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NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.60

PLANT PRE-COMMISSIONING, COMMISSIONING

AND START-UP GUIDELINES

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

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GENERAL ENGINEERING SPECIFICATIONPLANT PRE-COMMISSIONING, COMMISSIONING

GES C.60Page 2 of 14

AND START-UP GUIDELINES Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 31.2 Other NOC Specifications 3

2.0 DEFINITIONS 3

2.1 Technical 32.2 Contractual 4

3.0 GENERAL 4

3.1 Codes and Standards 43.2 Vendor/Contractor Responsibility 53.3 Pre-Commissioning and Commissioning Documentation 53.4 Handover Documentation 6

4.0 COMMISSIONING OF SYSTEMS 7

4.1 Introduction 74.2 Plant Systems and Sub-Systems 74.3 Punch Lists 74.4 Pre-Commissioning and Commissioning 7

4.5 Start-Up 8

5.0 CHECK LIST FOR PRE-COMMISSIONING, COMMISSIONING ANDSTART-UP ACTIVITIES 9

5.1 General 95.2 Check Lists 9

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AND START-UP GUIDELINES Rev 0 1999 1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the completion of plant and mechanical equipment pre-commissioning, commissioning and start-up activities for refineries, onshore oil and gas installationsand processing facilities.

Commissioning of electrical equipment is covered by GES C.56. Commissioning of instrument and controlsystems is covered by GES C.54.

1.1.2 In this specification, it is assumed that the plant is mechanically complete, prior to the beginning of the pre-commissioning, commissioning and start-up activities. The definition of `mechanical completion' is given

below.

1.1.3 The Vendor/Contractor shall produce pre-commissioning, commissioning and start-up procedures that willcover items in their supply. These shall be used in conjunction with this specification, and be integrated

into the overall pre-commissioning, commissioning and start-up procedures for the entire plant.

1.2 Other NOC Specifications

The following NOC Specifications are referred to in this specification.

GES C.54 Commissioning of Microprocessor Based Instrument Systems

GES C.55 Field Installation, Calibration and Testing of Instruments

GES C.56 Electrical Commissioning

2.0 DEFINITIONS

2.1 Technical

Plant system or sub-system: A discrete utility, maintenance or process system, that forms part of theoverall plant, e.g. instrument air system, cooling water system, fuel gas system.

Mechanical Completion: The construction stage at which all items of equipment have been installed,equipment skids aligned and grouted, interconnecting process and utility piping flushed and hydrotested,valves, instrumentation and interconnecting wiring have been fitted.

Pre-commissioning: Begins after mechanical completion and means all cold/static checking, verification,testing, adjustment, calibration work on plant systems and sub systems, to ensure that all function inaccordance with their intended service, including the flushing and filling of oil systems.

Ready for Commissioning: The completion of the pre-commissioning activities.

Commissioning: The dynamic testing and adjustment of a plant system or sub-system, by the introductionof utility and process fluids, to ensure that the system functions in accordance with its intended purpose.

Start-up: The introduction of oil, gas or feedstock to the plant, and the operation together of the plantsystems and sub-systems, leading to the manufacture of the plant product.

Functional Test: A live test on a piece of equipment, instrument or electrical item.

Functional Test Sheet: A supporting document to record the results of a functional test.

Operational Test: On-line test of a sub-system in conditions as close as possible to normal operation.

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Site Performance Tests: Those tests made by the Owner with assistance from the Vendor/Contractor,during start-up, which confirm that the plant is operating at its design condition.

Handover: The passing of responsibility for the plant from the Vendor/Contractor to the Owner, afterdemonstration of satisfactory start-up and operation.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment andfacilities have been designed, constructed, inspected and tested in accordance with the requirements of thisspecification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,who verifies that the equipment and facilities have been designed, constructed, inspected and tested inaccordance with the requirements of this specification and the Purchase Order/Contract.

3.0 GENERAL

3.1 Codes and Standards

The Vendor/Contractor shall comply with this specification and the following API Code:-

API 700 Check list for Plant Completion

The codes and standards applicable to individual equipment and plant items are specified in the respectivespecifications.

3.2 Vendor/Contractor Responsibility

3.2.1 The Vendor/Contractor shall produce an overall set of pre-commissioning, commissioning and start-up

procedures covering the entire plant. This manual, for individual equipment items, shall be compiled intothe overall set of procedures for the entire plant.

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AND START-UP GUIDELINES Rev 0 1999 3.2.2 The Vendor/Contractor shall pre-commission, commission and start-up the plant, following the procedures

approved in the manual.

3.2.3 In addition the Vendor/Contractor shall have the following responsibilities:

a) to protect equipment from adverse weather, corrosion and damage;

b) to provide all commissioning tools, spares, lubricants, chemicals, temporary utilities and facilities;

c) to obtain technical assistance from the equipment Sub-Vendor's engineers, during commissioning;

d) to issue weekly reports on the progress of commissioning;

e) to carry out site modifications, shown to be necessary by the pre-commissioning andcommissioning activities;

f) to notify the Owner, two days in advance, of site tests to be made during pre-commissioning and

commissioning;

g) to provide copies of all test records to the Owner;

h) to provide continuous clean-up of the construction area, remove excess materials, temporaryfacilities, scaffolding and rubbish;

i) to verify to the Owner that all pre-commissioning activities have been completed, prior to thecommencement of the commissioning phase;

j) to verify to the Owner that all commissioning activities have been completed, prior to start-up ofthe plant;

k) to assist the Owner in site performance tests of specified equipment prior to handover.

3.3 Pre-Commissioning and Commissioning Documentation

The Vendor/Contractor shall submit the following documentation for review by the Owner.

3.3.1 A detailed list of Plant systems and sub-systems included in the pre-commissioning, commissioning andstart-up programme, four weeks prior to the start of pre-commissioning.

3.3.2 A pre-commissioning, commissioning and start-up plan four weeks prior to pre-commissioning, containing:

- a detailed schedule, in network form, and arranged by plant system, for carrying out the pre-commissioning, commissioning and start-up activities;

- an organisation chart showing the Main Vendor/Contractor's personnel, who will be responsiblefor pre-commissioning and commissioning;

- a list of spare parts required for pre-commissioning and commissioning;- a list of temporary utilities and facilities required during pre-commissioning and commissioning;- a list of lubricants and consumables required for commissioning;- a list of Sub-Vendor's representatives who will be available on site to support commissioning.

3.3.3 A Pre-Commissioning, Commissioning and Start-Up Manual as Section 3.2.1, four weeks prior to the startof pre-commissioning, containing:

- a set of approved for construction drawings and survey data, to be used during pre-commissioning

and commissioning;- a marked up set of plant P&IDs and utility P&IDs showing various plant systems;- a pre-commissioning and commissioning plan, arranged by plant systems, and detailing all of the

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AND START-UP GUIDELINES Rev 0 1999 activities and procedures to be used during pre-commissioning, commissioning and start-up;

- a list of all equipment, machinery and packages, arranged by plant systems which are subject to pre-commissioning and commissioning tasks. The list shall indicate the tasks, checks and tests to be made, and shall be a summary of the pre-commissioning and commissioning scope of work, thelist shall be a working document that monitors the progress of the work;

- operational test procedures;- design data and process flow diagrams;- process description;- pre-commissioning procedures;- commissioning procedures;- equipment Vendor/Contractor's procedures;- start-up procedures;- functional/performance test procedures;- proforma of check lists;- proforma of inspection logs;- proforma of test logs;- proforma of the weekly report sheet;

- proforma of non-conformance certificate;- proforma of release certificate.

3.3.4 A pre-commissioning and commissioning data dossier arranged by plant systems prior to start-up of the plant, containing:

- preliminary check report;- a plan with all stages of pre-commissioning and commissioning signed off by the Owner as

approved and supported by completed check lists;- inspection logs, arranged by discipline, signed off by the Owner as approved;- test logs, signed off by the Owner as approved;- non-conformance certificates signed off by the Owner as approved;

- a set of release certificates, arranged on discipline basis, and issued by the Owner, to confirm theiracceptance that the system has been satisfactorily commissioned;- test certificates for all lifting equipment;- list of plant modifications made during commissioning, supported by as-built drawings;- proforma of the Commissioning Acceptance Certificate which shall be used as the basis for the

final acceptance of the Plant by the Owner.

3.4 Handover Documentation

All documentation pertaining to the Commissioning operation shall be compiled in a specific HandoverDossier, arranged by sub-systems which will contain all information required to demonstrate a subsystemhas reached the 'Ready For Handover' status. Its content shall include but shall not be limited to:

- Handover Certificate;- Commissioning Acceptance Certificate;- Punch List;- Operational Test Procedures and Test Results;- Functional Test sheets;- Completed Commissioning Check Lists;- Mechanical Reports;- Leak Test and Inerting Reports;- As-Built Drawings;- List of Modifications.

The Handover Dossier shall be produced and presented to the Owner when the commissioning team are

confident the plant is "Ready For Handover", all the start-up activities have been completed and the plantoperates trouble free for a defined period of time.

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4.0 COMMISSIONING OF SYSTEMS

4.1 Introduction

4.1.1 The essential steps to achieve plant completion are to define, prepare and carry out all pre-commissioningcommissioning and start-up activities by plant systems and sub-systems.

4.2 Plant Systems and Sub-Systems

The partition of a plant into systems and subsystems shall be a key preparation activity, see Section 3.3.1.The subsystems shall be defined so as to be as independent as possible, not too small, but of manageablesize, and exactly adapted to the start-up sequence.

4.3 Punch Lists

During pre-commissioning checks and tests, all discrepancies, damaged or missing equipment,

malfunctions, missing documents, etc., shall be recorded in the subsystem punch lists. These lists shall beupdated during the pre-commissioning operations, to indicate the precise status of each subsystem at theReady for Commissioning stage.

4.4 Pre-Commissioning and Commissioning

4.4.1 Scope of Work

In general the pre-commissioning and commissioning scope of work shall include but not be limited to:

- the dynamic verification of the elementary plant functions;- the on-line test of utilities and major equipment;

- activities to prepare for the introduction of oil, gas or feedstock to the plant.

4.4.2 The pre-commissioning and commissioning scope of work may be divided into four separate activities:

a) Preliminary Checks

The Preliminary Checks shall be the cross verification by the Commissioning Team that a Plantsystem is ready for pre-commissioning. They shall take place when a system reaches themechanical completion status, and consist of;

- a physical on site check of the installation,- a review of the Pre-Commissioning, Commissioning and Start-Up Manual.

The Preliminary Checks shall be carried out by each discipline and formalised by a specific report.

b) Functional Tests

These shall be live tests performed on each piece of equipment. For instrument and electricalitems refer to GES C.54, C.55 and C.56 for precise requirements.

The functional tests shall be carried out in accordance with technical specifications, the results being recorded on Functional Test Sheets.

c) Operational Tests

The operational tests shall consist of bringing the system into operation under conditions as closeas possible to normal, in order to live test the automated devices, controls, normal start up andshutdown sequences and monitor pressures, temperatures, vibration, and fluid tightness.

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Typical subsystems subject to an operational test shall be, fire water system, air compressors, power generation equipment, export pumps in recycle mode, process compressors in recycle (withair or nitrogen).

Every operational test shall be conducted in accordance with a test procedure which has beenapproved by the Owner.

d) Pre-Start-Up Activities

These shall be the specific activities required to prepare for the introduction of oil, gas orfeedstock.

- leak test at operating pressure;- drying-out;- inerting;- loading of chemicals;

- chemical cleaning.

These shall be covered by specific procedures and reports.

4.4.3 Field equipment and packages shall be equally subject to commissioning operations, irrespective of theamount of testing that may have taken place at the place of manufacture.

4.5 Start-Up

Since the start-up of utilities is considered a commissioning operation, the real start-up phase begins withthe introduction of the feedstock into the plant.

The start-up activities are therefore:

- introduction of oil, gas or feedstock;- bringing the plant into operation;- performance tests, to prove the plant and equipment design capacities, and products specifications.

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AND START-UP GUIDELINES Rev 0 1999 5.0 CHECK LIST FOR PRE-COMMISSIONING, COMMISSIONING AND START-UP ACTIVITIES

5.1 General

5.1.1 This check list includes, but is not a complete list of all pre-commissioning, commissioning and start-upactivities, arranged by major types of equipment. The Vendor/Contractor shall submit a detailed listspecific to each individual item of plant.

5.1.2 The following lists the general activities applied to all equipment that shall be carried out during pre-commissioning:

a) remove rust inhibitor, oil, grease, etc. used to preserve equipment during construction and fill withthe specified lubricants;

b) check the condition of grease in lubricated bearings;

c) clear the operating area free of debris, tools and extraneous materials. Accessways shall be open

for emergency operation;

d) scaffolding shall be removed from areas needed for pre-commissioning access;

e) finish grading, paving, guardrail and fence installation, shall be complete;

f) first loading of any chemical installed.

5.2 Check Lists

5.2.1 Piping PCom Com S-Up

a) Restore piping, after pressure test, as required by drawings andspecifications, perform P&ID inspection on all piping. X

b) Alleviate any excess piping stresses that may be imposed on pipes,compressors, pump and equipment flanges.

X

c) Check/provide and install all strainers, both temporary and permanent,spectacle blinds and temporary blanks.

X

d) Set or check pipe anchors, guides, spring hangers and supports afterhydrotest. Provide cold and hot setting data.

X

e) Remove as necessary and transport all safety valves to and from testfacilities.

X

f) Test, set, and tag all safety valves, then carry out safety valves finalinstallation.

X

g) Carry out internal leak test of shutdown valves. X

h) Supply locking devices for block valves and safety equipment. X

i) Install car seals or locking devices on block valves and safetyequipment.

X

PCom Com S-Up

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AND START-UP GUIDELINES Rev 0 1999 j) Carry out piping water or air flushing operations. X

k) Perform chemical cleaning where applicable. X

l) Perform drying out where applicable. X

m) Carry out inert testing. X

n) Provide list and location of all blinds installed. X

o) Fill system with utility/process fluids. X

p) Check spring hangers, pipe anchors and guides in hot position. X X

5.2.2 Air Fin Coolers

a) Set and align fan and driver if applicable. Set V belts and check they

are antistatic if in hazardous area. Check fan blades pitch. Check fanring clearances. Check for any damage.

X

b) Check bearings for cleanliness and proper lubrication. X

c) Check satisfactory operation of louvres and variable pitch assembly. X

d) Check fan motor rotation. X

e) Start-up fans and check airflow, noise, vibrations, motor loading, and proper operation of autovariable fans.

X X

f) Run and recheck alignment. X

5.2.3 Pumps

a) Functionally check all subsystems such as lube oil and seal pipinghookup.

X

b) Check cold alignment of pump and driver. X

c) Carry out uncoupled run of motors and check bearing temperatures andvibration.

X

d) Check bearings for cleanliness and free movement; check bearinglubrication.

X

e) Check discharge dampers are correctly charged with nitrogen (if fitted- reciprocating pumps).

X

f) Check that plunger packing is correctly fitted (reciprocating pumps). Check seal (Centrifugal Pump).

X

g) Check seal piping and any water piping. XPCom Com S-Up

h) When pump is to be used for flushing, install temporary packing if permanent packing or mechanical seal is not suitable for flushing.

X

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AND START-UP GUIDELINES Rev 0 1999 i) Rotate pump manually, couple to driver and run pump onwater or flush fluid checking vibration, seal leakage, bearingtemperatures, oil condition, etc.

X X

j) Check hot alignment and dowel if necessary. X

k) Re-install mechanical seals or permanent packing after flushing. X

l) Check temporary strainers for cleanliness and replace same. X

m) Run pump on process fluid and repeat pump checks above plus performance check where possible.

X

5.2.4 Gas Turbines, Compressors and Expanders

a) Chemically clean equipment suction and interstage piping and lube/seal

oil piping, and inspect for cleanliness.

X

X

b) For gas turbines check cleanliness/operation of intake air filtration andfire/gas detection/extinguishing systems.

X

c) Fill and carry out flushing of lube and seal oil system until test screensand filters are clean; drain and refill with new oil as required to correctlevel. Check auxiliary/standby pump.

X

d) Check bearings/housings and seals for cleanliness. X

e) Pre-commission hydraulic oil system. X

f) Operationally check all subsystems such as lube and seal oil systems,fuel system, start air system, surge control system, etc as applicable.

X

g) Check cold alignment of driver and driven equipment. X

h) Run up driver uncoupled (except expanders) check overspeedshutdown. X

i) Couple driver to driven unit.

j) Run in compressor in recycle mode on air or inert gas. Check vibrationand operation etc.

X

X X

k) Check hot alignment.

l) Carry out comprehensive vibration check.

m) Check equipment noise level.

n) Run unit on stream on gas.

o) Stop unit and check hot alignment.

p) Conduct performance tests.

X

X X

X

PCom Com S-Upd

X

X

X

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5.2.5 Diesel Engines

a) Flush clean, check cleanliness of oil filters and fill lube oil system. X

b) Flush/check fuel oil system is clean including filters. X

c) Check cooling system is clean and functioning correctly. X

d) Check inlet air system is clean and starting system is functioning. X

e) Test run diesel engines and their accessories uncoupled. X

f) Drain lube oil system then refill with new oil, if required. X

g) Couple diesel engine to driven equipment. X

h) Test run coupled unit and verify operating parameters. X

i) Check hot alignment after operational test. X

j) Carry out noise measurement tests. X

k2Conduct performance test.

X X

5.2.6 HVAC Equipment

a) Check that fans and motors rotate manually and run freely. X

b) Check that anti-vibration mountings are correctly installed. X

c) Check that sealing compound of fire dampers is installed correctly. X

d) Check that linkage and blades of dampers operate correctly and freely. X

e) Check that damper actuators operate correctly. X

f) Check that airflow direction in preheaters is correct. X

g) Carry out ductwork leak tests. X

h) Energise and run unit. Test sequences and interlocks. Checkvibrations.

X

i) Carry out airflow and balancing tests. X

j) Control and adjust room temperatures and pressurisation. XPCom Com S-Upd

k) Conduct Performance Test. X X

5.2.7 Furnaces, Ductwork and Stacks

a) Chemically clean boiler tubes. X

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AND START-UP GUIDELINES Rev 0 1999 b) Empty hydrotest water from coil and air blow dry if necessary. X

c) Check inspect heater doors. X

d) Inspect explosion doors, inspect roof and flue duct seals. X

e) Inspect/test steam and air supplies to the furnace as applicable. X

f) Check mechanical operation of soot blowers, dampers and burnerlouvres.

X X

g) Check inspect air preheaters when installed. X

h) Prepare furnace and fuel systems for dry-out operation. Ensure tubesare vented adequately.

X

i) Apply smoke bomb test to check air tightness. X

j) Dry out the furnace following the Vendor/Contractor's procedure. X

k) After dry-out, clean stack and duct, open manholes and other openingsfor inspection. Check operation of dampers. Close stack and duct afterinspection.

X

l) Test run air supply fans, check for vibration. X

m) Introduce process fluid and check equipment performance. X X

5.2.8 Vessels - Towers, Reactors and Drums

a) Clean internally and carry out vessel inspection. X

b) Perform column tray leakage test and levelling adjustments as required. X

c) Issue to Vendor/Contractor written authority to close up each vessel. X

d) Properly close up all vessel internal manways and openings after finalinspection and after loading of chemicals, catalysts, etc. is completed,as applicable.

X

e) Cure and dry out castable linings. X

f) Carry out air blowing if required. X

PCom Com S-Upd

g) Carry out leak testing. X

h) Conduct run test and check performance where applicable and possible.

X X

5.2.9 Tankage

a) Hydrostatic test tank and internal piping, clean inside tank. X

b Carr out tank ins ection. Check external and internal X

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AND START-UP GUIDELINES Rev 0 1999 paintwork/lining. Check access to all valves and instrumentation.

c) Issue to Vendor/Contractor written authority to close up each tank. X

d) Close manways. X

e) Issue inspection record. X

f) Organise independent calibration of product tanks for custody transferwhere required by government regulations.

X

5.2.10 Lifting/Weighing Equipment

a) Fill lube and hydraulic oil systems of lifting equipment. X

b) Test lifting equipment in presence of Insurance Inspector orappropriate government authority.

X

c) Calibrate all solids weighing and measuring devices in their fieldinstalled operating positions. Show that equipment meets specifiedtolerance for accuracy over full range of operating conditions.

X

d) (As an exception to the above, Owner will arrange for independentcalibration of weight scales and product meters for custody transfer).

X

5.2.11 Fire Fighting Equipment

a) Check charge of all extinguishers without actual release. X

b) Check/test all fire and gas leak detectors. X

c) Function test C0 2/Halon/Other skids without actual release. X X

d) Carry out checks and tests on fire and gas detection systems. X

e) Carry out operational tests on fire extinguishing systems (DelugeSystem, Hydrants and Monitors).

X X

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