Commissioning Procedure of Northern Gas Compression Facilities

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

Khalda Petroleum Company Project: Northern Gas Compression Facilities, El Alemein Location: El Alamein, Egypt Ennpi Project No; 7917-470

Client’s Project No.: 05-2892

COMMISSIONING PROCEDURED

Doc. No. Revision

0

Date

Feb. 4,2009

File Ref.

Revision History Rev

Date

Owner

Description of Change

Developer

Reviewer

Approver

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

Malcolm Vickers

Page 1 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

INDEX Sr.No.

Topic

Page No.

1.0

Introduction

3

2.0

Health, Safety & Environmental Procedures

4

3.0

Brief Process Description

7

4.0

Commissioning Plan

9

5.0

Commissioning Spares & Consumables

12

6.0

Lubrication Schedule

12

7.0

Preservation & Maintenance

12

8.0

Equipment & Instrumentation Commissioning

12

9.0

Test Run of Rotating Equipments

13

10.0

Preparation for Plant Start up

16

11.0

Commissioning & Start up Sequence

17

12.0

Performance Guarantee Test Run

18

13.0

Initial Operation

18

14.0

Hand Over

18

Malcolm Vickers

Page 2 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

1.0

Introduction

1.0

General

Rev No. A

This document is developed for Commissioning of the systems / equipments installed in the Northern Gas Compression Facilities, after Mechanical Completion (MC), followed up by Start up & stabilization and Performance Guarantee Test Run. 1.1

Definitions Project

Northern Gas Compression Facilities Project No.

Company

Khalda Petroleum Company (KPC), EGYPT.

Contractor

J.P. Kenny / Enppi

Supplier (or Vendor)

Party who supplies equipment, materials and/or services as specified in the scope of supply.

Subcontractor

Petrojet.

Site

El Alemein Desert, Egypt.

Facilities

Northern Compression Facilities.

Pre-Commissioning

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

1.2

1.3

Mechanical Completion

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

Commissioning

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

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

Malcolm Vickers

Page 3 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

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

Organization Contractor Commissioning Team. Contractor Commissioning Team and Company Commissioning Team.

Appendix A Responsible for Phase Pre Commissioning. Commissioning, Start up and Performance Guarantee Test Run.

Works All Equipments, Systems, and Units. Utilities, Infrastructure, Telecom Systems, and Start up & Performance Guarantee Test Run.

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

2.0

Health, Safety & Environmental Procedures

2.1

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

2.2

Safety during Commissioning Safety during commissioning is a continuation of the safety rules during construction and pre-commissioning, which defines the organization and procedures adopted by Contractor, Sub Contractors and Vendors while performing site activities in a manner that provide a risk and security free, safety oriented working environment; thereby, protecting the health of the workforce and keeping the environment pollution free. The required labour force for Commissioning activities will be taken from construction. The Commissioning Operator / Technician Team will be developed jointly by Contractor and Company as shown in the Site Commissioning Organization Chart and Integrated Start-up Organization (Ref Page No. 12 & 13 of this manual). Inducting the personnel and ensuring their HSE compliance for commissioning is the responsibility of the respective Commissioning Managers of Company (KPC) and Contractor (Enppi). Although the HSE Site Manual covers all the site activities, the intent of this Safety Section is to highlight the hazards of the Commissioning activities, control measures put in place to manage these potential risks / hazards and the safety requirements to be followed up. Potential risks that need to be controlled during the commissioning execution are:

Malcolm Vickers

Page 4 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

2.3

Rev No. A



Use of hose and temporary hose connections for compressed air, nitrogen, and pressurized water supplies.



Temperatures above ambient during warm-up operation of the Heating Medium System and Compressors start-up/operations.



Flammable Hydrocarbon Gas used during system pressurization



Energizing of electrical systems.



Concurrent construction work in the neighbouring area during commissioning.



Running of machinery and rotating equipment during testing.

Permit to Work (PTW) System The Permit to Work system is a formal written system used to control the potential hazards in carrying out certain types of works during execution of commissioning. PTW system acts as a medium of communication among the site / installation / commissioning management, supervisors and technicians and the work force that carry out the work. Essential features of the PTW system are:  Clear identification of Issuing Authority, Receiving / Performing Authority and the necessary precautions and control measures to implement and follow up.  Training and induction in the issue and use of permits.  Monitoring and auditing to ensure that the system works as intended. The aim of the PTW System is to ensure that proper planning and consideration is given to the potential risks of a particular job in order to minimise the risk of harm to people, environment and the assets. The Permit is a written document, which authorizes certain people to carry out specific work at a specified time and place, and sets out the precautions required to follow up for completing the job safely.

2.3.1 PTW Management and Responsibilities The PTW system is used to control and manage specific hazards during the course of Commissioning activities. The purpose of such a system is to achieve a safe working environment by implementing necessary management control in carrying out various activities that may have potential for hazards. The PTW system requires the involvement of competent and responsible persons as well as the application of required safety measures in a controlled sequence. The PTW system ensures that responsibility and accountability for safe working practice is passed in a logical sequence to those responsible for the work being carried out and ensures that adequate safeguards are provided. Permit to Work (PTW) will be controlled by Contractor Enppi till Mechanical Completion (MC) stage and there after it will be controlled by Company (KPC) following their existing PTW system during commissioning phase. 2.3.2 Training and Induction All the key personnel within the PTW System will be adequately given training and induction on the roles and responsibilities of:  Issuing Authority 

Receiving Authority / Performing Authority and



The workforce

Malcolm Vickers

Page 5 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

All members of the workforce who are required to work within the PTW system shall receive instructions on the specific procedures applicable in their area of work execution and also briefed on a general overview of the PTW system and the specific responsibilities of every member of the workforce. The Issuing / Receiving / Performing Authorities shall receive additional training based on their level of competency. Vendor specialists who will work on the site to do a specific task under the PTW System, will receive the instructions on the PTW System, and be supervised by the PTW Receiving Authority until the work/activity is completed and the system or unit is handed over. 2.3.3 Communication Since a large number of people are involved in the PTW system with large number of interfaces, communication is one of the most important areas of concern for effective functioning of the PTW system. Special attention shall be paid for managing the possibility of communication problems on the site because more than one language is spoken. Areas of specific emphasis include:

2.4



Person requesting the Permit to Work (Receiving Authority) must state clearly the location, exact nature and scope of the work, the number of workers, different disciplines and special tools involved.



Person issuing the permit (Issuing Authority) must communicate clearly the potential hazards existing in the worksite (location), the precautions taken and control measures in place, and the additional precautions to be taken by the person in charge of the work (Receiving Authority). The Issuing Authority shall also ensure that any person or organization working nearby that may be affected by the work is communicated accordingly.



Person in charge of the work (Receiving Authority) must communicate clearly to the members of the workforce (Performing Authority), the information received on hazards, and precautions & the actions required to be taken in the event of an emergency. He must also inform the Issuing Authority in case any change occurs in the working conditions, which may affect the validity of the permit.

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

2.4.1 Lock Out and Tag Out Implementation of lock-out and tag-out shall be performed only by authorized personnel. All machinery or equipment shall be isolated and rendered inoperative before anyone proceeds with the assigned task, in order to prevent from unexpected start-up or release of stored energy. An approved locking device shall be used to isolate and render the machine or equipment inoperative, also a “Do Not Operate” Tag will be displayed on it. 2.4.2 Isolation and De-Isolations

Malcolm Vickers

Page 6 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

The isolations and de-isolations of the equipment under commissioning shall be done electrically and mechanically by authorised personnel only and shall countersign for the same before and after the jobs are declared complete by the job performing authority after issuing signatures on the work Permits. 2.5

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

3.0

Brief Process Description The Bapetco/Tarek/Salam gas export pipe line has been “hot tapped” across a pipe line block valve. In order to allow the gas compression facilities to extract gas form the export line, re-compress the gas and discharge the gas at a higher pressure back into the export pipe line. For the purpose of description Compression Train “A” shall be describe with Compression Trains B, C&D being equal to train “A”. 

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



Gas to the compressor manifold for A, B C&D is 964.8 mmscfd at a pressure of 66.5 barg. The gas temperature is 32/55 deg C.



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



Compressor “A” Suction is 319.4 mmscfd at a pressure of 66.0 barg. The gas temperature is 32/55 deg C.



Compressor “A” Discharge is 319.4 mmscfd at a pressure of 94.4 barg. The gas temperature is 60/84 deg C.



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



Compressor Export to the export pipe line (accumulative) is 958.1 mmscfd at a pressure of 93.4 barg. The gas temperature 55/55 deg C.



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



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

A typical Main Process Flow Diagram is shown below:

Malcolm Vickers

Page 7 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

Northern Gas Compression Facilities

From Gas Export Line

Gas Inlet Manifold

Gas Filter

Gas comp. Suction Scrubber

Gas Comp. Package “A”

Gas Compressor “A”

Gas Compressor Discharge Cooler

To Gas Export Pipe Line

4.0

Commissioning Plan

4.1

General

Gas Discharge Manifold

The Commissioning Team will impart the knowledge gained from construction and precommissioning into the commissioning phase, to achieve a safe & successful commissioning. Planning and performing the commissioning activities will be managed in a controlled and structured manner in order to provide visibility to the interested parties and also to ensure that all critical milestones are achieved as per the plan. 4.2

Commissioning Scope Commissioning Plan comprises of multi-discipline activities related to testing of functionality and operability of various systems, preparation for process plant start up, Start up (Hydrocarbon Feed Introduction) & Stabilization followed by Performance Guarantee Test Run.

Malcolm Vickers

Page 8 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

4.3

Rev No. A

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

4.3.1 Commissioning Organization / Roles & Responsibilities The Commissioning Organization comprises of:  Commissioning Manager  Commissioning Coordinator  Commissioning Engineers  Turnover Coordinator  Maintenance Engineer (mechanical)  Ad hoc support from Instrument / Electrical discipline engineers as required. Site Commissioning Organization Chart and Integrated Start-Up Organization are shown on page no. 11 & 12 of this Manual.

Malcolm Vickers

Page 9 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

Site Commissioning Organization Chart PRE COMMISSIONING / COMMISSIONING ORGANIZATION AND INTERFACE WITH COMPANY TEAM

Site HSE Manager Enppi

Construction Support Team

Mechanical Engineers (2)

Mechanical Technicians (4)

Work Permit Coordinator

Commissioning Manager Enppi

Commissioning Coordinator

Inst. /Control Engineers (3) Inst. /Control Technicians (6)

Planning / Vendor Coordinator Technical Support

Electrical Engineer (2)

Electrical Technicians (4)

Preservation / Maintenance Engineer

KPC Operation Supervisor Process Commissioning Engineer

KPC Discipline Engineer KPC Shift Supervisor

Preservation Technicians (2)

Plant Operators (DCS 2+ Field 4)

Punch List Coordinator

Reports to QA/QC

Page 10 of 18

Instrumentation Electrical Mechanical

Hand Over Coordinator

Malcolm Vickers

KPC Commissioning / Operation Representative

Document Controller (2)

KPC Plant Operators (8)

DOCUMENT TITLE: COMMISSIONING MANUAL

INTEGRATED START-UP ORGANIZATION

Operation Manager (KPC)

Lead Operations Supervisor (KPC) Start-up & Operation Lead

Shift Supervisors (2) KPC

Commissioning Manager (Enppi) Commissioning Coordinator (Enppi)

Senior Process Engineering Operators (2) Supervisors (2) KPC KPC DCS Operators (2) KPC

Field Operators (6) KPC

Enppi Process Engineer (Technical)

Sr. Electrical Technicians (2) KPC Sr.Mechanical Technicians (2) KPC Sr.Instrument Technicians (2) KPC

Malcolm Vickers

Page 11 of 18

Rev No. A

DOCUMENT TITLE: COMMISSIONING MANUAL

4.4

Rev No. A

Commissioning Schedule A detailed Commissioning Schedule is developed identifying the sequence and duration of the commissioning activities required to complete and make the systems ready for Start up. The schedule is based on,

4.5



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



Commissioning the Process Systems fully after Hydrocarbon Feed Introduction.

Resources The qualified & competent manpower required for Commissioning activities is provided jointly by Contractor and Company as shown in Site Commissioning Organization Chart on page 11 of this manual. The identified team shall carry out the operational activities in the process units complying with the safety requirements during the Commissioning / Start up & Stabilization / Performance Guarantee Test Run phases.

5.0 Commissioning Spares & Consumables Contractor is responsible for making the required commissioning spares available on the site as per the equipment specifications prior to commence the commissioning activities and also for suitable storage of the same in accordance with the manufacturer’s / vendor’s storage instructions. Commissioning spares left unused shall be handed over to Company at the end of Initial Operation. 6.0 Lubrication Schedule Lubrication Schedule showing the various kinds of lubricants used for the equipments and lubricating locations & frequency is in place for follow up during commissioning. 7.0 Preservation & Maintenance Preservation & Maintenance shall be carried out on the equipments supplied to site, installed, tested and commissioned for normal operation. Contractor is responsible for carrying out the pro-active preservation & maintenance by way of taking preventive measures and the routine preservation & maintenance as specified in the respective checklists and vendor requirements. This is also essential in maintaining warranties. Preservation Records will be generated and forwarded to Turn over Coordinator. 8.0

Equipment & Instrumentation Commissioning Commissioning of equipments & instruments shall be done after pre-commissioning checks / Mechanical Completion with Company’s clearance on Ready for Commissioning (RFC). Commissioning of Process equipments / systems shall be taken up after Utilities are commissioned and put into operation.

Malcolm Vickers

Page 12 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

8.1

Rev No. A

Static Equipment Commissioning Static Equipments like Vessel, Tanks, Filters, and Heat Exchangers & Heaters shall be commissioned in the following sequence; a. Mechanical Completion, including installation of internals and external instrumentation & piping as per P&ID/equipment drawing shall be verified. b. Internal visual inspection for cleanliness shall be completed. Person carrying out this cleanliness inspection shall witness the final closure of the equipment also. c. Final inspection / closure (box up) of the equipment shall be done following the completion of loading of packing, elements, etc. Respective Check Lists shall be used for final inspection and closure of the Vessel /Tank. d. Loading of packing, elements shall be carried out with vendor assistance as per the procedure given in the vendor manual. e. Leak Test / Inerting (purging) /Blanketing (where required), shall be done after final closure of the static equipments. Now the static equipment is ready for normal operation.

8.2

Rotating Equipment Commissioning The following observations shall be recorded in the Commissioning Check List of the specific Rotating Equipment. a. b. c. d. e. f.

8.3

Direction of rotation (DOR) Bearing temperature. Vibration and/or unusual noise. Lubrication leaks around the equipment, piping and coolers, if applicable. Excessive temperature at gland packing or seals and process fluid leaks. Hot alignment of couplings, shafts and/or belts.

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

9.0

Test Run of Rotating Equipments

9.1

General Test run of the Rotating Equipment shall be carried out after completion of Commissioning checks on it. Testing of Rotating Equipments covers decoupled run (of drive motor) and coupled run of pump, compressor, blower, fan, etc, for the test run.

Malcolm Vickers

Page 13 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

Ensure the inspection and calibration checks are completed for the associated instrumentation prior to start the Test Run of Rotating Equipments. 9.2 Test Run of Electrical Motors Electrical motors, wherever applicable, will undergo No Load Test run after de-coupling from the driven equipment and a Test Run Sheet shall be filled up with data on following parameters.  Direction of rotation (DOR)  Motor Vibration level  Bearing Temperature  Abnormal Noise & noise level  No Load current - amps (Compare it against specification of the motor) During the subsequent coupled run, record the base line data in the Test run Sheet on Current Load, Vibration Level and Bearing Temperature of the motor, as these data are important for future reference while checking the motor performance. 9.3 Dynamic Run of Process Pumps Dynamic Run of process pumps will be carried out as per the procedures where applicable, with vendor clearance, to assess the operability of the pump against the intended use before plant start up. Install temporary screen (preferably 40 mesh) in the suction strainer or in the selected flange joint between the suction strainer and the pump. Flag the strainers and keep a list to prevent /identify a ‘lost’ screen. (Temporary screen shall be removed after completion of Dynamic Run and the original strainer element installed). Carry out the final alignment checks for the pump after the Dynamic Run (where required), as per vendor guidance. Caution: Temporary screens in the suction line / strainer may require cleaning during dynamic run. Particular attention shall be given to any indications on ‘surging’ when fine mesh screens are installed. Indication will be, wild changes in pump discharge pressure and sudden changes in amperage of the motor. These changes will indicate the blockage of temporary screen in the suction line /strainer. 9.4 Test Run of Air Cooler Fan Test Run of Air Cooler Fan shall be carried out after completing the Commissioning Check Sheet. Test Run shall be conducted preferably for all fans of the particular bank section simultaneously in operation  Rotate Fan by hand to see if shaft, speed reducer, and driver turn freely.  Check and adjust for adequate fan blade tip clearance. The allowable clearance range is 5 – 15 mm.  Kick start the fan and check direction of rotation (DOR) and it should be clockwise when viewed into the discharge stream.  If the starting torque causes to trip vibration switch, adjust its sensitivity.

Malcolm Vickers

Page 14 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

       

Rev No. A

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

9.5 Test Run of Blower / Fan Test run shall be carried out for mutually agreed duration (normally four hours) after completion of Commissioning Check Sheet. Record data on the following observations during Test Run in the Test Run Sheet for future reference to review the blower / fan performance:  Check suction filter for cleanliness (if applicable)  On belt drive fans, check sheave alignment and v-belt tension.  Ensure the bearings are properly aligned and lubricated with special attention to the locking mechanisms, cleanliness, and possible corrosion. Bearings showing signs of corrosion must be replaced prior to operation of the Blower / Fan.  Check the clearance of impeller to inlet cone and impeller to fan housing in order to ensure that there is no interference. Turn the impeller by hand, and ensure it rotates freely.  Impeller should be stationary prior to start up. Start up while fan impeller is rotating backwards can cause damage.  When the fan is provided with damper or variable inlet vane, close the same to minimize the starting load of the drive motor.  Kick start the blower / fan and see the direction of rotation (DOR).  Start and run the blower / fan for mutually agreed duration (normally four hours). Suction damper can be operated to vary the load during the test run. Check and record the readings on following data: - Current load - Bearing Temperature - Vibration level - Abnormal noise / noise levels 9.6 Test Run of Compressor Centrifugal Compressors Test run will be carried out when process gas is available after Hydrocarbon Feed Introduction. Compressor Test Run Plan shall be jointly prepared with vendor assistance and it shall consist of the following elements, as minimum:   

Malcolm Vickers

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

Page 15 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

  

Rev No. A

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

Following parameters shall be monitored during the Test Run:  Vibration levels (during start-up & operating speed)  Noise levels  Speed  Driver operating data (current load)  Start-up logic and any other relevant process data. Following the test run, a hot alignment check of the coupling between the driver and driven equipment is to be carried out as per vendor guidance.

10.0

Preparation for Plant Start up The following activities shall be completed after the equipments / instrumentation commissioning to prepare the plant ready for start up:

10.1

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

10.2 (a) Removal of Spades: Spade register shall be maintained as per the list of spades appearing on approved P&ID. Data on spades installed in different location for hydro testing purpose shall be maintained as a separate document by construction. Finally, it is the responsibility of the construction team to remove these spades and hand over the document to Commissioning team so that the removal of spades can be ensured prior to commissioning / start up. (b) Checking Spectacle Blinds locations & Valves’ LO/LC position: Spectacle blind register is compiled during the pre-commissioning and commissioning preparation phase. This register serves as a basic reference document for physical verification prior to commissioning and it contains the list of Spec blinds with their locations that appear on approved P&IDs. Valves’ LO / LC position (Lock Open / Lock Closed) register is compiled during the precommissioning and commissioning preparation phase. This register serves as a basic reference document for physical verification prior to commissioning and it contains the list of Valves with their LO/LC position and their locations that appear on approved P&IDs.

Malcolm Vickers

Page 16 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

Rev No. A

10.3 Water / Moisture Removal from Piping and Equipment: Though the piping and equipment drying and inerting activity is completed at precommissioning stage, it is imperative to check the water sensitive sections of the plant These checks are necessary to prevent possible plugging of lines and equipment by hydrate formation. 10.4 Relief Valve Calibration: Prior to Hydrocarbon Feed Introduction, it must be ensured that all the relief valves have been calibrated, tagged and certificate issued and installed in position as per the P&IDs. The Calibration Certificate will remain valid as specified by the Vendor standards (generally the validity would be from six months to one year). If a relief valve is installed and the system becomes ‘Live’ within the certificate valid time then the relief valve will remain in situ otherwise it will have to be re-calibrated and re-certified again prior to use. 11.0 Commissioning / Start up Sequence Commissioning of Common Utilities & Offsite systems and Process Systems is in the following sequence: 1. Temporary Power. 2. Sub Station. 3. UPS. 4. HVAC. 5. Open Drain System. 6. EDG. 7. Telecommunication. 8. DCS, F&G, ESD Control Systems. 9. Fire Water System. 10. Potable / Fresh Water System. 11. Safety Systems: a) Foam & Deluge System, b) Safety Shower & Emergency Eye Wash Shower system & c) FM 200 System. 12. Closed Drains System. 13. Utility Air / Instrument Air System. 14. Inert Gas Generation System. 15. GTG units (using Fuel Gas from( Temporary connection). 16. Cold Flare System. 17. Fuel Gas System. 18. Feed Gas (Hydrocarbon) Introduction. 19. Leak Test of process systems at operating pressure. 20. Process Start up & Stabilization. 21. Performance Guarantee Test Run. After Gas-In, all the plant operation under Hydrocarbon will be managed by Company Operations Team, on 24 hours basis, under Company Operating Procedures & PTW system, and will be assisted by the Contractor Commissioning Team. This will ensure that all operating interfaces & metering are under Company Operation & Control.

Malcolm Vickers

Page 17 of 18

DOCUMENT TITLE: COMMISSIONING MANUAL

12.0

Rev No. A

Performance Guarantee Test Run Following the Start up Plant Operation will be stabilized by maintaining process parameters in the design After establishing the stable operation for minimum 24 hours with Plant Throughput Rate set at design or mutually agreed level, Performance Guarantee Test Run will be carried out for consecutive 72 hours, as per the Performance Guarantee Test Procedure The Contractor (Enppi) shall inform the Company (KPC) in advance on starting the Performance Guarantee Test Run of the Plant. Contractor (Enppi) is responsible for generating and maintaining the associated records and log sheets on Process conditions and Plant Performance during the Performance Guarantee Test Run.

13.0

Initial Operation Within 24 hours following successful completion of Performance Guarantee Test Run, Company (KPC) will issue Initial Acceptance Certificate and continue the Initial Operation for Three months period. Contractor (Enppi) shall assign a full time representative in the Control room along with Company's Operation representative, and he will maintain a logbook on plant operation during the Initial Operation period.

14.0 Hand Over The plant will be handed over to Company (KPC) using the Handover Dossiers containing the support documents for the pre commissioning, commissioning and performance guarantee test run and also the mile stone certificates of these phases. The formal handover will be achieved by signing off the Handover Dossier at the end of the Initial Operation.

------ooooo-------

Malcolm Vickers

Page 18 of 18