CSP20 Testing Precommissioning and Commissioning Guideline - Full Compilation

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 1

Document Authorisation Document Title

Testing, Pre-Commissioning & Commissioning Guideline

Document ID

CSP-20

Document Version

Revision 1.0

Version Date:

JUNE 2014

Document Status:

Approved for Execution

Document Revision History

Rev Date:

Version:

Summary of Changes:

Revised by:

JUNE 2014

1.0

Additional sub-subsystems, updates on existing info and format modification.

Department of Commissioning, Construction (DCC), P&E, PCSB

Document Classification

SECRET or RAHSIA CONFIDENTIAL or SULIT INTERNAL USE or UNTUK DALAMAN OPEN or TERBUKA

√

ALL DOCUMENTS MUST BE CLASSIFIED BY THE LEVEL OF SENSITIVITY ACCORDING TO THE DOCUMENT SECURITY CLASSIFICATION SCHEME AS DETAILED IN APPENDIX V OF THE PETRONAS RECORDS MANAGEMENT GUIDELINES FOR ACTIVE RECORDS.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 2

Acknowledgment This is dedicated especially to those who have shared their materials from various Departments and those who have participated and supported the development and review of this document. The individuals have shown commitments and continuous support throughout the whole process from inception to final issuance of this guideline. The constructive and comprehensive contributions to the content of the guideline have been proven invaluable in the process of developing and completing the guideline.

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Name Ir. Akbal B Abu Alfredo P. Vicente M Zhafri B Nasarudin Muhamad Muaz B Azman Nur Shairah Bt Ahmad Ho Joon Heng Dhandi Wijaya A. Murali Krishna Kumar Sanjay Kumar Singh M Hussain B M Salleh Mohammad Firoz Alam Siamak Alaee Shahid M Siddiquee Lim Chui Yean Filomeno Fernandez Valencia Jr Steven Hammond M Nur Iman B Zahari Nazihah Bt Abdullah M Helmi B A Malek Mohd. B Ludin M Fauzi B Awang Khamis B A Kadir Latifah Rohaniah Bt Selamat Siti Nur Khatiejah Bt Salahuddin Pang Wan Sin M Akhmal B Ahmad Daud Rarichan Joseph Viresh Kumar Bodhram Kartina Wati Bt Arbi Leong Chai Yin

Department DCC (Advisor) DCC (Team Leader) DCC (Co-Team Leader) DCC (Co-Team Leader) DCC (Technical Writer) DCC (Technical Writer) DCC DCC DCC DCC DCC DCC DCC DCF DCF DESE DESE DEME DEME DEME DEIC DEIC DEIC DEIC DEIC DEIC DEEE DEPE DSE DSE

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 3

TABLE OF CONTENTS 1.0

PURPOSE .................................................................................................................................................... 8

2.0

ABBREVIATION &DEFINITION ..................................................................................................................... 9

2.1 2.2 3.0

ABBREVIATIONS ................................................................................................................................................ 9 DEFINITIONS..................................................................................................................................................... 9 SCOPE ...................................................................................................................................................... 11

3.1 SYSTEM DEFINITION......................................................................................................................................... 11 3.2 SYSTEM DESCRIPTION AND SCOPE OF WORKS ....................................................................................................... 32 3.3 TESTING AND PRE-COMMISSIONING COMMON SCOPE OF WORK .............................................................................. 33 3.3.1 General ................................................................................................................................................... 33 3.3.2 Piping ..................................................................................................................................................... 34 3.3.3 Mechanical ............................................................................................................................................. 37 3.3.4 Electrical ................................................................................................................................................. 40 3.3.5 Instrumentation& Telecommunication .................................................................................................. 40 3.4 COMMISSIONING ............................................................................................................................................ 43 3.5 COMMISSIONING AND START-UP PROCEDURE ....................................................................................................... 45 3.6 SYSTEM BY SYSTEM SCOPE OF WORK .................................................................................................................. 45 3.6.1 100 – PROCESS ....................................................................................................................................... 46 3.6.1.1 3.6.1.2 3.6.1.3 3.6.1.4 3.6.1.5 3.6.1.6 3.6.1.7 3.6.1.8

3.6.2

200 – PROCESSUTILITIES ...................................................................................................................... 106

3.6.2.1 3.6.2.2 3.6.2.3 3.6.2.4 3.6.2.5 3.6.2.6 3.6.2.7

3.6.3

210 – UTILITY GAS ........................................................................................................................................ 106 220 – INERT GAS .......................................................................................................................................... 110 230 – VENTING ............................................................................................................................................. 113 240 – PRODUCED WATER ............................................................................................................................ 117 250 – DRAIN ................................................................................................................................................. 120 260 – PROCESS HEATING ............................................................................................................................. 127 270 – CHEMICAL (DOSING) INJECTION/TREATMENT ................................................................................... 131

300 – GENERAL UTILITIES ..................................................................................................................... 145

3.6.3.1 3.6.3.2 3.6.3.3 3.6.3.4 3.6.3.5 3.6.3.6 3.6.3.7

3.6.4

110 – FULL WELL STREAM.............................................................................................................................. 46 120 – PROCESS LIQUID (PL) ............................................................................................................................ 54 130 – PROCESS GAS (PG)................................................................................................................................ 66 140 – GAS COMPRESSION .............................................................................................................................. 71 150 – GAS DEWPOINTING .............................................................................................................................. 81 160 – WATER INJECTION ................................................................................................................................ 90 170 – ACID GAS REMOVAL ........................................................................................................................... 100 180 – CONTAMINANT REMOVAL ................................................................................................................. 102

310 – FUEL AND LUBRICATION .................................................................................................................... 145 320 – COMPRESSED AIR ............................................................................................................................... 150 330 – WATER................................................................................................................................................ 155 340 – STEAM ................................................................................................................................................ 163 350 – HEATING, VENTILATION AND AIR-CONDITIONING ............................................................................. 167 360 – HYDRAULICS ....................................................................................................................................... 172 370 – MARINE SYSTEM ................................................................................................................................ 173

400 – SAFETY ........................................................................................................................................ 178

3.6.4.1 3.6.4.2

410 – FIRE FIGHTING .................................................................................................................................... 178 420 – LIFESAVING EQUIPMENT .................................................................................................................... 183

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.5

4.1 4.2 4.3 4.4 5.0

710 – MAIN BACKBONE LINK ....................................................................................................................... 256 720 – RADIO COMMUNICATIONS SYSTEM .................................................................................................. 261 730 – VOICE AND DATA COMMUNICATION................................................................................................. 267 740 – SURVEILLANCE AND SAFETY SYSTEM ................................................................................................. 271 750 – COMMUNICATIONS EQUIPMENT ....................................................................................................... 275

800 – MISCELLANEOUS ........................................................................................................................ 276

3.6.8.1 3.6.8.2 3.6.8.3 3.6.8.4 3.6.8.5 3.6.8.6

4.0

610 – PROCESS CONTROLS........................................................................................................................... 228 620 – SAFEGUARDING SYSTEM .................................................................................................................... 241

700 – TELECOMMUNICATION .............................................................................................................. 256

3.6.7.1 3.6.7.2 3.6.7.3 3.6.7.4 3.6.7.5

3.6.8

510 – POWER GENERATION/SUPPLY ........................................................................................................... 188 520 – DISTRIBUTION .................................................................................................................................... 197 530 – UNINTERRUPTIBLE POWER SUPPLY ................................................................................................... 209 540 – SMALL POWER AND LIGHTING ........................................................................................................... 213 550 – EARTHING & LIGHTNING PROTECTION .............................................................................................. 216 560 – DRIVES AND CONTROLLERS................................................................................................................ 219 570 – CONSUMERS ...................................................................................................................................... 222

600 – CONTROL AND SAFEGUARDING ................................................................................................. 228

3.6.6.1 3.6.6.2

3.6.7

REVISION : 01 PAGE : 4

500 – POWER ....................................................................................................................................... 188

3.6.5.1 3.6.5.2 3.6.5.3 3.6.5.4 3.6.5.5 3.6.5.6 3.6.5.7

3.6.6

PROCEDURE NO: CSP-20

810 – MATERIAL HANDLING ........................................................................................................................ 276 820 – FURNITURE/APPLIANCES.................................................................................................................... 284 830 – AVIATION ........................................................................................................................................... 289 840 – MARINE AND CORROSION PROTECTION ............................................................................................ 291 850 – STRUCTURAL ...................................................................................................................................... 295 860 – CIVIL ................................................................................................................................................... 300

REFERENCES ........................................................................................................................................... 304 CODES AND STANDARDS ................................................................................................................................. 304 CONSTRUCTION DRAWINGS............................................................................................................................. 305 CARIGALI STANDARD PROCEDURE (CSP) ......................................................................................................... 305 PETRONAS TECHNICAL SPECIFICATION ............................................................................................................ 305 PROCEDURES ......................................................................................................................................... 307

5.1 MECHANICAL AND PIPING PRE-COMMISSIONING PROCEDURE ................................................................................ 308 5.1.1 Turbine Driven Generators ................................................................................................................... 308 5.1.2 Diesel Engine and Gas Engine Driven Generators ................................................................................ 310 5.1.3 Diesel Engine Driven Firewater Pumps................................................................................................. 312 5.1.4 Electric Motor Driven Submersible Pumps ........................................................................................... 314 5.1.5 Diesel-Engine-Driven Start Air Compressors ........................................................................................ 315 5.1.6 Electric-Motor-Driven Air Compressors ................................................................................................ 317 5.1.7 Diesel-Engine-Driven Survival Crafts (Life Boat) ................................................................................... 318 5.1.8 Heating, Ventilation and Air Conditioning ........................................................................................... 320 5.1.9 Pedestal Cranes .................................................................................................................................... 323 5.1.10 Vapour Compression Type Water Makers ....................................................................................... 326 5.1.11 Wellhead Diesel Injection Pumps ..................................................................................................... 328 5.1.12 Electric-Motor-Driven Centrifugal Pump ......................................................................................... 329 5.1.13 Gas- And Diesel-Engine-Driven Centrifugal Pumps .......................................................................... 330 5.1.14 Gas-Engine-Driven Reciprocating Gas Compressors ........................................................................ 332 5.1.15 Turbine-Driven Centrifugal Compressors ......................................................................................... 335 5.1.16 Reinstatement Leak Test Procedure ................................................................................................ 336

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 5

5.1.17 Electro-Chlorinators ......................................................................................................................... 339 5.1.18 Nitrogen Gas Generators ................................................................................................................. 341 5.1.19 Standard Alignment Procedure ....................................................................................................... 342 5.1.20 Nitrogen Purging Procedure ............................................................................................................ 346 5.2 ELECTRICAL PRE-COMMISSIONING PROCEDURES.................................................................................................. 348 5.2.1 Insulation Resistance Test Procedure ................................................................................................... 348 5.2.2 Turbine-Driven Main Power Generator ................................................................................................ 348 5.2.3 Diesel-Engine or Gas-Engine-Driven Generators .................................................................................. 353 5.2.4 High Voltage Motor Control Center and Switchgear ........................................................................... 359 5.2.5 Low Voltage Motor Control Center and Switchgear ............................................................................ 361 5.2.6 Transformers ........................................................................................................................................ 363 5.2.7 Batteries and Battery Charger ............................................................................................................. 364 5.2.8 Uninterruptible Power Supply .............................................................................................................. 365 5.2.9 Navigational Aids ................................................................................................................................. 367 5.2.10 Small Power and Lightings............................................................................................................... 368 5.2.11 Earthing and Lighting Protection ..................................................................................................... 369 5.2.12 Heat Tracing .................................................................................................................................... 370 5.2.13 Un-coupled and Coupled Run Test of Electric Motors...................................................................... 373 5.2.14 Heater Control Panels and Heaters ................................................................................................. 376 5.3 INSTRUMENTATION PRE-COMMISSIONING PROCEDURES ....................................................................................... 379 5.3.1 General Construction Verification ........................................................................................................ 379 5.3.2 Loop Test of Pressure Instrument......................................................................................................... 379 5.3.3 Loop Test of Level Instruments............................................................................................................. 384 5.3.4 Loop Test of Temperature Instruments ................................................................................................ 392 5.3.5 Loop Test of Flow Instruments ............................................................................................................. 394 5.3.6 Loop Test Final Control Instruments .................................................................................................... 400 5.3.7 Loop Test Rotating Equipment Monitoring System ............................................................................. 407 5.3.8 Process Monitoring Control System (PMCS)......................................................................................... 412 5.3.9 Safety Instrumented System (SIS) (LAT) ............................................................................................... 416 5.3.10 Fire and Gas System (FGS) ............................................................................................................... 419 5.3.11 Pneumatic Instrument Control Panel ............................................................................................... 428 5.3.12 Wellhead Control Panel(WHCP) ....................................................................................................... 433 5.3.13 Fusible Plug Loop ............................................................................................................................. 440 5.3.14 Test of Pressure Safety Valve (PSV) ................................................................................................. 441 5.3.15 Test of Analyzer ............................................................................................................................... 441 6.0

GENERAL REQUIREMENTS ...................................................................................................................... 442

6.1 ORGANIZATION ............................................................................................................................................. 442 6.1.1 Organization Chart ............................................................................................................................... 442 6.1.2 Individual Roles and Functions ............................................................................................................. 443 6.2 TESTING AND PRE-COMMISSIONING SEQUENCE................................................................................................... 452 6.2.1 Flowchart ............................................................................................................................................. 452 6.2.2 Preparation Activities ........................................................................................................................... 464 6.2.3 Critical Path Network ........................................................................................................................... 466 6.2.4 Bar chart .............................................................................................................................................. 467 6.2.5 Manpower Histogram .......................................................................................................................... 468 6.2.6 Jobcards ............................................................................................................................................... 470

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 6

6.3 SAFETY ........................................................................................................................................................ 471 6.3.1 Pre-cautions ......................................................................................................................................... 471 6.3.1.1 6.3.1.2 6.3.1.3 6.3.1.4

General ........................................................................................................................................................ 471 Rotating Equipment ..................................................................................................................................... 471 Electrical Equipment .................................................................................................................................... 472 Pressurized Equipment ................................................................................................................................ 474

6.4 PUNCHLIST ................................................................................................................................................... 475 6.5 FINAL DOCUMENTATION................................................................................................................................. 478 6.6 COMMISSIONING AND OPERATING SPARES......................................................................................................... 479 6.7 SHIPLOOSE MATERIALS................................................................................................................................... 480 6.8 PRESERVATION ............................................................................................................................................. 481 6.9 TOOLS AND EQUIPMENT ................................................................................................................................. 482 6.9.1 Mechanical ........................................................................................................................................... 482 6.9.2 HVAC .................................................................................................................................................... 484 6.9.3 Piping ................................................................................................................................................... 485 6.9.4 Electrical ............................................................................................................................................... 487 6.9.5 Instrumentation ................................................................................................................................... 489 6.10 CONSUMABLES ............................................................................................................................................. 491 6.10.1 Preservative Lubricants .................................................................................................................... 491 6.10.2 Lubricants ........................................................................................................................................ 492 6.10.3 Miscellaneous .................................................................................................................................. 493 6.10.4 Others .............................................................................................................................................. 494 7.0

RECORDS ................................................................................................................................................ 495

7.1 ITR LISTING ................................................................................................................................................. 496 7.1.1 Architectural ........................................................................................................................................ 496 7.1.2 Civil ....................................................................................................................................................... 497 7.1.3 Electrical ............................................................................................................................................... 498 7.1.4 HVAC .................................................................................................................................................... 500 7.1.5 Instrumentation ................................................................................................................................... 501 7.1.6 Mechanical ........................................................................................................................................... 503 7.1.7 Piping ................................................................................................................................................... 505 7.1.8 Safety ................................................................................................................................................... 506 7.1.9 Structural ............................................................................................................................................. 507 7.1.10 Telecommunication ......................................................................................................................... 508 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10

APPENDIX I: ITR – A (CONSTRUCTION) ................................................................................................... 509 APPENDIX I-I: ARCHITECTURE (A) .................................................................................................................. 509 APPENDIX I-II: CIVIL (C) .............................................................................................................................. 509 APPENDIX I-III: ELECTRICAL (E) ..................................................................................................................... 509 APPENDIX I-IV: HVAC (H)........................................................................................................................... 509 APPENDIX I-V: INSTRUMENTATION (I) ............................................................................................................ 509 APPENDIX I-VI: MECHANICAL (M)................................................................................................................. 509 APPENDIX I-VII: PIPING (P) .......................................................................................................................... 509 APPENDIX I-VIII: SAFETY (S)......................................................................................................................... 509 APPENDIX I-IX: STRUCTURAL (ST) ................................................................................................................. 509 APPENDIX I-X: TELECOMMUNICATION (T) ....................................................................................................... 509

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 9.0

REVISION : 01 PAGE : 7

APPENDIX II: ITR – B (PRE-COMMISSIONING) ......................................................................................... 510

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 10.0

PROCEDURE NO: CSP-20

APPENDIX II-I: ARCHITECTURE (A)- NA .......................................................................................................... 510 APPENDIX II-II: CIVIL (C)- NA ....................................................................................................................... 510 APPENDIX II-III: ELECTRICAL (E) .................................................................................................................... 510 APPENDIX II-IV: HVAC (H).......................................................................................................................... 510 APPENDIX II-V: INSTRUMENTATION (I) ........................................................................................................... 510 APPENDIX II-VI: MECHANICAL (M)................................................................................................................ 510 APPENDIX II-VII: PIPING (P) ......................................................................................................................... 510 APPENDIX II-VIII: SAFETY (S)........................................................................................................................ 510 APPENDIX II-IX: STRUCTURAL (ST)- NA ......................................................................................................... 510 APPENDIX II-X: TELECOMMUNICATION (T) ...................................................................................................... 510 APPENDIX III: ITR- C (COMMISSIONING) ................................................................................................. 511

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10

APPENDIX III-I: ARCHITECTURE (A)- NA ......................................................................................................... 511 APPENDIX III-II: CIVIL (C)- NA ...................................................................................................................... 511 APPENDIX III-III: ELECTRICAL (E) ................................................................................................................... 511 APPENDIX III-IV: HVAC (H)......................................................................................................................... 511 APPENDIX III-V: INSTRUMENTATION (I) .......................................................................................................... 511 APPENDIX III-VI: MECHANICAL (M)............................................................................................................... 511 APPENDIX III-VII: PIPING (P) ........................................................................................................................ 511 APPENDIX III-VIII: SAFETY (S)....................................................................................................................... 511 APPENDIX III-IX: STRUCTURAL (ST)- NA ........................................................................................................ 511 APPENDIX III-X: TELECOMMUNICATION (T)................................................................................................. 511

11.0

APPENDIX IV: ITR OVERVIEW ................................................................................................................. 512

12.0

APPENDIX V: OVERALL SYSTEM DESCRIPTION ........................................................................................ 513

13.0

APPENDIX VI: ENDURANCE & PERFORMANCE TESTING CRITICAL PARAMETERS .................................... 514

14.0 APPENDIX VII: SAMPLE TABLE OF CONTENT (TOC) FOR OVERALL DETAILED TESTING, PRECOMMISSIONING AND COMMISSIONING PROCEDURE. ..................................................................................... 521 END OF DOCUMENT ........................................................................................................................................... 522

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 1.0

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 8

PURPOSE

The Testing, Pre-commissioning and Commissioning Guideline is prepared for use as a minimum requirement in performing testing, pre-commissioning and commissioning activities at the fabrication yard and offshore/onshore installation. It is CARIGALI's intention to ensure all systems are fully tested, pre-commissioned and commissioned in the fabrication yard to the maximum extent possible followed by final commissioning at site. The guideline is also intended to better define the workscope between fabrications, hookup and commissioning stages thus improving area of responsibilities for the personnel. The intent of onshore/offshore testing, pre-commissioning and commissioning are to: i)

verify all equipment are installed in accordance to Approved For Construction As-Built drawings and manuals,

ii) prove equipment is able to function according to its design specifications and intentions, iii) minimize problems during Start-up iv) identify equipment shortfalls and deficiencies so that corrective actions could be carried before Start-up, v) compile test data and results with all other documents into a complete equipment final documentation, vi) pre-determine outstanding activities (punchlist)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 2.0

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 9

ABBREVIATION &DEFINITION

2.1

2.2

Abbreviations Term CSP ESD HUC ITR DMC RFC NDT PSV SDV BDV DBB PT AGRU MRU GTG GTC CEM FAT SAT EDG HVAC PCHE ICE EM

Definition Carigali Standard Procedure Emergency Shut Down Hook-up and Commissioning Inspection Test Records Discipline Mechanical Completion Ready for Commissioning Non-Destructive Testing Process Safety Valve Shut Down Valve Blow Down Valve Double Block and Bleed Valve Performance Test Acid Gas Removal Unit Mercury Removal Unit Gas Turbine Generator Gas Turbine Compressor Cause & Effects Matrix Factory Acceptance Test Site Acceptance Test Emergency Diesel Generator Heating, Ventilation & Air Conditioning Printed Circuit Heat Exchanger Internal Combustion Engine Electric Motor

Definitions 2.2.1

Testing An act of examination, trial or proof to prove and validate the correct and complete execution of the WORKS.

2.2.2

Pre-commissioning An act of ensuring that the functions and operations of system/ sub-systems are in accordance to the designed purpose and intended services and meet all applicable specifications, regulations, codes and standards. On successful completion of the activity the system/sub-systems shall be ready for commissioning activities.

2.2.3

Commissioning Act of putting certain items into active service for the first time as intended by

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 10

design and specifications. It includes dynamic functional testing and documentation of an assembly, system or sub-system independently or together with associated systems and facilities to ensure that it fulfils its designed purpose and services. 2.2.4

Verify To determine or test the accuracy of, as by comparison, investigation or reference.

2.2.5

Perform To begin and carry through to completion.

2.2.6

Check Supervise control, as of accuracy or efficiency.

2.2.7

Performance Test-Run (PTR) An act to prove and demonstrate overall plant reliability and operability, in accordance with agreed Performance Test Procedure which shall be depend on available throughput but not lower than plant turndown ratio.

2.2.8

No-Load Test A trial or proof as to the way in which individual machinery functions without load.

2.2.9

Load Test A trial or proof as to the way in which individual machinery functions with design load.

2.2.10 Endurance Test A trial of proof as to the ability to carry on through, usually for a specific period of time. 2.2.11 Mechanical Completion The checking and testing of equipment and construction to confirm that the installation is in accordance with drawings & specifications and ready for commissioning in a safe manner and in accordance with project requirements.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.0

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 11

SCOPE

3.1

System Definition

3.1.1

All facilities and equipment are categorized into a specific system. A system is defined as a configuration of pipeworks and/or equipment that fall within the same process medium. OR SYSTEM is the first level of breakdown, being either process or utility that performs an overall operational function of a facility or plant.

3.1.2

A system is identifiable from the Piping and Instrumentation Diagram (P&ID) drawings.

3.1.3

Systems are broken down into two more categories; Subsystem and SubSubsystems. Each subsequent category identifies the relevant system in more detail.  Sub-system is a major subdivision of the system that performs a Major operational function of the facility or plant.  Sub-subsystem is a part of the sub-systemthat performs a given partial operational function,with minimum interference from the other subsubsystems and can be completed and commissioned as a separate entity.

3.1.4

CONTRACTOR shall identify and select only the relevant systems applicable to the Works. CONTRACTOR shall be responsible to identify and develop new systems should additional systems be applicable.

3.1.5

A chart showing the list of most identifiable systems at the different levels are shown in the subsequent pages.

3.1.6

Sub-system can be further breakdown into level 4 category for ease of handover to Operations. For example, the flowline for a cluster of Wellhead to be systemized at level 4 category to enable the Operations to start with the minimum throughput. Thus, every project is unique- a mix and match to tailor the process is required for handover to take place.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.1.7

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 12

Sub-Subsystem limitation Rules: 1) Process/Utility; A) General rule: i)

Boundary limits of process / utility pipework should be an isolation valve, or spade, allocated to the Sub-subsystem that has the highest priority, and will be commissioned first.

ii)

Where the blind is necessary, the limit will be most suitable flange

Described Sub-subsystem Other Sub-subsystem Figure 3.1-1:

Example System Boundaries of a Sub-subsystem for Process/Utilities

B) Flare/Vent Sub-subsystems limit will be Downstream of: i) Safety valves ii) Pressure control valves iii) Blow down valves iv) Choke valves v) Isolation valves.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 13

Flare/Vent Sub-subsystem Other Sub-subsystem Figure 3.1-2:

Example System Boundaries of a Sub-subsystem for Flare/Vent

C) Closed drain Sub-subsystem limit will be down stream of: 1- Safety Drain valves 2- Level control valves 3- Blow down valves and will be down stream of first valve of double isolation valves.

Close

Closed Drain Sub-subsystem Other Sub-subsystem Figure 3.1-3:

Example System Boundaries of a Sub-subsystem for Closed Drain

D) Fuel gas Sub-subsystemslimit will be Up stream of the last manual supply isolation valve. E) Nitrogen Sub-subsystem Limit will be Up stream of the last double manual supply isolation valves.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 14

CARIGALI STANDARD PROCEDURE

Nitrogen/Fuel Sub-subsystem Other Sub-subsystem

Figure 3.1-4:

Example System Boundaries of a Sub-subsystem for Nitrogen/Fuel

F) Chemical injection Sub-subsystems Limit will be Upstream of the supply isolation valve for eachInjection point into the process line. G) Fuel and Lubricant Sub-subsystemsLimit will be Upstream of the first supply isolation valveto each user. H) ExchangersBoundaryLimit will be down stream of the Utility supply isolation valve.

TC

To and From Utility Systems Such as: Steam, Hot Oil, Cooling Water…

Utility Sub-subsystem Exchanger Boundary Figure 3.1-5:

I)

Example System Boundaries of a Sub-subsystem

Instrument Air / Utility Air / Black start Air Limit is Upstream of the final piping isolating valves and before the items of Equipment being supplied.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE CV

BD V

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 15

ESD

INSTRUMENT AIR

HVAC FIRE DAMPER 1-

AIR OPERATED PUMPS

Instrument Sub-subsystem Exchanger Boundary Figure 3.1-6:

Example System Boundaries of a Sub-subsystem for Instrument Air

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 16

2) Instrument Sub-subsystems A) The measuring devices (instrument device and Local Panel) are a part of process or utility Sub- subsystem. B) DCS is a standalone Sub-subsystem from the input/output racks (Cabling, JB, DCS Panel and Marshaling Panel). Outgoing wiring to individual loops will be allocated to process Sub-subsystem as either open or closed loops.

SIS/FGS EFFECT FEEDBACK TO DCS

INST. DEVICES

LOCAL

FIELD

DCS

DCS

MARSHALLING

PANEL

IJB

FIELD

CABINET

SIS

PANEL

SIS

MARSHALLING

SJB

CABINET

Process/Utility Sub-subsystem DCS Sub-subsystem SIS Sub-subsystem FGS Sub-subsystem

Figure 3.1-7:

Example System Boundaries of a Sub-subsystem

PANEL

SIS /F GS CA US E FE ED BA CK TO DC S

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

DCS SUB-SUBSYSTEM

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 17

PROCESS/UTILITY SUB-SUBSYSTEM

DCS

ESD

JB

LOCAL PANEL

OUTPUT MARSHAL ING

BDV ESD

CABINET

JB

LOCAL PANEL

BDV

DCS PANEL FT

JB

DCS

LOCAL PANEL

LT

PT

INPUT MARSHAL ING CABINET JB

Figure 3.1-8:

LOCAL PANEL

LT

Interface of DCS and PROCESS/UTILITY Sub-subsystems

C) SIS Programmable Logic Controller (PLC) based system will stand alone as a Subsubsystem, from the Input/Output racks as for Distributed Control Systems. Input/Output loops will be classified as open loops and allocated to Subsubsystems as the outgoing/incoming wiring of distribution control systems. D) FGS Programmable Logic Controller (PLC) based system will stand alone as a Sub-subsystem, from the Input/Output racks. Loops will be classified as open loops and that allocated to FGS Sub-subsystems with the exception that these Sub-subsystems will be based on designated FGS Zones.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE

Note: Zone A: Process Unit Zone B: Utility Unit

Figure 3.1-9:

Interfaces of FGS Sub-subsystems

REVISION : 01 PAGE : 18

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 19

Figure 3.1-10: Interfaces of SIS Sub-subsystems and also between SIS and FGS

3) Electrical Sub-subsystems

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 20

A) An Electrical Sub-subsystem will contain all items relative to the distribution network (LV or HV) but excluding all starters, contactors, switch-fuse, etc., where the electrically powered device is allocated to a Process or Utility Sub-subsystem. B) Switchboards and Distribution Boards are dedicated to one service and this form the basis of an Electrical Sub-subsystem. C)

Depending on the complexity of the distribution network then these base Subsubsystems will be further sub-divided to suit the Project requirements.

D) Some important sub-subsystem need to use uninterrupted power and also to be alive during total power shutdown like as DCS, FGS, Process/Utility Local Panel, EG Control Panel, Telecom that the power will be supplied by AC/DC UPS System.

Note: For the UPS Sub-subsystemscertain large machines have Uninterrupted Power Supplies which are dedicated to that machine only (for example Compressor).In this instance the Uninterrupted Power Supply (UPS) system and distribution will be allocated to that Vendor package equipment sub-subsystem

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.1-11: Electrical Sub-subsystems

4) Mechanical Equipment

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 21

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 22

A) Items of Mechanical Equipment will fall completely within the limits of a Process or Utility Sub-subsystems. In certain instances, Stand-by and/or Parallel equipment, which are often complete VENDOR Packages, may also be designated as complete Sub-subsystems. This will match the initial Start-up philosophy, in order to achieve, for example, early Oil & Gas production. Typical examples: 1) Main Oil Pump 2) Gas Compressor 3) Main Generator 4) Pedestal Crane…

Figure 3.1-12: Interfaces of Sub-subsystems

B)

HVAC systems are normally dedicated to a specific building or area. Some designs will consist of individually controlled systems, each with their own air handling unit and control panel. In this case, each system will probably be allocated its own Sub-subsystem number. It is also possible for a number of areas to be controlled from a central control panel. In this case, the need to divide the system into Subsubsystems will probably be dictated by start-up constraints.

Note: In the case of individual systems, all ductwork, dampers, grills, sensors, heaters etc. will be included in the same Sub-subsystem as the air handling unit and control panel. Common or shared utilities, such as cooling water and boilers should be placed in separate Sub-subsystems. If these utilities are dedicated to

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 23

HVAC systems, and are required to be commissioned at the same time, they could be included in the same Sub-subsystem.

Figure 3.1-13: HVAC Systems

5) Telecommunication A) Telecommunication systems tend to be custom designed for each project, and the technologies for these systems is constantly changing. As a general rule, the systems listed will each have their own Sub-subsystem. Sub-subsystem boundaries will include all field equipment up to the outgoing terminals of the control console or distribution rack. The rack control consoles or distribution racks should be included in the Sub-subsystem of the equipment that will be commissioned first.

SYSTEM

SUBSYSTEM

100

110

SUB-SUBSYSTEM 111

WELLHEADS (DRY X-MAS TREES)

P&ID Number 01,02,03

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE FULL WELL STREAM 120 PROCESS LIQUID (PL)

130 PROCESS GAS (PG)

140

GAS COMPRESSION

112 113

WELLHEADS (WET TREES) WELL TESTING

121 122 123 124 125 126

PL COLLECTION AND RECEIVING PL SEPARATION (OIL FACILITIES) CRUDE OIL STABILISATION CONDENSATE STABILISATION PL TRANSFER / STORAGE SYSTEM PL METERING AND EXPORT / OFFLOADING

34 13 13, 33

131 132

PG COLLECTION AND RECEIVING PG SEPARATION (GAS FACILITIES)

04 20

133

PG METERING

26

SUCTION MANIFOLD OFF GAS COMPRESSOR COMPRESSOR TRAIN (BOOSTER/ EXPORT/GAS 143 LIFT/GAS INJECTION) 144 DISCHARGE MANIFOLD 145 EXPORT / DOWNHOLE INJECTION 151 152

GAS DEW POINTING

153 154

160

WATER INJECTION

161 162 163 164 165

170 ACID GAS REMOVAL

180 CONTAMINANT REMOVAL

04 10

141 142

PROCESS 150

REVISION : 01 PAGE : 24

24,25

07

GAS DEHYDRATION TRAIN (WATER DEW POINT) ADSORPTION (WATER DEW POINT) TURBO EXPANDER (HYDROCARBON DEW POINT) DIRECT COOLING (HYDROCARBON DEW POINT)

21, 22,23

SEAWATER INTAKE FILTRATION DEAERATION TREATED WATER PUMPING TREATED WATER EXPORT / DOWNHOLE INJECTION

96

171

ACID GAS REMOVAL UNIT

181

MERCURY REMOVAL UNIT(ADSORPTION)

182

MERCAPTAN REMOVAL UNIT(ADSORPTION)

21, 22,23 21, 22,23 21, 22,23

09 09

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 200

210 UTILITY GAS

211 212

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 25

FUEL GAS SYSTEM INSTRUMENT GAS

60 58

220

221

INERT GAS

222

NITROGEN (NITROGEN GENERATION & NITROGEN BOTTLES) SPENT/FLUE GAS

230

231 232 233

ATMOSPHERIC VENT HP FLARE LP FLARE

95 63 62

240 PRODUCED WATER

241 242

PRODUCED WATER SYSTEM DISCHARGED WATER TREATMENT

40,41,42 40,41,42

250

251 252 253 254

OPEN DRAIN (NON-HAZARDOUS) HAZARDOUS DRAIN CLOSED DRAIN SEWAGE

65 65 64 57

261

WASTE HEAT RECOVERY

PROCESS HEATING

262 263

HOT OIL WARM OIL

270

271 272 273 274 275 276 277 278 279-1 279-2 279-3 279-4 279-5

SODIUM HYPOCHLORITE POLYELECTROLYTE COROSSION INHIBITOR DIESEL GLYCOL ANTIFOAM SCALE INHIBITOR DEMULSIFIER REVERSE DEMULSIFIER PH MODIFIER BIOCIDE METHANOL POUR POINT DEPRESSANT (PPD)

88 68 68 68 68 68 68 68 68 68 68 68 68

310 FUEL AND LUBRICATION

311 312 313

DIESEL FUEL JET FUEL LUBRICATION OIL

67 66

320 COMPRESSED AIR

321 322

INSTRUMENT AIR UTILITY AIR

54 55

VENTING

DRAIN

59

PROCESS UTILITIES 260

CHEMICAL (DOSING) INJECTION/TREAT MENT

300

GENERAL UTILITIES

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE

330

WATER

340 STEAM 350 HEATING, VENTILATION AND AIRCONDITIONING (HVAC) 360 HYDRAULICS 370 MARINE SYSTEM

400

410 FIREFIGHTING

REVISION : 01 PAGE : 26

323

BLACK START/STARTING AIR

331 332 333 334 335 336

SERVICE WATER FRESH AND DISTILL WATER FEED WATER POTABLE WATER HOT WATER COOLING WATER

341 342 343

STEAM GENERATION STEAM DISTRIBUTION STEAM CONDENSATE

351 352

DIRECT EXPANSION UNIT CHILLED WATER UNIT

50 50

353

AIR HANDLING/ VENTILATION UNIT

50

361

HYDRAULICS POWER UNIT (HPU)

371 372 373 374

BALLAST BILGE AND SLUDGE WATERTIGHT DOOR TURRET & MOORING

411 412

FIREWATER DELUGE AND SPRINKLER TOTAL FLOODING FIRE SUPRESSION & FIRE EXTINGUISHER

53 86 86/84

413

51

52 69

77

SAFETY

500

420 LIFESAVING EQUIPMENT

421 422 423

LIFERAFTS SURVIVAL CRAFTS ESCAPE AND RESCUE EQUIPMENT

82 82 82

510

511 512

MAIN POWER GENERATION EMERGENCY POWER GENERATION ELECTRICAL NETWORK MONITORING SYSTEM / POWER MANAGEMENT SYSTEM (ENMC / PMS)

75 75

TRANSFORMERS HIGH VOLTAGE SWITCHGEAR AND MOTOR CONTROL CENTER

76 76

POWER GENERATION/ SUPPLY

513

POWER 520

521

DISTRIBUTION

522

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE

525 526

LOW VOLTAGE SWITCHGEAR AND MOTOR CONTROL CENTER INTEGRATED MOTOR CONTROL SYSTEM (IMCS) OVERHEAD LINE / CABLE CAPACITOR / REACTOR

530 UNINTERRUPTIBLE POWER SUPPLY

531 532 533

AC UPS SYSTEM DC UPS SYSTEM ELECTRICAL POWER UNIT (EPU)

540

541

EMERGENCY DISTRIBUTION BOARD

SMALL POWER AND LIGHTING

542

NORMAL DISTRIBUTION BOARD

543

NAVIGATION AID

550 EARTHING & LIGHTNING PROTECTION

551

EARTHING

552

LIGHTNING PROTECTION

560 DRIVES AND CONTROLLERS

561

VARIABLE SPEED DRIVE (VSD)

562

HEATER CONTROL SYSTEM

570

571 572 573

575 576

ELECTRIC HEATERS HEAT TRACING SYSTEM AUX DISTRIBUTION IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) SYSTEM LIGHTING SOCKETS

611

DISTRIBUTED CONTROL SYSTEM (DCS)

523 524

CONSUMERS CONTROLLER

600

CONTROL AND SAFEGUARDING

REVISION : 01 PAGE : 27

610 PROCESS CONTROLS

620

574

613 614

SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) INFORMATION MANAGEMENT SYSTEM (IMS) SUBSEA CONTROL

621

SAFETY INSTRUMENTED SYSTEM (SIS)

612

76 76 76 76

89

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE

SAFEGUARDING SYSTEM

622

FIRE AND GAS SYSTEM (FGS)

623

FUSIBLE PLUG LOOPS HIGH INTEGRITY PRESSURE PROTECTION SYSTEM (HIPPS) WELLHEAD CONTROL PANEL (WHCP) INSTRUMENT CONTROL PANEL

624 625 626

700

710

711

713 714 715

DIGITAL MICROWAVE RADIO (DMR) SYSTEM VERY SMALL APERTURE TERMINAL (VSAT) SATELITE SYSTEM FIBRE OPTIC TRANSMISSION SYSTEM UHF RADIO LINK TROPOSCATTER RADIO SYSTEM

721 722 723 724 725 726

VHF/FM (MARINE COMMUNICATION) VHF/AM (AVIONICS COMMUNICATION) HF/SSB RADIO SYSTEM NON-DIRECTIONAL BEACON (NDB) SYSTEM DIGITAL TRUNK RADIO WIRELESS SYSTEM

712 MAIN BACKBONE LINK

720 RADIO COMMUNICATIONS SYSTEM

730 TELECOMMUNICA TION

800 MISCELLANEOUS

VOICE AND DATA COMMUNICATION

REVISION : 01 PAGE : 28

731 732 733 734

PABX AND TELEPHONE SYSTEM (ANALOG & DIGITAL) LOCAL AREA NETWORK (LAN)/WIDE AREA NETWORK (WAN) NETWORK MANAGEMENT SYSTEM (NMS) MOBILE BROADBAND

740

741

SURVEILLANCE AND SAFETY SYSTEM

742

PUBLIC ADDRESS GENERAL ALARM (PAGA) SYSTEM CCTV AND INTRUSION SYSTEM

743

METEOROGICAL SYSTEM

750 COMMUNICATIONS EQUIPMENT

751

ENTERTAINMENT SYSTEMS

810 MATERIAL HANDLING

811 812 813

PEDESTAL CRANE GANTRY/BRIDGE/JIB CRANE MONORAIL / TROLLEY HOIST

80,81,83, 85

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 29

814

ELEVATORS

821 822 823 824 825

GENERAL ACCOMODATION SPACES GALLEY / MESS HALL OFFICES COLD ROOM SICKBAY

830 AVIATION

831 832

HELIDECK AVIATION REFUELLING

840 MARINE AND CORROSSION PROTECTION

841 842

SACRIFICAL ANODE CATHODIC PROTECTION MARINE GROWTH PREVENTION

843

DE-HUMIDIFIER SYSTEM

850

851 852 853 854 855

TOPSIDE JACKET LIVING QUARTERS (LQ) BRIDGES TELECOM TOWER

861

PROCESS AREA (INSIDE BATTERY LIMIT) NON PROCESS AREA (OUTSIDE BATTERY LIMIT) RECEIVING AREA LAUNCHING/EXPORT AREA

820 ARCHITECTURAL

STRUCTURAL

860

862 CIVIL

863 864

Figure 3.1-14: Overview of Systems, Subsystems &Sub-subsystems

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.1-15: Level 1 Commissioning & Start-up Sequence

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 30

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.1-16: Level 2 Commissioning & Start-up Sequence

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 31

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.2

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 32

System Description and Scope of Works 3.2.1

System description provides, to some extent, information on the processes, the system point of origin and ending, the equipment involved and other pertinent facts.

3.2.2

Scope of Works depicts activities required to be performed by CONTRACTOR during Testing, Pre-commissioning and Commissioning stage. Activities described with words like verify, check or ensure mean the tasks should have been completed by Fabrication Team and only to be checked by Testing, Precommissioning and Commissioning Team using the relevant documentation. Should there be a need to re-perform any of the completed activity on the basis of equipment or material flaw or failure; this shall be executed upon concurrence by CARIGALI.

3.2.3

Activities described with the word perform mean the tasks to be executed by Testing, Pre-commissioning and Commissioning Team only. This includes start-up and vendor representative supervision.

3.2.4

Activities identified in the Scope of Works listed in subsequent pages are in no means final. CONTRACTOR is advised to elaborate further using the documentation provided i.e. vendor data, in determining the actual extent of work required.

3.2.5

CONTRACTOR shall be responsible for identifying and developing Scope of Works that are not depicted in this section.

3.2.6

Contractor shall obtain manufacturer's (vendor) assistance to ensure satisfactory installation of equipment.

3.2.7

Contractor shall obtain manufacturer's (vendor) warranty service if outlined in contract documents.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.3

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 33

Testing and Pre-commissioning Common Scope of Work Many activities are repetitive in many systems or subsystems as it is common for a specific task performed on certain equipment in a particular system or subsystem may also be required for similar equipment under a different system or subsystem. For example, an electric-motor-driven pump testing and pre-commissioning activities are essentially the same for all such pumps be it in a liquid metering system or a compression system. A standard and common Scope of Works is therefore readily identifiable as depicted in the following subsections. Should a specific system require additional activities, then the relevant activities would be stated under the respective system by discipline.

3.3.1

General

3.3.1.1

Verify equipment manuals, reference drawings, factory calibration certificates, test reports and test certificates are available.

3.3.1.2

Verify equipment skid structure and on-skid items are free of any damage.

3.3.1.3

Verify nameplate data for all items are as per datasheet and specification.

3.3.1.4

Verify tagging and numbering for all items are correct.

3.3.1.5

Verify equipment temporary shipping braces, stoppers and other protective structures are removed.

3.3.1.6

All test/calibration equipment shall have a valid calibration certificate from the manufacturer or certified by authorized third party.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.3.2

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 34

Piping

3.3.2.1

Verify conformity line checking against IFC Instrumentation Diagram (P&ID) drawings as follows:

Process and

i)

Verify valves, flanges, blind flanges and piping items were properly installed and tightened

ii)

Verify gaskets plusbolts & nuts installed are of the right specification

iii)

Verify the flow direction of check valves, globe valves, Restriction Orifices, and other inline instruments

iv)

Verify pipeworks were adequately supported as per drawings.

v)

Verify the accessibility and operability of manual valves and all of instrument indicators

vi)

Verify all process pipes, process equipment and line instrument plus isolation valves has been leak tested

vii)

Verify color coding, line numbering and directional arrow are provided correctly

viii)

Verify functional test of all manually-operated, isolation and block valves

3.3.2.2

Verify flushing had been completed which shall be referred to CSP-22 Flushing/ Hydrotest Procedure and Paragraph 6.2.1 Piping Matrix for guideline.

3.3.2.3

Verify hydrotesting had been completed which shall include the following activities: i)

FAT and Valve leak test has been done based on acceptance criteria on API 6D and BS 5351 Codes and Standards

ii)

Non-return valves and swing check valves shall be returned to its original position after completion of hydrotesting

iii)

Temporary spade and blinds were removed after hydrotesting

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 35

iv)

Pipeworks are drained and blown with dry air once hydrotesting completed

v)

All instruments and relief valves which are removed during test shall be reinstated back to its original location

vi)

Refer to CSP-22 Flushing/Hydrotest Procedure for detailed hydrotest procedure

3.3.2.4

Verify the internal chemical cleaning for piping system as per para 6.2.1 Piping Matrix chemical cleaning

3.3.2.5

The flange management shall be performed prior to Re-instatement Leak Testwhich consist of :

3.3.2.6

a)

Flanges alignment to ensure the correctness of flange to flange alignment, gaskets, cleanliness flanges facing,

b)

Bolt tensioning/tourqing as per approved procedure to ensure the tightness of stud bolt with correct tension/ torque value including the correctness of stud bolt installation.

Perform reinstatement leak test which shall include the following activities (refer to Section 5.1.16 for details): i)

Perform internal inspection and verify cleaning of vessels is completed and "Final Closure Certificates" have been issued

ii)

Gross leak test with 7 bar compressed air may be required prior to Reinstatement leak test to ensure the early detection of the major leaking point and then to avoid any wastage of Nitrogen consumable. However the Gross Leak test (with compressed air) is not allowed for existing facilities.

iii)

Verify test instruments used have a range of fifty (50) percent higher than the test pressure. Test instrument validity period do not exceed six (6) months after certification or re-calibration by third party.

iv)

Upon completion of Re-instatement Leak test the system shall be preserved by 1 bar nitrogen.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 36

3.3.2.7

For general utilities (as per para 6.2.1 Piping Matrix), service test is to be carried out in lieu of Reinstatement Leak Test. Test pressure shall be operating pressure.

3.3.2.8

Verify insulation and claddings are conformed to specification and drawings.

3.3.2.9

Verify pipework(as per para 6.2.1 Piping Matrix)is adequately supported, internally cleaned and preservation applied after pickling or acid cleaning.

3.3.2.10

Verify the systems (as per para 6.2.1 Piping Matrix) have been purged with nitrogen and achieved below 4% oxygen content.

3.3.2.11

Verify the Base Line Survey on the basis of Corrosion Risk Assessment for corrosion management of piping system.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.3.3

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 37

Mechanical Rotating Equipment

3.3.3.1

Verify hold down bolts and vibration dampeners (if any) has been adequately installed and tightened.

3.3.3.2

Verify skid and equipment levelness as recommended by manufacturer or vendor. Should grouting is applied; Vendor Representative’sconcurrence may be required during inspections.

3.3.3.3

Verify alignment of suction/discharge piping flange, driver and driven equipment i.e. motor to pump, motor to gearbox, turbine to gearbox, accessory drive to turbine, etc., is completed and the values are within vendor acceptable values.

3.3.3.4

Verify Lube Oil flushing has been completed as per vendor recommendation

3.3.3.5

Check air, fuel and lube oil filters for cleanliness and replace as necessary.

3.3.3.6

Check lubrication or greasing of all external bearings and check lube oil for contamination, replace if necessary

3.3.3.7

Check cooling system and ensure coolant and corrosion inhibitor are added.

3.3.3.8

Perform no-load test of critical rotating equipment such as compressor, engine, etc.

3.3.3.9

Secure and preserve equipment after pre-commissioning for sea transportation.

Note: Vendor Representative’s assistance and concurrence may be required.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 38

Static Equipment

3.3.3.10

Verify hold down bolts have been adequately installed and tightened.

3.3.3.11

Verify Equipment as-built drawings, test reports and Certificates are available.

3.3.3.12

Verify tagging and nameplates data for equipmentas per Fabrication drawing/PID.

3.3.3.13

Verify equipment temporary shipping braces,stoppers and other protective structures have been removed.

3.3.3.14

Performinternal and external installation and inspection and verify cleaning of vessels and tanks have been completed and issue Final Closure Certificates.

3.3.3.15

Verify equipment manuals reference drawings; factory calibration certificates;test reports and test certificates are available.

3.3.3.16

Verify all of flanges and stud bolt for man hole, hand hole and all of nozzles have been aligned and tightened.

3.3.3.17

Baseline thickness measurement for static equipment. This shall be carried out prior to commissioning at selected test points to facilitate future real time corrosion rate.

3.3.3.18

Baseline measurements to be included in the Equipment Record Cards if any.

3.3.3.19

A check of record of all manufacturing data books, shop inspection reports, and manufacturer inspection and test reports should be kept in the equipment file. This information shall be recorded in Equipment Record Card, which shall be completed before COMMISSIONING.

3.3.3.20

To check correct Installation of Equipment (ex: sliding saddle movement for expansion; bolts to be loose).

3.3.3.21

Check whether special (maintenance) tools and inspection manuals have been supplied.

3.3.3.22

Check that test holes in Reinforcement Pads are open (filling hard grease). Shall not be plugged with metal plugs).

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 39

3.3.3.23

For air-coolers, check that the fan rotation and blade setting are correct.

3.3.3.24

Check accessibility of manhole covers, davits, valves, gauges.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.3.4

3.3.5

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 40

Electrical

3.3.4.1

Inspect and verify all electrical equipment supplied and installed are as per the specification.

3.3.4.2

Verify nameplate data, tagging and numbering of cables, relays, devices.

3.3.4.3

Verify electrical cables are installed correctly, continuity checked and insulation resistance tested.

3.3.4.4

Verify electrical junction box installations and power cable terminations are completed as per specification.

3.3.4.5

Verify all earthing connections are terminated.

3.3.4.6

Perform inspection and function test of motor RTU. Hand-off-auto and ammeter function.

3.3.4.7

Perform uncoupled/solo run test of electric motors and record direct of rotation after motor windings and space heaters are insulation tested. Confirm that all motors are rotating in correct direction as per vendor datasheet and marked direction of rotation.

3.3.4.8

Perform coupled run test of electric-motor-driven equipment.

3.3.4.9

Perform start-stop function test.

3.3.4.10

De-energize subsystems after completion of pre-commissioning activities.

3.3.4.11

Perform visual inspection of battery condition.

3.3.4.12

Perform visual inspection and functional test for UPS system.

3.3.4.13

Perform visual inspection and functional test for the batteries and solar panel/charger for the navigational aid system.

Instrumentation& Telecommunication

3.3.5.1

Verify all individual instruments comply withCARIGALI specifications prior to calibration by comparing instrument name tags and datasheets to the specifications.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.3.5.2

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 41

Verify all instruments on skid and off skid installation, testing and calibration are completed and recorded on standard forms and ITRs.

Note: Completion of these activities shall be clearly indicated by attaching colour-coded labels or stickers to each instrument or instrument system.

3.3.5.3

Verify calibration and pop test certificates of all relief valves are valid.Relief valve should have a minimum certificates validity of 6 months upon RFSU.

3.3.5.4

Verify that all field instruments including skid mounted instruments should have a minimum certificates validity of 6 months upon RFSU.

3.3.5.5

Verify FGS field devices installation; testing and calibration are completed and recorded on standard ITR form and checklist.

3.3.5.6

Verify that all tubing for primary process, impulse line, signal line, instrument air supply, sample lines and hydraulic lines are correctly installed and are leak/pressure tested to the specification requirements (see instrumentation pre-commissioning procedure under Section 5.3).

Note: The tubing needs to be purged before leak/pressure test

3.3.5.7

Verify instrumentation isolation valves and manifold valves could be opened and closed easily.

3.3.5.8

That all instrument junction box installations and cable terminations (including Fibre Optic) are correctly installed as per in engineering drawing.

3.3.5.9

Verify completion of instrument and control cable insulation resistance checks and continuity checks. All thermocouples and RTDs signal and control wirings shall be checked for polarity and continuity, including external power if required.

3.3.5.10

Perform loop checking of all field instruments (indication, control, alarm and shutdown) to control Process Monitoring and Control System, Safeguarding System, Unit/Local Control Panel, Turbine Control Panel, telecommunication, etc.). This includes stroking of valves i.e. shutdown valves, blowdown valves, control valves, etc. and function testing of local control panel.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 42

3.3.5.11

Perform alarm and shutdown test of system (Safety Instrumented System, Fire and Gas System, etc.)by simulating abnormal/tripcondition at the primary element. It shall be ensured that the correct operational sequence and action of all components are as per specifications.

3.3.5.12

Perform function testing for all control panels (Process Monitoring and Control System, Unit/Local Control Panel, Turbine Control Panel, telecommunication, etc.)

3.3.5.13

Perform Instrument Earth, Safety Earth and I.S. Earth Checks within Control Panel.

3.3.5.14

Verify instrumentation isolation valves and manifold valves could be opened and closed easily and sight glasses are not obstructed with paint, etc.

3.3.5.15

Verify wire terminals for solid and clean connections.

3.3.5.16

Check all lugs and connectors (electric, pneumatic, hydraulic) for correct tagging and numbering

3.3.5.17

In case of field bus installations, verify loop resistance, cable capacitance, inductance values and provision of end resistance as applicable.

3.3.5.18

Verify connections of proper wire terminals.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.4

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 43

Commissioning

3.4.1

Detail Commissioning & Start-Up procedure shall be crossed reference to CSP-21 for minimum requirement and Contractor shall develop Project Specific Testing, Pre-Commissioning &Commissioning procedure at each stage of the project (live documents which will be continuously updated throughout project).

3.4.2

Commissioning Common Scope of Works i)

Ensure that all pre-commissioning activities are complete andReady for Commissioning (RFC) certificates signed off.

ii)

Line-up/ open isolation valve per P& ID

iii)

Purge the piping with N2 before allowing hydrocarbon into it, applicable for hydrocarbon systems.

iv)

Keep the loop under positive nitrogen pressure.

v)

Allow the process liquid into the system slowly and replace the nitrogen

vi)

Check and monitor for any leakage during gas-in and pressurization of line.

vii)

Carry out equipment and its control system tuning until achieving the desired operating conditions.

viii)

The system shall achieve the product specifications as described in P&ID specifications and DBM.

ix)

Carry out endurance test for: 1. Continuously running equipment (72 hours); 2. Non-continuous running equipment (4 hours)

x)

Ensure all the parameters shall be within the safe operating limit as per P&ID/ equipment specifications, such as: a. Level b. Pressure c. Flowrate d. Temperature e. Vibration f. Noise Level

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE xi)

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 44

Refer to vendor Site Acceptance Test (SAT) procedure and relevant ITR-C.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.5

3.6

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 45

Commissioning and Start-up Procedure 3.5.1

Run the system continuously for duration of recommended hour(s) based on the system requirement. Necessary adjustment for temperature, pressurization, air flow, etc. at system is to be made (if required).

3.5.2

Check for all parameters and characteristic stated inside manual are correct.

3.5.3

Record performance and other critical parameters

3.5.4

Ensure that all necessary documentation is available and attached to the report.

System by System Scope of Work The subsequent page illustrates the detailed Scope of Works for the pre-determined systems. Illustrations to depict the mentioned systems/subsystems are also included for reference only. CONTRACTOR shall utilize the particular project Piping and Instrumentation Diagram drawings for accurate details. CONTRACTOR shall review the content against other relevant documentation such as vendor manuals and drawings to acquire a more complete Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 46

3.6.1

100 – PROCESS

3.6.1.1

110 – FULL WELL STREAM

3.6.1.1.1

111 – PROCESS | FULL WELL STREAM | WELLHEAD (DRY TREES)

111.1

System Description A Wellhead is the component at the surface of an oil or gas well that provides the structural and pressure-containing interface for the drilling and production equipment. Christmas (X-mas) tree is an assembly of valves, spools, and fittings used for an oil well, gas well, water injection well, water disposal well, gas injection well, condensate well and other types of wells. Dry X-mas trees are installed on the surface. Offshore, where a wellhead is located on the production platform it is called a surface wellhead, and if located beneath the water then it is referred to as a subsea wellhead or mudline wellhead.Process controls is classified separately under SubSubsystem 625 - Wellhead Control Panel (WHCP).

The major components covered by Topside Contractor are:     

Flowline from X-mas Tree up to the Production/Test Header High Integrity Pressure Protection System (HIPPS) Production Choke Valve (PCV) Position Transducer (ZT) Downstream Pressure/ Temperature (DPT)

The major components covered by Drilling Contractor  Annulus Master Valve (AMV)  Annulus Access Valve (AAV)  Chemical Injection Valve (CIV)  Production Master Valve (PMV)  Production Wing Valve (PWV)  Downhole Pressure /Temperature Gauge (DHPTG)  Annulus Pressure/Temperature (APT)  Upstream Pressure/ Temperature (UPT)

111.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

111.3

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 47

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical If applicable, refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning common scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.1.2 112.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 48

112 – PROCESS | FULL WELL STREAM | WELLHEADS (WET TREES) System Description

The subsea X-mas tree sits on top of the subsea wellhead and provides a means to monitor and control oil or gas production from well, or injection of water or gas into a well. A subsea Xmas tree maybe a vertical type or a horizontal type depending on valve configuration. The major components are:                

Tubing Retrievable Surface Controlled Subsurface Safety Valve (TRSCSSV) / Surface Controlled Subsurface Safety Valve (SCSSV) Annulus Master Valve (AMV) Annulus Access Valve (CIV) Methanol Injection Valve (MIV) Crossover Valve (XOV) Production Master Valve (PMV) Production Wing Valve (PWV) Production Choke Valve (PCV) Downhole Pressure /Temperature Gauge (DHPTG) Annulus Pressure/Temperature (APT) Upstream Pressure/ Temperature (UPT) Subsea Multiphase/Wet Gas Flow Meter (MPFM/WGFM) Position Transducer (ZT) Downstream Pressure/Temperature (DPT) Acoustic Sand Detector (ASD) Subsea Control Module (SCM).

Other associated equipment for subsea production system (SPS) may include but not limited to:      

Jumper Manifold Pipeline End Termination (PLET)/Pipeline End Manifold (PLEM) Flowline Umbilical/Hydraulic Flying Leads (HFL)/Electrical Fling Leads (EFL) Subsea Umbilical Termination Assembly (SUTA)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 49

112.2 Pre-commissioning Scope of Works Post installation testing of a subsea tree is normally undertaken by the drilling rig using an IWOCS (Intervention and Workover Control System). Pre-commissioning must wait until subsea hook-up is complete and is limited to testing from the topside to include:     

Communication tests Sensor checks (pressure, temp, sand rate, flow rate) Valve operations (excluding downhole safety valve) Choke operations Shutdown tests

112.3 Commissioning Scope of Works Commissioning is limited to testing and operating from the topside. Activities are the same as pre-commissioning except with the inclusion of opening the downholesafety valve.

Figure 3.6.1-1: Dual Cluster Manifold SPS

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-2: Simple & Generic SPS Flow Diagram

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 50

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.1.3 113.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 51

113 – PROCESS | FULL WELL STREAM | WELL TESTING System Description The Sub-Subsystem is generally associated with its boundaries defined from the Test headers to the well testing facilities. It includes equipment such as Test Separator, Multi Phase Flow Meter (MPFM) and Subsea MPFM Wet Gas Meter (WGM) for well testing which located at each individual flow line. Test separator is provided to enable well testing. The following is the basis of Test Separator operation: i.

The well testing is conducted for one well at any time.

ii.

Well to be tested is disconnected from the production header and then it is connected to test header.

iii.

The test separator measures the oil and gas flowrates, water cut and the GOR of the well fluid.

iv.

The oil, water and gas streams leaving the test separator are re-mixed and co-mingled into the production header to mix with the fluids from other wells.

Each of the Well flow lines is provided with a connection to Test header. During testing of a well, the corresponding flow line is opened into the Test separator via the test header and its connection to the production header is isolated. Only one flow line is opened into the Test separator at a time. The instruments on the Test Separator are level transmitters to control the flow rate of water and oil, pressure transmitter, local temperature gauge, level gauges and pressure gauges. 113.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 52

CARIGALI STANDARD PROCEDURE iv)

113.3 i)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works Refer to Commissioning common scope of works (Section 3.4.2)

BDS

TEST SEPARATOR

FROM TEST MANIFOLD

SDV

PC

P-12

FI PCV

BDV

SDV

S

LC

TC

FI LCV

Figure 3.6.1-3: Well Testing Facilities Schematic

SDV

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE V-CONE TYPE

WCM

PT

TT

PDT

WET GAS METER COMPUTER (FMC) H FLA

L

Figure 3.6.1-4: Wet Gas Meter – V-cone Type

H FM

L

FQI

FT

PT

FT

TT

VENTURI TYPE FE

Figure 3.6.1-5: Wet Gas Meter – Venturi Type

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 53

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 54

3.6.1.2

120 – PROCESS LIQUID (PL)

3.6.1.2.1

121 – PROCESS | PROCESS LIQUID (PL) |PROCESS LIQUID (PL) COLLECTION AND RECEIVING

121.1

System Description This Sub-Subsystem is generally associated with process crude with its boundaries defined from the wellheads to the respective collection headers and/or from a receiving pipeline riser to the inlet of a separator vessel. Equipment in the Sub-Subsystem includes production headers, test headers, receiver, allocation metering, and production manifold. It also includes associated instruments such as pressure and temperature gauges and transmitters.

121.2

121.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i) Refer to Commissioning common scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-6: Liquid Collection and Receiving system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 55

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.2.2

122.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 56

122 – PROCESS | PROCESS LIQUID (PL) |PROCESS LIQUID (PL) SEPARATION (OIL FACILITIES) System Description Separation of incoming crude is common on most facilities. Separation vessels are equipped with internal weirs; baffle plates, etc. to segregate crude, gas and water. Gas being the lightest would be released at the top of the vessel whereas water and crude outlets are generally located at the bottom of the vessel. It comprises of several pressure vessels such as a High Pressure Separator (HP Separator), a Low Pressure Separator LP (Separator), a Test Separator, a Surge Vessel, relief valves and special items such as interlocks. It also involves associated instrumentations such as pressure and temperature gauges and transmitters, level indicators and flow elements, to mention a few. Free Water Knockout (FWKO) vessel is used to separate the gas and bulk of free water of the preheated crude oil coming from crude exchangers. The FWKO vessel has two main sections, the oily water separation section and the Oil collection section. The following are the design features and principles of the operation of FWKO vessel; i)

A distribution plate located at the immediate downstream of the inlet baffle distributes the oil and water phases uniformly across the vessel cross section.

ii)

Vertical plate coalesce pack section to enhance coalescing of the water droplets in the oil phase and for coalescing of the oil droplets in the oil phase and in the lower water phase.

iii)

The area downstream of the coalescing packs provides further residence time required for the settling of water droplets from oil phase into water phase and rising of oil droplets from water phase to mix into oil phase.

iv)

A weir plate at the downstream of the oil water separation section prevents flow of the bottom water layer into the oil compartment, and also prevents movement of sand particles into the oil section.

v)

Water is withdrawn from the bottom of the oil water separation section through a water level control valve. The flow rate of the water is controlled to maintain steady level of oil water interface.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE vi)

122.2

122.3

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 57

Oil is withdrawn from the bottom of the oil collection section through an oil level control valve.

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical a)

Refer to Section 3.3.3 - Common Mechanical Scope of Works.

b)

Perform inspection of pressure vessels and its internals.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

v)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning common scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-7: Process Liquid Separation system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 58

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-8: Process Liquid Separation system

Figure 3.6.1-1: Production Separator

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 59

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE 3.6.1.2.3

123.1

REVISION : 01 PAGE : 60

123 – PROCESS | PROCESS LIQUID (PL) |CRUDE OIL STABILISATION

System Description Crude oil received from Separator is fed to crude oil stabilization unit for removing the light gas along with hydrogen sulfide before the oil is stored and transporting for downstreamuses. The crude stabilization process sweetens the Sour crude and reduces the vapor pressure to make safe for shipments. Crude Stabilization system is comprises of Flash Drum, Desalter, Dehydration Vessel, Crude Stabilization Column, KettleReboiler, Pumps etc. It includes the extensive pipework and instruments like Shutdown valves, Control valves for various application, Analyzers, transmitters and indicators.

123.2

123.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 – Common Piping Scope of Work

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Work i)

Refer to Commissioning common scope of work (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE 3.6.1.2.4 124.1

REVISION : 01 PAGE : 61

124 – PROCESS | PROCESS LIQUID (PL) | CONDENSATE STABILISATION System Description Condensate received from slug catcher and Knockout drum is fed to stabilization unit to reach the required specification for transportation of condensate or for the use of the condensate in drown stream process. The stability is specified in True Vapor Pressure or Reid Vapor Pressure (TVP or RVP). Condensate stabilization unit is comprises of Surge Drum,Filter Coalescer, Stabilization column, Pumps, Exchangers and Re-boiler etc. It includes the extensive pipework and instruments like Shutdown valves, Control valves for various application, Analyzers, transmitters and indicators.

124.2

124.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 – Common Piping Scope of Work

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Work i)

Refer to Commissioning common scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.2.5

125.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 62

125– PROCESS | PROCESS LIQUID (PL) |PROCESS LIQUID (PL) TRANSFER / STORAGE System Description The cargo system associates with FPSO/FSO are FPS/Spar facilities normally consists of cargo tanks, cargo pumps, cargoeductors. It covers storage for crude oil, crude off loading/export, crude oil washing and crude stripping facilities. Crude oil washing system uses dry oil from cargo tank to clean and wash away sediment of other cargo tank and return back the washing to crude oil tank using eductor. It is normally done during the time between exports and during export operations. The COW operation is to be carried out with inert gas system fully functional due to the static electricity involvement. The cargo tanks are normally equipped with tank gauging using radar sensor/guided microwave sensor to monitor and analyze the level content of cargo oil tank and slop tank. It is also fitted with temperature sensors to monitor the fluid temperature.

125.2

125.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning common scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.2.6

126.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 63

126 – PROCESS | PROCESS LIQUID (PL) |PROCESS LIQUID(PL) METERING AND EXPORT / OFFLOADING System Description Liquid transfer and metering is an integration of several skid equipment originating from the discharge nozzle of a separator/surge vessel through a pumping subsystem and metering sub-subsystem before ending at the shutdown valve downstream of the scraper launcher. It comprises of an extensive array of pipeworks with Crude Oil Transfer Pump (COTP), metering runs, flow element (e.g. turbine, orifice), Meter Prover (if applicable), Auto Sampling Station (if applicable), Export Launcher, Heat Tracing/Exchanger/Heater. All signals are hardwired to its Metering Control System consisting flow computer(s) and supervisory computer(s). It also includes a variety of instruments like shutdown valves, control valves for various applications, transmitters and indicators. Several local control panels for individual equipment are also involved.

126.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation a)

Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

b)

Confirm all communication and hardwired signals to other systems e.g. PMCS, SIS etc. are established.

c)

Confirm Factory Acceptance Test (FAT) punchlist has been demonstrated cleared with relevant calibration certificates and test reports attached.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 64

d)

Perform functional test of pump control panel including interfaces with other systems.

e)

Perform functional test of metering panel including interfaces with other systems.

f)

Perform functional test and loop checking of auto sampler, sampler pump (if applicable) and metering skid including interfaces with metering panel.

Note: Presence of vendor is required during functional test

126.3

Commissioning Scope of Works i)

Refer to Commissioning common scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 65

Figure 3.6.1-9: Typical Process Liquid Metering and Export/Offloading Schematic

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 66

3.6.1.3

130 – PROCESS GAS (PG)

3.6.1.3.1

131 –PROCESS | PROCESS GAS (PG) |PROCESS GAS (PG) COLLECTION AND RECEIVING

131.1

System Description Process gas is collected and received in a manner identical to liquid collection and receiving system. It comprises of a gas header, a test header, flow lines from the gas producing wells, riser shutdown valve, scraper launcher and receiver, choke valves, associated piping and instrumentations.

131.2

Pre-commissioning Scope of Works Activities are similar to the listing stipulated under Sub-Subsystem 121.

131.3

Commissioning Scope of Works Activities are similar to the listing stipulated under Sub-Subsystem 121.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-10:

PG Collection and Receiving system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 67

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.3.2

132.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 68

132 – PROCESS | PROCESS GAS (PG) |PROCESS GAS SEPARATION (GAS FACILITIES) System Description Slugcatcher is used to remove liquid slug in the gas. As gas passes through the vessel, an arrangement of baffle plates reduces velocity of the incoming gas thus providing opportunity for the heavier hydrocarbon component to precipitate into liquid. This liquid is called condensate. There is also a possibility of other forms of liquid such as water to be present that requires removal as well. The Sub-Subsystem comprises of a knockout vessel called a Slugcatcher, a production separator, a surge vessel, a pressure relief subsystem, associated piping and instrumentations. This Sub-Subsystem is reflected as part of the process schematics in Figure 3.6.1-10shown under SubSubsystem 131.

132.2

Pre-commissioning Scope of Works Activities are similar to the listing stipulated under Sub-Subsystem 122.

132.3

Commissioning Scope of Works Activities are similar to the listing stipulated under Sub-Subsystem 122.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.3.3

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 69

133 – PROCESS | PROCESS GAS (PG) | PROCESS GAS METERING

133.1System Description On a gas processing facility, gas export Sub-Subsystem boundary begins from the discharge of a liquid knockout vessel or a separator to the riser shutdown valve at the export pipeline. However, on a gas compression facility the boundary for gas transfer and metering Sub-Subsystem is identified from the end of the discharge manifold system to the riser shutdown valve of the particular export pipeline. It comprises of an extensive array of pipework with Gas Metering runs, flow element (e.g. ultrasonic meter, orifice), Gas Chromatograph/Analyzer System (if applicable), Auto Sampling Station (if applicable), Export Launcher Heat Tracing/Exchanger/Heater. All signals are hardwired to its Metering Control System consisting flow computer(s) and supervisory computer(s). It also includes a variety of instruments like shutdown valves, control valves for various applications, transmitters and indicators. 133.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 – Common Piping Scope of Work

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation a)

Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

b)

Confirm all communication and hardwired signals to other systems e.g. PMCS, SIS etc. are established.

c)

Confirm Factory Acceptance Test (FAT) punchlist has been demonstrated cleared with relevant calibration certificates and test reports attached.

d)

Perform functional test of metering panel including interfaces with other systems.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 70

CARIGALI STANDARD PROCEDURE e)

Perform functional test and loop checking of auto sampler and metering skid items including interfaces with metering panel.

f)

Verify the serial number of the calibration and carrier gas for the Gas Chromatograph (GC) as per approved datasheet/certificate.

Note: Presence of vendor is required during functional test

133.3

Commissioning Scope of Works i)

SSC

Refer to Commissioning common scope of works (Section 3.4.2)

GAS SAMPLING AND ANALYZER CABINET (OFFSKID) MANUAL SPOT SAMPLING

SSC GC PRIMARY SAMPLE CONDITIONING SYSTEM

GC SECONDARY CONDITIONING SYSTEM

GAS CHROMATOGAR PH (PAY)

GC PRIMARY SAMPLE CONDITIONING SYSTEM

GC SECONDARY SAMPLE CONDITIONING SYSTEM

GAS CHROMATOGRA PH (CHECK)

MOISTURE ANALYZER

SSV M

M

M

M

M

FT

PT

QT

PG

TG

TT

TW M

M

M

M

M

M

M

M

M

FT

PT

QT

PG

TG

TT

TW

M

M

SSV

SSV

Figure 3.6.1-11:

FT

PT

QT

PG

TG

TT

TW

Typical Process Gas Metering Schematic

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.4

140 – GAS COMPRESSION

3.6.1.4.1

141 – PROCESS | GAS COMPRESSION |SUCTION MANIFOLD

141.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 71

System Description Suction manifold, also called suction header, is pipework from the gas outlet of separators or slug catchers to the inlet of a compressor train suction scrubber or a heat exchanger. Minimal equipment is involved; primarily the associated piping and instrumentations such as shutdown valves, gauges transmitters and indicators.

141.2

141.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical - None.

iii)

Electrical - None.

v)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 72

Figure 3.6.1-12: Process Schematics for Gas Compression consisting of Suction Manifold, Compression Train and Discharge Manifold Sub-Subsystem

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.4.2 142.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 73

142– PROCESS | GAS COMPRESSION |OFF GAS COMPRESSOR System Description The combined off gas streams from Crude/Condensate stabiliser, Surge Drum and acid gas of GSU are compressed by two stages centrifugal compressors. Off gas compressor are driven by fixed/variable speed motor. Each stage is equipped with its own Anti-surge/Recylce control valve designed for full flow condition. The main components of the system are shown in the Fig XX below. Off Gas Compressor train Sub-subsystem is divided into smaller components such as: i)

Prime movers for compressors is electric motor,

ii)

Speed reducing gearbox,

iii)

Centrifugal Compressors

iv)

Scrubber vessels,

v)

Control panels, and

vi)

Ancillary subsystems; for example Dry gas seal, fuel gas, diesel, air inlet filtration, start system, etc.

It also includes numerous instrumentations. Usually, a gas compression system is equipped with its own control system and it is linked to other control systems such as DCS, SIS and FGS. 142.2

Pre-commissioning Scope of Works. For the Compressor pre-commissioning activities, the vendor or supplier guidelines are to be followed strictly. Line cleaning, chemical cleaning activities, charging seal gas, lube oil circulation are few of the precommissioning activities. i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 74

CARIGALI STANDARD PROCEDURE vi)

142.3

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i) Refer to Commissioning scope of works (Section 3.4.2)

1st Stage

Figure 3.6.1-13:

2nd Stage

Off Gas Compressor

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE 3.6.1.4.3

143.1

REVISION : 01 PAGE : 75

142– PROCESS | GAS COMPRESSION | COMPRESSION TRAIN (BOOSTER/EXPORT/GAS LIFT/GAS INJECTION) System Description Gas Compression is required to provide secondary recovery to a field in the form of gas lifting and gas injection. It is obtained through use of compression. A train is defined as a sequential arrangement of equipment that makes up one compression system (refer schematic in Figure 3.6.1-12 under Sub-Subsystem 141). A compression train Sub-Subsystem is divided into several smaller components such as: i)

Prime movers for compressors; for example a turbine, an internal combustion engine or an electric motor,

ii)

Speed reducing gearbox,

iii)

Compressors; either centrifugal or reciprocating, booster

iv)

Heat exchanger,

v)

Scrubber vessels,

vi)

Control panels, and

vii)

Ancillary subsystems; for example seal gas, fuel gas, diesel, air inlet filtration, start system, etc.

It includes where applicable of prime movers (Turbine or ICE or EM), Gearbox, compressor (Centrifugal or Reciprocating), booster compressor, heat exchanger, scrubber/vessels, control panels, and ancillary equipment. It also includes numerous instrumentations. Usually, a gas compression system is equipped with its own control system and it is linked to other control systems such as DCS, SIS and FGS. 143.2 Pre-commissioning Scope of Works. For the Compressor pre-commissioning activities, the vendor or supplier guidelines are to be followed strictly. Line cleaning, chemical cleaning activities, charging seal gas, lube oil circulation are few of the precommissioning activities. i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

143.3

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 76

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

vii)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i) Refer to Commissioning scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.4.4 144.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 77

144 – PROCESS | GAS COMPRESSION |DISCHARGE MANIFOLD System Description Discharge manifold Sub-Subsystem starts at the outlet of the discharge scrubber or a heat exchanger of the compression train and ends at the inlet nozzle to the lift gas distribution network. Minimal equipment is provided in this system; primarily the associated piping and instrumentations such as shutdown valves, gauges transmitters and indicators.

144.2

Pre-commissioning Scope of Works Activities are similar to the listing stipulated under Sub-Subsystem 141.

144.3

Commissioning Scope of Works Activities are similar to the listing stipulated under Sub-Subsystem 141.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-14:

Discharge Manifold System

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 78

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.4.5 145.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 79

145 – PROCESS | GAS COMPRESSION |EXPORT/DOWNHOLE INJECTION System Description Every installation after processing of oil or gas is required to be exported to next user. Oil and/or gas are exported through long pipelines from offshore installation to onshore plant. Pipelines are normally provided with pig launcher in this case called Export Launcher. Oil can be exported to oil tankers also. In case of FPSO, after processing oil is stored in the hull of FPSO and transferred to shuttle tankers. Shuttle tankers take oil to onshore for offloading. For the reservoir maintenance and ultimate more oil recovery, reservoir is flooded with gas or water. Thus water or gas is injected in the reservoir. The injection is done through X-mas trees. Normally X-mas tree is on the surface but water or gas through X-mas tree is injected in the reservoir and sometimes called downhole injection.

145.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

viii)

Instrumentation Refer to Section 3.3.5 -Common Instrumentation Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 145.3

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 80

Commissioning Scope of Works i)

Refer to Commissioning common scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 81

3.6.1.5

150 – GAS DEWPOINTING

3.6.1.5.1

151 – PROCESS | GAS DEWPOINTING | GAS DEHYDRATION TRAIN(WATER DEW POINT)

151.1

System Description Removing water vapor from the gas is important because it prevents hydrates from forming when the gas is cooled in the transmission and distribution systems and prevents water vapor from condensing that create corrosion problem. Glycol contactor is a pressure vessel used in gas dehydration process. It is a vertical vessel equipped with several trays of small outlets that are methodically situated. Instead of trays Glycol Contactor can have structured packing also. As wet gas or gas laden with water vapor travels from bottom of the vessel upwards, it meets with the glycol that is sprayed from the top. As glycol has a very high affinity for water, water vapor is extracted from the gas thus making the gas dry. The major equipment are Glycol contactor, glycol/gas heat exchanger, glycol storage vessel, glycol transfer pumps, complete glycol regeneration package (re-boiler, skimmer vessel, charcoal/glycol filters, heat exchangers, glycol trim cooler/fan and electrical motor drivers etc.), anti-foam chemical injection system, local control panel, thyristor control panel, dew point analyzer and all associated piping, valves, instrumentation, moisture analyzer, tubing, instrument/electrical cabling and junction boxes. The Sub-Subsystem comprises of a contactor vessel and regeneration skid and its associated piping and instrumentation.

151.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE v)

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 82

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Figure 3.6.1-15:

Gas Dehydration system

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 151.3

Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

Figure 3.6.1-16:

Gas Dehydration system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 83

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.5.2 152.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 84

152 – PROCESS | GAS DEWPOINTING |ADSORPTION(WATER DEW POINT) System Description Adsorption is the adhesion of water molecules from a gas, liquid, or dissolved solid to a surface. This process creates a film of the adsorbate on the surface of the adsorbent. Note that adsorption is a surface-based process while absorption involves the whole volume of the material. Solid desiccants, Molecular sieves used as adsorbents. Major equipment involved are Adsorption bed, Regeneration unit, heat exchanger, cooler, LCP, Dew point analyzer and all associated piping, valves, instruments, moisture analyzer, tubing, electrical cabling and JB.

152.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

ii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

vi)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Figure 3.6.1-17:

152.3

Adsorption system

Commissioning Scope of Works

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE i)

Refer to Commissioning scope of works (Section 3.4.2)

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 85

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE 3.6.1.5.3

153.1

REVISION : 01 PAGE : 86

PROCESS | GAS DEWPOINTING |TURBO EXPANDER AND RECOMPRESSION (HYDROCARBON DEW POINT) System Description The turbo expander with compressor unit is used to provide refrigeration for the sales gas purification/treatment process in a hydrocarbon processing plant.It is representative of a natural gas dew pointcontrol process where the low pressure ratio expander cools thegas only enough to lower the hydrocarbon dew point to beappropriate for pipeline transmission of the gas. Expander outletliquid fractions are usually in the range of 2 to 8% by weight. The expansion turbine is of the radial inflow type with advanced aerodynamic design maximizing the isentropic efficiency. The machine is of a proven cartridge concept which allows a quick replacement of the machinery capsule including rotating parts without interference with expander process pipes. A high efficiency compressor wheel is utilized as a loading device, recovering the mechanical energy from the expander. A vane diffuser ensures optimum efficiency and head flow characteristic. Turbo expanderand re-compression is equipped with following: i) Quick Shut off Valve ii) Joule-Thompson Control Valve iii) Anti-Surge Controller iv) Variable guide Vane v) Dry Gas Seal vi) Active Magnetic Bearing(AMB) vii) Automatic Thrust Balancing Unit viii) Cold Vessel Recovery Unit ix) Suction and Discharge Knockout Drums x) Magnetic Bearing Control System

153.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii) Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 87

iii) Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works. iv) Instrumentation Refer to Section 3.3.5 -Common Instrumentation Scope of Works.

153.3 Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

Figure 3.6.1-18:

Turbo Expander

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE 3.6.1.5.4

153.1

REVISION : 01 PAGE : 88

154 – PROCESS | GAS DEWPOINTING |DIRECT COOLING (HYDROCARBON DEW POINT) System Description Hydrocarbon Dew Point system is designed to inhibit the formation of solid hydrates in the gas stream i.e. to perform a level of dehydration. The major equipment are Refrigeration Compression package, Dew point control package. The system includes the refrigeration system. This is achieved through the injection of a liquid agent directly into the gas stream. The liquid agent is selected based on low viscosity and low freezing temperature rather than dehydration ability.

153.2

153.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

vii)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-19:

Cooling system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 89

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE 3.6.1.6

160 – WATER INJECTION

3.6.1.6.1

161 – PROCESS | WATER INJECTION | SEAWATER INTAKE

161.1

REVISION : 01 PAGE : 90

System Description Normally found only on water injection facilities, seawater intake SubSubsystem starts from the submersible "lift" pump to the inlet of a coarse filtration unit. Installation of the pumps are frequently performed offshore as it requires pre-installation of its "caissons"; tubular structures where the pumps are protected from the surrounding oceanic environment. However, the respective discharge piping and control instrumentation are preinstalled in the fabrication yard. The Sub-Subsystem includes one or more electric-motor-driven submerged centrifugal pumps, vacuum relief valves, discharge pipings, Sea Water Lift Pump (SWLP), Electro- chlorination package and associated instrumentations.

161.2

161.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3- Common Mechanical Scope of work

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

–

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-20:

Seawater Intake system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 91

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.6.2 162.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 92

162 – PROCESS | WATER INJECTION | FILTRATION System Description There are two types of filtration equipment provided for in this SubSubsystem. One is called "coarse" filtration and the other "fine" filtration (refer to attached process schematics in Figure 3.6.1-21). Coarse filters are essentially vessels equipped with internal elements that provide filtration of particles of 100 microns or more. The filter elements are rotated with the assistance of an electric motor to shake the trapped particles out of the elements whereby the particles are then released into the drain. This sequence is called a "backwash". In the fine filtration equipment, filter vessels are filled with different layers of filter media. The media are normally made of garnet and anthracite. As dirty water flows through the media from the top, particles bigger than 2 microns are trapped thus provided very clean water. Unlike coarse filters, trapped particles are removed on a fixed period by reversing the flow. This process is also helpful in restoring the media fluffiness for another cycle of filtration. The Sub-Subsystem starts at the inlets of the coarse filters and ends at the outlet of the fine filters. It comprises of pressure vessels, motor-driven mixers and blowers, butterfly valves, control valves and other associated piping and instrumentations. The major equipmentare injection pumps and all associated drive equipment and accessories and local control panels. All conditioning equipment, including suction filters and dedicated chemical injection systems, all suction and discharge piping and headers, valves, instrumentation, tubing and any electrical/instrument cabling and junction boxes.

162.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

162.3

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 93

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

v)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Work i)

Refer to Commissioning scope of works (Section 3.4.2)

Figure 3.6.1-21:

Filtration system

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.6.3 163.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 94

163 – PROCESS | WATER INJECTION | DEAERATION System Description Deaeration is a process of oxygen removal from the water. It is mostly achievable through two processes; gas stripping and vacuum. Under gas stripping, process gas passes through water droplets and "strips" the oxygen from the water molecules. Under vacuum, separate equipment is required to create the necessary vacuum thus allowing the oxygen molecules to separate from the water molecules. The whole process occurs in a tower vessel called a "deaerator tower". Inside a deaerator tower, packings are randomly arranged with the sole purpose of increasing the contact between two phases i.e. water and gas, thus removing oxygen under vacuum condition. The Sub-Subsystem includes a pressure vessel, electric-motor-driven pumps, vacuum ejector sets, control valves and other associated piping and instrumentation.

163.2

163.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 -Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-22:

Deaeration system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 95

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE

PROCEDURE NO: CSP-20

CARIGALI STANDARD PROCEDURE 3.6.1.6.4 164.1

REVISION : 01 PAGE : 96

164 – PROCESS | WATER INJECTION | TREATED WATER PUMPING System Description Treated water pressure is increased prior to injection into the wells by employing different sets of pumps. For low pressure requirements, a 'booster" pump is sufficient to meet the needs. It is used to maintain inlet suction pressure for the high pressure pump. It is normally a single-stage centrifugal pump driven by an electric motor. The major equipment are low pressure booster pump, high pressure multistage pump (turbine or diesel /gas engine drive) ancillary equipment. Shutdown valves control valves, blowdown valves, gauges and transmitters

164.2

164.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

v)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-23:

Treated Water Pumping system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 97

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.6.5

165.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 98

165 – PROCESS | WATER INJECTION | TREATED WATER EXPORT/DOWNHOLE INJECTION System Description The Sub-Subsystem starts from the discharge of the injection pump and ends at the gate valves to the water injection wells. It includes discharge manifold, riser shutdown valves, scraper launcher and receiver, injection water header, flowlines to water injection wells, associated piping and instrumentations.

165.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical - None.

v)

165.3

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-1:

Treated Water Export / Downhole Injection system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 99

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 100

3.6.1.7

170 – ACID GAS REMOVAL

3.6.1.7.1

171 – PROCESS | ACID GAS REMOVAL | ACID GAS REMOVAL UNIT

171.1

System Description In case of high H2S, where it may not be suitable to re-inject or flare the acid gas, further treatment would be required by introducing acid gas to Acid Gas Enrichment Unit (AGEU) to selectively remove H2S over CO2 in order to produce an acid gas composition which enables acceptable operating conditions for Sulphur Recovery Unit (SRU). The Sulphur Recovery Unit consists of modified Claus Units with catalytic stages with common degasser and incinerator where acid gas is pre-heated to around 195 °C. Elemental sulphur is produced which is routed to sulphur blocking area and the tail gas routed to incinerator to convert remaining sulphur species to SO2. This is also known as gas sweetening and acid gas removal in downstream plants referring to processes that use aqueous solutions of various amines to remove H2S and CO2 from gases. Main equipment involved are Absorber, tanks and vessels, reboiler, pumps, reflux drum, associated piping and instruments.

171.2

171.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

ix)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-24:

Acid Gas Removal system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 101

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 102

3.6.1.8

180 – CONTAMINANT REMOVAL

3.6.1.8.1

181 – PROCESS | CONTAMINANT REMOVAL | MERCURY REMOVAL UNIT(ADSORPTION)

181.1

System Description Also known as de-mercurization in downstream plants found after the dehydration process where mercury is removed from gas by adsorption using activated carbon beds or other technology such as silver-doped molecular sieve, sulfur impregnated carbon, copper sulfide and the like. Major equipment involved is Packed Bed columns, Tanks, vessels and associated piping & instrumentation.

181.2

181.3

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

v)

Catalyst Loading by Specialized Subcontractor

Commissioning Scope of Works i) Refer to Commissioning scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

Figure 3.6.1-25:

Mercury Removal system

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 103

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.8.2

182.1

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 104

182 – PROCESS | CONTAMINANT REMOVAL | MERCAPTAN REMOVAL UNIT(ADSORPTION) System Description Natural gas having contaminants Mercaptans which is a sulphur-containing compounddefined as RSH where R represents radical, and having an extremely offensive, garlicky odor. Dewpoint Gas is feed to the unit from the Mercury Removal Bed. The incoming gas is first cooled in the Mecaptan Unit Gas/Gas Exchanger and then by the Chiller Package. It is then feed into the Molecular Sieve Vessels. Two (2) out of the three (3) Molecular Sieve Vessels will be online at any one time. The vessels have a duty time of 16 hours before entering an eight (8) hour regeneration cycle. The regeneration cycles are staggered to ensure two (2) vessels are always online. The conditioned gas exits the Molecular Sieve Vessels with a total sulphur content of