust all equipment prior to turning over to the Company.
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c) Provide and install guards, barriers warning signs and other safety devices in accordance with Contract Safety Requirements.
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d) Provide noise reduction devices or noise `walls’ if required to comply with specifications.
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21.0 CHEMICALS a) Store and protect chemicals, desiccants, oils, refrigerants and other fluids/gases to be filled or charged into the Work, in a sheltered area.
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b) All fluids/gases per item (a) to be labelled, and located in a safe and proper area outside the Work area until ready for installation.
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c) Test samples of transformer insulating oils, and any other fluids deemed necessary by Equipment Manufacturer’s to confirm that such meets with the requirements and/or Company standards.
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d) Replace and/or refill fluids with permanent charge where required, this includes, but not limited to, halon (after halon discharge test) nitrogen (for inerting and/or tightness test). e) Allocate proper sheltered areas in the Gathering Centre for storage of chemicals, desiccants and lubricants, etc.
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22.0 PACKAGE UNITS a) Check physically for any damage, defects on the surface, mountings and leakage etc.
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b) Remove all rust preventatives, oils, paints and blinds used to protect the equipment during shipment and construction period whenever these protective materials will be detrimental to operation. c) Inspect package for completeness and correctness of installation and perform all non-operating checks in accordance with Approved Manufacturer’s instructions. d) Obtain and charge liquid, chemical as required. [텍스트 입력] e) Pre-commission and Commission auxiliaries as detailed elsewhere under the appropriate equipment type.
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f) Pre-commission and Commission piping, electrical, instrumentation as detailed elsewhere under the relevant section.
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g) Conduct initial start, making the associated checks and adjustments in accordance with Approved Manufacturer’s instructions.
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h) Conduct all operating test and obtain the certification, if required, in accordance with Approved Manufacturer’s instructions.
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i) Obtain the assistance of Approved Manufacturer, if required.
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Attachment 2: Pre-Commissioning/Commissioning Organization
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