Commissioning Tankage Package and Associated Interconnecting Piping

TANKAGE PACKAGE & ASSOCIATED INTERCONNECTING PIPING

RUWAIS REFINERY EXPANSION PROJECT

TAKREER PROJECT NO. 5578

TENDER ENQUIRY NO. 09-5578-E-4

3.5.4 COMMISSIONING PLAN

3.5.4.1 Overview of Commissioning Plan

3.5.4.2 INITIAL SERVICE

3.5.4.3 MECHANICAL COMPLETION / PRE-COMMISSIONING

3.5.4.4 COMMISSIONING

3.5.4.5 TEST RUN

3.5.4.6 REPORTING

3.5.4.7 VENDOR ASSISTANCE

3.5.4.8 TRAINING

3.5.4.9 HAND-OVER FOR PROVISIONAL ACCEPTANCE

3.5.4.10 FINAL ACCEPTANCE

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3.5.4 COMMISSIONING PLAN

This Commissioning Plan covers CONTRACTOR’s plan how to manage and execute activities from Mechanical Completion to Test Run and Provisional Acceptance.

A detailed Commissioning and Test Run Plan will be provided after Contract Award following the requirements of ITT, the TAKREER Ruwais Refinery Expansion (RRE) Project’s Execution Manuals and Specifications. As a minimum, those are:

Exhibit A.10 Test Run and Commercial Production

Exhibit B.38 Acceptance

Exhibit B.50 Mechanical Completion Commissioning Planning and Documentation

Exhibit B.52 Commissioning and Test Run

Exhibit B.53 Mechanical Completion and Commissioning Services

Exhibit C, Doc. No. 5578-REP-PA-01: Pre-commissioning, Commissioning and Start-up Plan

Other related COMPANY Procedures and Specifications in the draft Contract.

This is to enhance Engineering, Procurement and Construction Schedule guidance and to allow smooth handover from Construction activities to Commissioning / Test Run activities.

Execution Strategy

Our proposed execution strategy is as follows:

Overall management and control of CONTRACTOR’s scope for Pre-commissioning, Commissioning and Test Run will be the responsibility of CONTRACTOR, including coordination to COMPANY.

Provide full support to EPC-3 Offsites & Utilities Contractor for their Lead Role in implementation of Commissioning and Test Run.

Perform commissioning interfaces and coordination to COMPANY and EPC-3 Contractor, as well as coordination to other RRE EPC Contractors (as necessary).

CONTRACTOR’s direct hire Commissioning Team will supervise and monitor all commissioning activities (from Mechanical Completion to Test Run and Provisional Acceptance) to enhance the effectiveness of their efforts, and will ultimately bring the handover of the Tankage facility to COMPANY.

The interface between Vendors and Subcontractors will be controlled and coordinated by CONTRACTOR.

3.5.4.1 OVERVIEW OF COMMISSIONING PLAN

This Overview Commissioning Plan gives description how to implement Pre-Commissioning, Commissioning, Start-up of RRE Tankage Project. It describes preparations, mobilizations, methodologies and implementation schedules of Start-Up of Project to show CONTRACTOR’s technical abilities of successful conducting of Pre-

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commissioning, Commissioning, Test Run and Training. Main items of Execution Plan are described in the succeeding topics.

3.5.4.1.1 Commissioning Organization

The organization structure of commissioning should be finally agreed between Commissioning Manager from CONTRACTOR and COMPANY. The organization shall be led by team leader taking charge of each team. The main positions are as follows.

Commissioning Manager

Commissioning Coordinator

Commissioning Engineers, for:

- Process

- Mechanical/Piping

- Electrical

- Instrumentation

CMS Administrator (or System Handover Engineer)

Test Run Supervisor

Training Manager

Technicians, Subcontractors, Vendor Representatives

Likewise, Commissioning Manager monitors Training Manager in conduction of training to COMPANY Trainees, to prepare these personnel for the operations and maintenance of the Tankage facilities.

The Commissioning/Test Run Organization Chart is provided in Section 3.2: Organization Details.

3.5.4.1.2 Home Office Commissioning (Planning)

Commissioning Team well in advance of his assignment to the Site will be assigned to the Home Office in order to carry-out the Home Office commissioning planning, preparatory work, in strict conjunction with the Project Management Team.

The activities to be done at this stage are:

Review and comment of P&ID’s from the point of view of Pre-commissioning, Commissioning, and Test Run operations (e.g. connections for purging, accessibility of instruments and machinery for maintenance etc.)

Identification of Systems and Sub-systems and marking up on P&ID’s;

CMS Installation and database set-up. Preparation of components data base (System Matrix) including line list, list of safety valves, list of equipment (static and rotating), list of instruments, list of all components. Each component is attributed to the pertinent system.

Preparation of Plant Systems other than Process Systems in consultation with respective Lead Engineers (Civil/Electrical/Instrument/Mechanical and QA)

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Preparation of Hand Over procedure, in conjunction with Construction & QA Teams. complete with forms and certificates for various disciplines and covering the Pre-commissioning activities up to the Contractual Hand-Over to the COMPANY.

Preparations of the blank forms of the record sheets associated with general procedures and CMS database, and define applicable Test Plan’s for relevant packages.

Pre-Commissioning, Commissioning and Test Run Dossiers

Pre-Commissioning, Commissioning Scheduling

CONTRACTOR will thoroughly examine and prepare all means to implement each step. Orientation of our staffs and their early mobilization from preparation step prior to Pre-commissioning and commissioning are made to conduct the project smoothly.

3.5.4.1.3 CMS (Commissioning Management System)

CMS IT system which manages whole processes from completion of construction to the conclusion of test-run, which will be responsible for input data review and revision. The system shall be used by CONTRACTOR once approved by COMPANY.

WinPCS is commercial software from Complan Network AS, will be applied as Commissioning Management System (CMS) tool. This software is for populating commissioning database, scheduling and tracing all certification. CONTRACTOR is currently using this system in one of our Oil & Gas Plant project in Africa, for the following functions;

Database that tracks the completions progress of every equipment tag number installed on the project.

Links to the equipment tag number which is fundamental to the requirements of inspection, test and commissioning at each stage of the project.

Verify engineering data.

Database is transparently layered over a number of applications (e.g. Word and Excel).

Certification system, Management system, Tracking, and document Output.

CMS will be fed by CONTRACTOR by acquiring basic data from designers as the system is required to be managed as database by using design material by other organization. While the corrections and management of CMS are open for feeding according to fields due to the complexity of internal links and great capacity of system, special manpower is needed to manage systems and processes.

CMS is computerized to manage Pre-commissioning using computer for the preparation of computerized Tracking Data Base (i.e. Check sheet and Document) and Computerized Tracking System.

Pre-commissioning team shall utilize an easy to use CMS project control tool to populate the Pre-commissioning database, sustain the required focus on where completions work is needed to meet schedule, provide traceability for all acceptance certification, demonstrate

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technical integrity of Pre-commissioning work completed and ultimately to verify project completion. Support features of the selected CMS might include:

Computerized database structured by node, by Sub-system, by System comprising the register of equipment tag numbers and loop numbers (basic functions) imported from the Engineering Database.

Relevant check sheets allocated against them prescribing requirements for Mechanical, Pre-commissioning and commissioning completion

Capability to rapidly populate required work from database and integral Inspection and Test Reports (ITR`s)

3.5.4.1.4 Punch List

Construction, pre-commissioning and commissioning completion is monitored System wise, and supported by QC documentation, i.e. all Quality Control documentation summary sheets duly signed by involved parties, accompanied by Test Certificate records.

Essential part of this Pre-commissioning and Commissioning plan is the categorization of Punch List. This will give undisputable evidence of identified remaining activities from construction, pre-commissioning and commissioning needs to be done, while CONTRACTOR can still proceed towards the Provisional Acceptance of the Work acceptable to COMPANY.

The Punch List items shall be categorized as follows:

Category-“A” : To be completed prior to MECHANICAL COMPLETION.

Category-“B” : To be completed prior to the completion of COMMISSIONING.

Category-“C” : To be completed prior to PROVISIONAL ACCEPTANCE, or as soon as practicable thereafter in accordance with a schedule to be agreed with COMPANY.

The Mechanical Completion Certificate may be issued subject to a written undertaking by CONTRACTOR to complete a schedule of outstanding work. Such outstanding work may include final completion of painting, insulation, and scaffolding removal, at COMPANY’s discretion. Upon issuance of the Mechanical Completion Certificate CONTRACTOR may proceed with COMMISSIONING.

The Punch Lists shall be recorded in a database as a dynamic document. The CONTRACTOR shall maintain a record of completion and signing-off of the completed items. Additional punch list items, found during COMMISSIONING and initial operation, shall also be recorded. Updated Punch List status shall be provided to COMPANY as and when requested.

3.5.4.1.5 Documentation and Commissioning Management Plans

CONTRACTOR will prepare and submit the following manuals several months ahead before the beginning of the commissioning works, for approval from COMPANY.

Pre-Commissioning and Commissioning Execution Plan

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Commissioning Test Procedures

Pre-Commissioning Procedures

Review of Operation & Maintenance Manual

System Numbering and Marked-Up P&ID and SLD

3.5.4.1.6 Pre-Commissioning and Commissioning Scheduling

Commissioning schedule shall be developed from the Overall Project (Master) Schedule. CONTRACTOR will make commissioning schedule in detail with reference to master schedule and commissioning schedules shall be linked accordingly with possible schedule changes in the future. As schedule includes all possible activities on the project, both makeup and changes in the schedule shall be discussed and agreed upon by personnel taking charge of commissioning whenever these events happen.

3.5.4.1.7 Pre-commissioning, Commissioning & Test Run Dossier

Pre-commissioning, Commissioning & Test Run Dossiers shall be made by CONTRACTOR as classified by systems and be submitted before Pre-commissioning starts. It is the Procedure which prepares Document (System-by-system) such as check list for Pre-commissioning, Commissioning & Test Run.

CONTRACTOR shall develop Pre-commissioning, Commissioning and Test Run Dossiers by system, incorporating all discipline activities (Mechanical, Pipelines, Electrical, Instrumentation, Control and Telecoms, etc.). These must be prepared, ready for population with test results prior to the commencement of pre-commissioning activities.

Each System Pre-commissioning, Commissioning & Test Run Dossier might include as items:

System description and limits, associated systems and statement of intent

Safety precautions to be taken during work on the system, include work permit system

Mechanical Completion procedures, system cleaning and integrity check procedures, water sources, characterization and disposal means, “A” work instructions, discipline and system check sheets and resource requirements

Pre-commissioning procedures, resource requirements, “B” work instructions, discipline and system check sheets

Factory Acceptance Testing strategies and procedures and acceptance criteria

Vendor support requirements in line with the vendor call-out register

Preservation, lay-up and de-preservation procedures

Commissioning spares and consumables requirements

Test equipment and temporary supplies

Commissioning and Test Run procedures, manuals (F&G, HVAC, Instrument., Safety Equipment, Telecoms, etc), defining the pre-requisites and the commissioning steps leading to the full commissioning of a system and acceptance criteria and defining the resource requirements. This procedure shall describe steps for

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documenting and recording commissioning performance and define system hand over requirements including witnessing of steps by COMPANY.

Testing requirements and procedures, indicating parameters to be measured and performance evaluation mechanisms and acceptance criteria for individual plant/equipment and for systems

Drawings and vendor data requirements

Handover strategy, documentation and protocols

The systems and sub-system activities shall be executed and documented using the above structure. These dossiers for the various systems shall form part of the handover documents to COMPANY. Commissioning Dossiers shall be set up in advance from CMS to define the work to be done by system, by node for later population as systems are handed over from Construction.

3.5.4.1.8 Orientation of Staff

It is essential to orient sufficiently all staffs of CONTRACTOR and related Subcontractor/Vendor who will participate in the project for its smooth execution.

The programs are anticipated to fulfill the following results;

Overall understanding of the project.

Sufficient understanding of each discipline’s job.

Communication skill for smooth job accomplishment.

Full knowledge of what must be observed in the project.

Knowledge of HSE.

Others necessary for smooth and effective project execution.

3.5.4.1.9 COMPANY Staff

Dedicated engineers and technicians from COMPANY are needed for operations of Tankage facilities.

Regarding Commissioning, Test Run of Tankage, we will appoint the most competent people in terms of careers from operations & maintenance field and have them successfully execute the project through diversified indoor and on-site training from the preparation step.

CONTRACTOR will also employ highly skilful Trainers and technicians through well-established training programs.

3.5.4.1.10 Commissioning Interface

Commissioning Manager is the primary deals with all interface activities during commissioning phase of the work. He will be assisted by his Commissioning Coordinator who will monitor interface and coordination activities with Other Contractor (i.e. EPC-3 Contractors), COMPANY’s Commissioning and Operations Representatives, Subcontractors, Vendors and Third Party Agencies (if any).

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The anticipated commissioning interfaces are as follows;

Training of COMPANY Operations & Maintenance personnel

Coordination with COMPANY regarding EPC-3 O’s & U’s works interface

Vendor assistance for equipment commissioning

Feed-in oil and gas

Interface coordination meetings

Handover of Facilities (or part of Facilities)

More of construction interface activities are discussed in Section 3: Project Execution Strategy, Interface Management Plan.

3.5.4.1.11 Commissioning Coordination

In principle the Construction Coordination Procedure includes commissioning coordination activities. However, at the start of commissioning stage, Site Management Team will modify Construction Coordination Procedure to suit specific administration instructions related to commissioning activities, primarily in dealing with COMPANY. The commissioning coordination will provide specific instructions for the following;

Commissioning Organization

Project Documentation and Correspondence

Conference, Meetings at Site and Minutes of Meeting

COMPANY Review, Comment and Approvals

Progress Reporting

Informal communication

Coordination with Other Contractors, Subcontractors/Vendors and Third Parties

3.5.4.1.12 Test Equipments, Tools and Consumables

Test Equipments, Tools and Consumables required including heavy equipments will be provided by CONTRACTOR.

The expendable supplies and accessories on Vendor Package shall be managed after it purchased those supplies upon the recommendations of equipment vendors. The purchase and management of expendable supplies and spare parts required for pre-commissioning and maintenance on each vendor package purchased by CONTRACTOR or vendors.

3.5.4.2 INITIAL SERVICE

CONTRACTOR intends to describe services for successful execution of Commissioning, Initial Operation of the Tankage for RRE Project.

Objectives of these Pre-commissioning and Commissioning activities are to ensure that all systems are correctly installed and fit for the purpose of the project and then to deliver

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Tankage that are mechanically complete and properly functioning at the earliest possible date.

For this purpose, the Commissioning Organization will carry out the following activities:

Overall management of preparation and planning

System Identification dossier and mark-up drawing

Detailed test run procedures

Black start sequence

Detailed sub/systems commissioning and start-up sequence

List and description of operational tests

Pre-Commissioning & Commissioning technical data base

Pre-Commissioning & Commissioning check lists and procedure

Test Run procedure and Start-up procedure

Pre-Commissioning/Commissioning progress and reporting

Pre-Commissioning & Commissioning of the facilities

Commissioning spares, consumables. fist fills and lubricant schedule

As built documentation

Hand over dossiers.

3.5.4.2.1 Mechanical Completion/ Pre-commissioning

CONTRACTOR will take the following actions at the step.

Organizing a project team and dispatch it to the site.

Understanding of the features of processes and specifications of equipment by taking part in pre-commissioning step.

Obtaining materials required for preparations of manuals and procedures.

Reviewing of operation and maintenance manual.

Establishing all kind of procedure to take pre-commissioning and submitting for COMPANY’s approval one (1) month before pre-commissioning.

Listing temporary equipment necessary for work.

Training staffs who will be committed to work (safety work, firefighting and etc.).

Listing spare parts needed for ordinary maintenances and making inventories of remains at an appropriate level.

3.5.4.2.2 Commissioning

CONTRACTOR will confirm functions of equipment and test operation conditions with injecting hydrocarbon fluids into equipment and facilities. Commissioning requires preparations for various plans, procedures and check sheets for tests, which includes:

Preparation for Commissioning Test Procedures.

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Preparation for Commissioning Schedule.

Preparation for procedure, log sheet, instruction and calculation sheet necessary for testing function of each system.

Preparation of procedures and log sheets for Test Run.

3.5.4.2.3 Test Run Operation until Handover

CONTRACTOR will perform the test run operation until handover to COMPANY and should operate equipment in accordance with specifications. CONTRACTOR will make the following preparations to satisfy contents stated in specifications.

During the period fixed by COMPANY, CONTRACTOR will conduct equipment Test Run (reliability tests) and make sure the stable operation.

CONTRACTOR will make a list of important materials for the stable operation.

Through proper maintenance and management of general and special tools, CONTRACTOR will endeavor to prevent any problems occurring.

CONTRACTOR will make efforts to save cost by securing spare parts and holding appropriate number of inventories.

CONTRACTOR will improve maintenance skills and accumulate technology by developing maintenance plans.

3.5.4.3 MECHANICAL COMPLETION / PRE-COMMISSIONING

The supervision of pre-commissioning will be held by CONTRACTOR and interface should be maintained among personnel taking charge of such respective fields as electricity, machines, operation and personnel on construction. The procedure shall be made by CONTRACTOR by respective fields and be permitted by COMPANY to commence.

The Commissioning Organization led by team leaders taking charge of each team and appropriate consideration should be given according to job services and locations for flexible management of manpower.

3.5.4.3.1 Mechanical and Piping

Cleaning and flushing

As the job of cleaning and flushing piping and equipments by using of blowing method to get rid off debris is the kind to be proceeded after draining shall be performed after taking hydrotest as a QC task of piping, construction team will take charge of the task.

Dewatering and Drying Out

Construction team will take charge of the task of dewatering and drying which shall be proceeded after hydrotest and be responsible for the tasks on attaching and detaching accessories of pipelines including blind flange.

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Removing, Cleaning and Replacing Screens and Filters

Construction team shall precede the tasks of cleaning and exchanging filters and screens including the replacement and adjustment of packing and seals of all kinds of pipelines which shall be preceded after air blowing to keep continuity.

Chemical Cleaning

As chemical cleaning which applies to major suction pipeline of compressors shall be proceed under the supervision of Construction team. COMPANY recommends that the contract for the above cleaning be may implemented through contracting with specialist subcontractor in separate of process

Alignment Checks

The alignment for special equipment such as gas turbine and pump with large capacity shall be operated by the technicians of equipment vendors.

Manual Valve Function Test

The operation test of manual valve to be executed before commissioning and operation shall be done by CONTRACTOR. As deemed to be fatal if any problem happens to this test, measures should be made by construction team as soon as possible.

No Load Running Tests

No load running tests of driven machinery should be made to operate in accordance with pre-commissioning test procedure by CONTRACTOR.

Mechanical Test

Pursuant to commissioning test procedure, CONTRACTOR will perform running test, string tests and performance tests.

Installation of Final Gaskets, Tightening of Flanges

By the request of Commissioning team, the task shall be performed by construction team.

Verification of UCP Interfaces with DCS

As the confirmation of communication between UCP, enabling sending and receiving data among systems and PAS is considered important part, communication and database connection among systems shall be done by manufacturers or vendors. CONTRACTOR shall support it comprehendingly.

Test Cables (Continuity and Earth Resistance Test)

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Construction team will operate insulation test and continuity test of power and instrument cable as these tests are cold check items which are involved in mechanical completion.

Manual Rotation

Manual and hand turning of prime movers and driven equipment shall be performed at once a week under the supervision of construction team.

Installation and Removal of Temporary blinds and Gasket

If it is necessary to install and remove the temporary blind and gasket for commissioning and test-run of plant, construction team will handle it by the request of commissioning team.

Installation of Safety Equipment

By the request of commissioning team, construction team will perform Installation of safety equipment and ensuring they are charged and being fully functional.

Performance of Final Touch-Up Paint and Insulation Repair

The task of final touch-up paint shall be performed by Construction Team.

3.5.4.3.2 Instrumentation

Reinstatement

The reinstatement on all kinds of control valves, relief valves and orifice plates installed on pipelines shall be performed by construction team by the request of CONTRACTOR.

Calibration and Testing

The calibration and testing of all instruments including those installed on packages or skids in the early stage before installation shall be performed by construction team, while it shall be performed by commissioning team for the purpose of breakdown or confirmations after operation start-up.

Relief and safety valve pressure setting shall be calibrated through an outside party which will acquire the permission of ordering party.

Instrumentation Loop Checks

Pursuant to commissioning test procedure, commissioning team will perform instrument loop checks and verification of communication protocols.

Function Testing of Control Loops and Third Party Interfaces

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The communications among systems shall be performed among manufacturers or vendors as being considered one of the important parts in the operation and CONTRACTOR will support it.

Testing of Alarm Management

Pursuant to commissioning test procedure and standard of manufacturers or vendors, CONTRACTOR will test and manage alarm management system. Pursuant to commissioning test procedure and the standard of vendors, CONTRACTOR will test and manage event time stamping in sequence of events recorder, and synchronization of entire system time.

Stroking Test of Valve

The inspection before installation of control and shut-down valve shall be performed under the supervision of CONTRACTOR at the field-site, and stroking test shall be made during loop checking.

3.5.4.3.3 Electrical

Testing of All Electric System

Pursuant to commissioning test procedure, pre-commissioning and commissioning with the cooperation of construction team, shall execute various test of all electrical system components including switchgear and motor starters, transformers, battery systems, motors, primary injection testing of protection systems.

Electrical Loop Test

The loop test shall be done by Commissioning team with the support of construction team after the construction is completed.

Electrical Power Initial Energizing

The pressurization of switch board at early stage shall be executed by Commissioning team with the support of construction team after pre-commissioning is completed.

Functional and Load Test

Functional and load testing of equipment in compliance with vendor’s requirements, including all motors, electrical systems, alarms and shutdown devices shall be proceeded by CONTRACTOR with the support of vendors.

Miscellaneous Checks

The tasks on operation of other instruments such as fuse ratings and polarity installed at the field-site shall be determined through mutual discussions.

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Running Test of All Electric Motors

Load test on various kinds of motor and pumps installed at the field-site shall be executed pursuant to the operation procedure manuals.

Cable Checks and Tests

As the construction team will take charge of power and control cable checks and tests including integrity checks of HV and LV cables, Commissioning team will proceed overall operation of instruments by the support of vendors.

3.5.4.4 COMMISSIONING

CONTRACTOR will provide full support EPC-3 Os & Us Contractor to their lead role in implementation of Commissioning of overall Ruwais Refinery Expansion Project. CONTRACTOR will implement commissioning activities which are part of EPC-4 responsibilities, in close coordination with EPC-3 Contractor.

Commissioning will be executed after completion of equipment installation and Pre-Commissioning. Utilities such as electricity, fuels, air and lubrication system should be ready to work. In addition, cleaning of impurities resulting from piping, welding, and installation must be completed before the commencement of Commissioning.

CONTRACTOR must share all problems and data with COMPANY and execute each step in accordance with commissioning and test run procedure accepted by COMPANY. CONTRACTOR will keep commissioning progress according to the commissioning schedule. To minimize any loss in time, CONTRACTOR will submit detailed schedules to COMPANY. If any modification of schedule and procedure is needed due to unexpected impacts, CONTRACTOR will discuss it COMPANY.

As commissioning step may require a lot of employees, CONTRACTOR will endeavor to execute commissioning systematically by assigning manpower and workloads properly. For better commissioning, CONTRACTOR will get information on equipment and process in advance prior to pre-commissioning. The personnel to be committed to commissioning work consist of experts who were involved in the preparation step of the project

3.5.4.4.1 Documentation

Due to criticality of operation of gas facilities, CONTRACTOR will make it sure that the project can be executed successfully. Perfect plans, procedures, schedules and manuals should be prepared by competent professionals to be assigned to the project. Here are some considerations in preparing documents.

Understanding the entire process and features of equipment.

Preparing for procedures for each equipment and step.

Keeping continuity among steps.

Proper use of data for next steps by attaching forms associated with operations of each step.

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Cooperation with equipment manufacturers or vendors.

Schedules and procedures about manpower and organization.

Information on temporary electric power, valve-driven devices, temporary pipes and subsidiaries required for initial operation.

Disaster-proof devices, firefighting systems and personnel safety devices.

Safety procedures.

3.5.4.4.2 Spare Parts and Consumables

CONTRACTOR will prepare a list of spare parts by analyzing equipment based on vendor’s manuals and experiences from the preparation step in order to secure stability of equipment during Initial Operation. Spare parts will be stored in a warehouse and managed by CONTRACTOR. Spare parts will be securely supplied and maintained with an appropriate level of inventories by CONTRACTOR.

3.5.4.4.3 Commissioning of Systems

Systems to be commissioned are as follows;

Crude Oil Tank System

Naphtha Tank System

Gas Oil Tank System

Jet Fuel Tank System

Propylene Storage Tank System

Intermediate Tank Storage Systems

Gasoline Blending and Storage System

Bunker Oil Blending and Storage System

Gauging System

Heating System

After commissioning is completed, initial operation for each equipment will be executed. But all utilities at the site must remain at normal operation condition, leakage and explosives must be removed.

As equipment vendors have a significant role in commissioning, CONTRACTOR should mobilize vendors' manpower in line with commissioning schedule.

3.5.4.4.4 Commissioning Activities

Commissioning Test of Hydrocarbon System

Pursuant to commissioning test procedure, CONTRACTOR will execute commissioning test of hydrocarbon systems on simulated fluids where practicable prior to introduction of well fluids with the support from Operations team.

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Verification of F&G System

Commissioning team will perform verification and confirmation of F&G system, with assistance from Construction team.

Cause and Effect Checks

With the support of Vendor, CONTRACTOR will perform Cause and Effect checks including commissioning of all safety detection systems such as fire detection, smoke detection, gas detection, public address system, manual alarm/call points pursuant to commissioning test procedure.

Leak Test

Air and N2 leak test of the entire facilities up to their maximum operating pressure and correcting / arresting the resulting leaks relating to pipelines and equipments to be performed at the next stage of hydro test and draining & drying shall be performed by construction team.

Nitrogen inside pipelines and equipments shall be filled up pursuant to provisions and be handed over to CONTRACTOR for exchanging and pressurizing by unit installation and systems.

Purging of the Individual System

Air and N2 leak test relating to pipelines and equipments to be performed at the next stage of hydro test and draining & drying shall be performed by construction team. Nitrogen inside pipelines and equipments shall be filled up pursuant to provisions and the nitrogen density should be maintained below one percent. Pipelines should be handed over to Commissioning team for exchanging and pressurizing by unit installation and systems.

Full Emergency Shutdown System Test

Tests relating shut-down signal and trip which are interconnected shall be performed by CONTRACTOR with the support of vendor.

Testing of Equipment Package

Communication of each installation related to operation shall be performed pursuant to operation procedure.

Purging of the Entire Facilities

The exchange of gas and pressurization shall be the most important task relating to equipment operation and be required to be exercised by keeping the regulations of ordering party.

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3.5.4.4.5 Commercial Production

Run-in Test

Run-in will be conducted if there is no mechanical and electric fault at Pre-Commissioning and Commissioning step.

For the test, processes on the site must remain at operational condition. CONTRACTOR will operate for twenty (20) to thirty (30) minutes with a minimum load during run-in test.

Manual Test

Manual test is to check operational condition and load capacity prior to load test. In the test, features of equipment must be carefully looked into. Load test will be carried out from minimum to maximum capacity of the equipment. When any abnormal noises and mechanical vibration are detected, immediate actions must be taken.

Load Test

Load test will be conducted at the end of commissioning to figure out features and capacity of equipment. It is recommendable to maintain the best condition for the test, because load increases as time goes. In particular, a series of preparatory actions can be taken against any incidents.

3.5.4.5 TEST RUN

CONTRACTOR will provide full support EPC-3 Os & Us Contractor to their lead role in implementation of Test Run of overall Ruwais Refinery Expansion Project. CONTRACTOR will implement test run activities which are part of EPC-4 responsibilities, in close coordination with EPC-3 Contractor.

Auto Test

In the test, equipment will be operated automatically. When one intends to adjust load, he has to record data and change load into next step, if equipment is stabilized for five (5) minutes after changing the step. If load test is completed, each equipment will run for about twenty (20) to thirty (30) minutes at the maximum load, then operators will implement tuning and conduct 72 hours test. All test data must be recorded and compiled.

Tuning and Stabilization of Process

Tuning will be executed between the completion of load test and the beginning of 72 hours performance test. To make a tuning condition, operation mode must be set at 'Auto Mode'. And pressure or flow rate should not be changed. In particular, equipment which may cause hunting or trip must be stopped before tuning. When all works are completed, all set values should be restored to their initial status. In addition, all features and details of tunings should be sent to operators with a printed report produced during tuning.

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Performance Test

After tuning, 72 hours performance test will make progress. Until the completion of the test, Operations team will record various events and values on log sheet in order to utilize them as initial data of the operation. They will also be used as sources for analyzing performance.

It aims to test load capability of equipment under full load for 72 hours.

Measured data associated with noise and vibration as well as details of operation must be recorded for 72 hours.

After the completion of 72 hours performance test, a report must be prepared with the recorded data.

Graphic chart will be added to the test report to make operators understand easily.

To avoid unnecessary delays, CONTRACTOR will agree with COMPANY exact format of performance test within the start-up and operating constraints of the facilities.

3.5.4.6 REPORTING

CONTRACTOR will set up a reporting system and will inform important operations activities to COMPANY. CONTRACTOR will make an endeavor to provide detail of data and information for COMPANY. To this end, CONTRACTOR will submit the reports such as weekly and monthly reports.

Daily Report

If site meeting will be held every morning for the daily reporting, CONTRACTOR representative will attend and report the following, as a minimum.

Daily Training program for COMPANY staffs.

Work details for the following day.

Work progresses.

Various activities including quality and safety activities.

Valuable information for COMPANY.

Highlights and Out-standings

Items requested by COMPANY.

Weekly and Monthly Report

CONTRACTOR will provide a weekly and monthly progress report to COMPANY. The progress report will be submitted in a format agreed among the parties relevant to this report.

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3.5.4.7 VENDOR ASSISTANCE

CONTRACTOR will make contracts of purchasing equipment in which vendor assistance provisions on duration of the project are included. CONTRACTOR will make preparations for vendor assistance by reviewing the contracts with vendor in preparation stage.

Furthermore, CONTRACTOR will be responsible for obtaining and receiving operations and maintenance instructions from each equipment Vendors as part of the procurement package.

3.5.4.8 TRAINING

The provision of Training by CONTRACTOR is discussed under Section 2: Specific Requirements, 2.4 Training Proposals.

CONTRACTOR will make arrangement for COMPANY staffs to receive from Vendors of equipment and control systems, specific trainings that are required by the project specifications, particularly Process training, Mechanical training, Control Systems training and Inspection training.

Further identification of special training required for each of the equipment and from each Vendor, will be determined with the Vendor in the early engineering/ procurement phase.

3.5.4.9 HAND-OVER FOR PROVISIONAL ACCEPTANCE

Following satisfactory completion of the Tankage facilities Test Run, CONTRACTOR and COMPANY will agree upon a schedule for formal Hand-over of the facilities. At the same time CONTRACTOR will submit an application to COMPANY for issuance of Certificate of Provisional Acceptance.

System Hand Over Package, Provisional Acceptance

CONTRACTOR will compile a system hand-over package that will include COMPANY approved certificates demonstrating successful completion, commissioning and acceptance of the Test Run.

After receipt of CONTRACTOR’s request and providing there are no outstanding items, a Certificate of Provisional Acceptance will be issued pursuant to, which COMPANY will formally accept the EPC phase of the contract as being completed.

3.5.4.10FINAL ACCEPTANCE

CONTRACTOR shall request for an application of FINAL ACCEPTANCE CERTIFICATE upon fulfilling all the project and contractual obligation for RRE Tankage Project, provided no major deficiencies were noted, with the approval of the COMPANY and/or COMPANY’s representative.

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CONTRACTOR shall immediately rectify deficiencies (if found contrary to the contractual requirements), deemed by the COMPANY immediately after receipt notification.

The COMPANY shall promptly issue the CONTRACTOR’s requested FINAL ACCEPTANCE CERTIFICATE if all project contractual conditions are complied, with the satisfaction of the COMPANY.

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Commissioning Tankage Package and Associated Interconnecting Piping

Documents

commissioning activities

commissioning organization

commissioning interfaces

detailed commissioning

commissioning plan page

overview of commissioning

overview commissioning

test run plan