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Nasr Full Field Development Project Package2 ADMA OPCO

Commissioning
Engineering & Execution Plan

Nasr Full Field Development Project Package2

26th Feb. 2016

HYUNDAI HEAVY INDUSTRIES CO., LTD.

HYUNDAI
HEAVY INDUSTRIES CO., LTD.
Nasr Full Field Development Project Package2 ADMA OPCO

Contents

1. Introduction & Organization


2. Commissioning Engineering
3. Commissioning Execution
4. QA / QC
5. Construction Engineering
6. HHI Preservation work

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1. Introduction & Organization

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Nasr Full Field Development Project Package2 ADMA OPCO

1. PRECOMMISSIONIG & COMMISSIONING INTEGRATION ORGANIZATION


PRECOMMISSIONING & COMMISSIONING INTERGRATION ORGANIZATION

PROJECT MANAGER

S.I. Chang

COMMISSIONING
MANAGER

G.W.Kim

Coordinator of
Comm. and
Precomm.
S.U.Jeong

COMMISSIONING CONSTRUCTION
QM DEP'T PROCESS DEP'T HSE TEAM CONSTRUCTION 4
DEP'T ENG. DEP'T
Head Head Head Head
Head Head
S.B.Kang S.C.JUNG D.G.Ha J.Y.Kim J.T.Kim J.H.Pyun

PRE-
COMMISSIONING COMMISSIONING CONSTRUCTION
QA/ QC MANAGER HSE MANAGER COMMISSIOING
ENGINEERING MANAGER ENG. DEP'T
MANAGER
O.J.Jeon K.H.Joung N.C.Sung G.W.Kim J.Y.Lim S.U.Jeong

4
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Nasr Full Field Development Project Package2 ADMA OPCO

Onshore Commissioning Organization chart for NASR-2 Project


Head of Comm. Dep't
J.Y.Kim

Head of Comm. Dep't


G.W.Kim

PTW Coordinator Mech. Comm. Lead Engr E&I Comm. Lead Engr Engineering Coordinator

Mech. Comm. Engr Mech. Comm. Engr E&I Comm. Comm. Engr INST. Comm. Engr

Process Foreman Mechanical Foreman Electrical Foreman Instrument Foreman Telecom Foreman

Tech. Tech. Tech. Tech. Tech.


Tech. Tech. Tech. Tech. Tech.
Tech. Tech. Tech. Tech. Tech.
Tech. Tech.
Tech. Tech.
Tech. Tech.

Source MGR ENGR Foreman Tech. PTW Total


Comm.
E&I, T
Mech
Total

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2. Commissioning Engineering

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PROJECT SCOPE
Nasr Full Field OF WORK
Development Project Package2 ADMA OPCO

NASR FIELD EPCC CONTRACTS SCOPE OF WORK

PACKAGE 1 (NPCC) PACKAGE 2 (HHI SCOPE)

WHT 3- 9 Super Complex (NSGTP, NSSP & NSAP)


Infield Pipeline & MOL NSFL 1 and 2
Brownfield Modifications at USSC Manifold Tower Upper Deck
PDP at USSC
Subsea Power Cable(132kV)
Infield Cable (55Km)
PACKAGE 3 Substation(Das Island)
DAS Process Facility Modification Modification to Existing MFT, WHT1, WHT2
Onshore MOL Pipe
Gas Turbine Generator Package

Final commissioning for the entire NASR field and facilities performed by EPC Pkg-
2 with support Pkg-1, Pkg -2 and ADMA

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PROJECT SCOPE
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Development Project Package2 ADMA OPCO

COMPANY SPECIFICATIONS

AD177-NSG-G-SOW-00165 :
Scope of Work

AD177-NSG-G-PHY-00133 :
Precommissioning and Commissioning Philosophy

GDL 006 :
Guideline For Pre-commissioning, Commissioning And Handover Of
Projects

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ORGANIZATION CHART Project Package2
Nasr Full Field Development ADMA OPCO

HHI Commissioning Engineering Organization


COMM ENG'G TEAM LEADER
S.S. PARK
seong35@hhi.co.kr

COMM ENG'G TEAM


PROJECT COORDINATOR
KH Joung

SYSTEM Project Completion System HVAC


ELEC./ I&C
(Process/Mech/Safety) (ICAPS) (Outfitting Dept)

K. H. JOUNG D. H. OH S. W. KONG SH LEE


Leader khjoung@hhi.co.kr Leader thekey@hhi.co.kr Leader kongsw@hhi.co.kr Leader suho.lee@hhi.co.kr
202-1056 202-1069 202-1054 206-1254

M. K. HWANG S. W. CHUNG S. W. Kim


mkhwang@hhi.co.kr csw116@hhi.co.kr castleone@hhi.co.kr
202-4763 202-1528 202-1071

D.K. SHIN Thomas E. H. Jung


dongkishin@hhi.co.kr thomasraymond@hhi.co.kr jrabbit829@hhi.co.kr
202-1096 202-1080 202-1071

Soe Hut Thura Htun J.H. Yang


soe_htut@hhi.co.kr thtun@hhi.co.kr jhyang@hhi.co.kr
202-1096 202-1080 202-1054

V. DIVAKAR
divakar15@hhi.co.kr
202-1069

K. ASTAYA
astaya76@hhi.co.kr
202-1096

B. Ghosal
bamdeb.ghosal@hhi.co.kr
202-1096

A. J. KIM
aejeongislove@hhi.co.kr
202-1096

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PROJECT SCOPE
Nasr Full Field OF WORK
Development Project Package2 ADMA OPCO

COMMISSIONING WORKING SEQUENCES (as Per Contact Spec)

Construction / MC Pre-Commissioning Commissioning

Platform Reinstate all equipment removed Perform Pre-Start-up Activities


Fabrication Completion for MC testing - Leak Testing
Onshore Structure Installation Preparation punch list - Drying
Completion Cleaning (Mechanical/Chemical) - Purging / Inerting
Flushing and where necessary - Blowdown Test Ready for
chemical cleaning of all pipework Complete B Punch Items Start up
Mechanical Completion and equipment Complete System OTPs Certificate
Completion A Punch List Pressure leak test
Items Cold loop test
All Equipment set on Loading all first fill chemicals
foundations and Aligned and fluids
All Equipment Cleaned Vessel Internal check Final Commissioning
All Pipework flushed and dried Final equipment cold alignment
All systems re-instated with Complete A punch Items
items Introducing hydrocarbon gas
All electrical, instrumentation, Establishing the flare and drain
navigation aids and telecomm. Pressuring the total plant with
Systems installed, checked and
Provisional
Hydrocarbon
calibrated. Bringing the total plant to full
Acceptance
All offshore hook-up ship loose operational status Certificate
items trial-fitted Operational function tests and
performance test on all
hydrocarbon equip.& system
Final commissioning arising
from the test

Note : ICAPS (OPERCOM) : Precommissioning = Mechanical Completion


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DELIVERABLES & PLAN Project Package2
Nasr Full Field Development ADMA OPCO

Commissioning Preparation Sequence (Commissioning Engineering)

Prepare initial Startup Sequence


General
Define Systems and Subsystems
Define Sub-Systems Indicate Subsystem contents on P&ID`s/SLD`s
Mark-Up Drawings Identify Spares and Special Tools required

Pre-commissioning Populate the Precom database (tasks)

Define Tasks Produce Task Lists by Subsystem


Collate all Precommissioning documentation
Issue Status Index Prepare Subsystem Precommissioning Dossiers
Prepare Dossiers Prepare Precom Planning and Resource levels

Populate the Com database (tasks)

Commissioning Produce Task Lists by Subsystem


Develop Test Procedures (OTP and PVP)
Define Tasks
Collate all Commissioning documentation
Issue Technical Data Base Prepare Subsystem Commissioning Dossiers
Dossiers Preparation Identify and Organize all required Temporaries
Arrange Vendor/Specialist assistance as required
Prepare Comm Planning and Resource levels

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DELIVERABLES & PLAN Project Package2
Nasr Full Field Development ADMA OPCO

Precommissioning & Commissioning Deliverables


Comm'g Start
P&ID (IFA) P&ID (AFD) MC Start Sail Away

2015 2016 2017 2018


4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6
Engineering Deliverables Review (P&ID, SLD, etc)

Commissioning General Procedures


(PCS control, Precom & Comm exection strategy etc)

System - Subsystem Register


System Boundary Mark-up Drawing
(P&ID, SLD, Telecom, PCS, F&G etc)

PCS Database
- Status Index
- Technical Database

Precomm'g Procedures
(Hydrotest, Flushing, Leak test, preservation etc)
Operational Test Procedures
Comm'g Procedures
(N2/He leak, Energisation, Black Start etc.)

Precom'g Dossier
Comm'g Dossier

Vendor Mobilisation Plan

Performance Test Procedure

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DELIVERABLES & PLAN Project Package2
Nasr Full Field Development ADMA OPCO

Precommissioning & Commissioning Deliverables


Precommissioning Deliverables Commissioning Deliverables

Precommissioning Execution Plan Commissioning Execution Plan

Flushing Procedure for Piping System - Subsystem Register

System Boundary Mark-up Drawing


Hydro / Pneumatic Test Procedure
(P&ID, SLD, Telecom, PCS, F&G etc)

Chemical Cleaning & Oil Flushing Procedure Commissioning Procedures

Gross Air Leak Test Procedure Electrical Energization Procedures

Calibration Procedure N2/He Leak Test Procedure

Bolt Tightening Procedure Performance Test Procedure

Piping Hydro Test Packs Preservation Procedure

Punch Control Procedure RFSU Dossiers Preparation

RFC Dossiers Preparation


Operating Manual

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DELIVERABLES & PLAN Project Package2
Nasr Full Field Development ADMA OPCO

Commissioning Deliverables Present Status

No DESCRITPION Doc No STATUS

GENERAL PROCEDUES

1 COMMISSIONING STRATEGY & EXECUTION PLAN AD220-705-G-00511 Preparing Next revision

2 ICAPS CONTROL & MANAGEMENT PROCEDURE AD220-705-G-00512 Ready to Issue IFA Rev.

CORE TEST PLAN Need Clarification Meeting with COMPANY b


3 AD220-705-G-00513
(PC&C SCOPE OF WORK BY LOCATION & SUBSYSTEM) efore next revision issuing.

4 OTP'S LIST AND OBJECTIVE (ACCEPTANCE CRITERIA) AD220-705-G-00541 IFCC issued (on 12nd Feb.)

5 PLANT START-UP SEQUENCE AD220-705-G-00514 Preparing

MARKUP DRAWINGS

1 SYSTEM & SUBSYSTEM REGISTER AD220-705-G-00520 Preparing Next Revision

2 SYSTEM BOUNDARY MARKUP ON P&ID AD220-705-G-00521 Ready to Issue IFA Rev.

3 SYSTEM BOUNDARY MARKUP ON SLD AD220-705-G-00522 Preparing Next Revision

4 SYSTEM BOUNDARY MARKUP ON ICSS AD220-705-G-00523 Preparing Next Revision

5 SYSTEM BOUNDARY MARKUP ON F&G AD220-705-G-00524 Preparing Next Revision

6 SYSTEM BOUNDARY MARKUP ON MATERIAL HANDLING AD220-705-G-00525 Preparing Next Revision

7 SYSTEM BOUNDARY MARKUP ON SAFETY PLAN AD220-705-G-00526 Preparing Next Revision

8 SYSTEM BOUNDARY MARKUP ON TELECOM AD220-705-G-00527 Preparing Next Revision

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SYSTEM & SUBSYSTEM
Nasr Full Field Development DEMARCATION
Project Package2 AND NUMBERING ADMA OPCO

NASR PROJECT System & Subsystem Definition Rule

1. NO CONTRACT REQUIREMENT FOR System & Subsystem


Applied HHI Experience and TOTAL GS EXP 501 rule for System Code

2. MANY PLATFORMS
Applied the Sector Code (added Area Code and Location Column)

3. DEMARCATION RULE
As per General Rule, HHI Standard (refer to the next slide and sample)

GTP P/F (Sector Code 711), Firewater System (System No 01)


- 711 01 01 : Firewater pump A
- 711 01 02 : Firewater pump A
- 711 01 03 : Firewater Ring main & distribution
- 711 01 04 : Deluge Distribution for main deck

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COMMISSIONING PROCEDURE
Nasr Full Field Development Project Package2 ADMA OPCO

COMMISSIONING ENGINEERING EXPERIENCE (LAST 10 YEARS)

Project Work Volume


Client Type Methodology PCS
Name (OTP No)

MHN FPU TOTAL FPU OPERCOM 76 ea (Topside) ICAPS


MHN TLP TOTAL TLP OPERCOM 39 ea ICAPS
BCP Carigali Hess F/P 35 ea HHIPCS
GOLIAT ENI FPSO 81 ea ProCoSys
DSO Chevron F/P 68 ea Zenator
OFON TOTAL F/P OPERCOM 42 ea ICAPS
BONGKOT PTTP F/P OPERCOM 38 ea ICAPS
BARZAN RasGas F/P 85 ea HHIPCS
SHWE DAEWOO F/P 145 ea HHIPCS
USAN TOTAL FPSO OPERCOM 116 ea ICAPS
USGIF ADMA F/P 85 ea HHIPCS

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PROJECT COMPLETION
Nasr Full Field Development SYSTEM (ICAPS)
Project Package2 ADMA OPCO

DATABASE PREPARATION
PRECOM COMM
Line DOSSIER DOSSIER
List DOCUMENTS DOCUMENTS

Equip.
List

ICAPS
OPERCOM
CERTIFICATES
Cable
List
STATUS INDEX :
PRECOMMISSIONING PUNCHLIST
Instr.
scope of work DATABASE
List
Technical dBase :
Other COMMISSIONING
Lists scope of work PROGRESS
REPORTS

Subsystem
List
PRECOM/COMM
FEEDBACK
PLANNING
SUS REPORT
STATUS

ENGINEERING PREPARATION EXECUTION


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PROJECT COMPLETION
Nasr Full Field Development SYSTEM (ICAPS)
Project Package2 ADMA OPCO

PROJECT/ COMMISSIONING TASKS


COUNTRY SUBPROJECT

COMMISSIONING EXECUTION
OPERATIONAL
1) Preliminary Checks ZONE SUBSYSTEMS TESTS
(OTS)
2) Functional Tests
3) Operating Tests
4) Pre-Start Up Activities PROCESS
FUNCTIONS
5) Commissioning Dossiers PRESTART-UP
6) Handover to Operations ACTIVITIES
(PSA)

AREA PRELIMINARY
FUNCTIONAL
BASIC CHECKS
TESTS
FUNCTIONS (PRC)
(FTS)

ITEMPACK
ITEM PACKS TESTS
(PIP)
PRECOMMISSIONING EXECUTION

1) Conformity Checks CONFORMITY


2) Static Tests SUBAREA ITEMS CHECKS
(CCK)
3) Piping Static Tests
4) Precommissioning Dossiers Piping line STATIC
5) Handover to Commissioning Cable TESTS

Equipment (STS)

Instrument
ENGINEERING PRECOMMISSIONING TASKS
EQUIPMENT LISTS

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PROJECT COMPLETION
Nasr Full Field Development SYSTEM
Project Package2 ADMA OPCO

A. Project Completion System Reference

HHI PCS ICAPS


HHI Developed Software TOTAL Projects (OPERCOM)
Reference Projects Reference Projects
- Rong Doi Project - Yadana Project
- BP Plutonio Project - Moho Bilondo Project
- EGP 3A Project - OFON Project
- East Area Project - AKPO Project
- USGIF Project, - USAN Project
- SHWE Project - Bongkot Project
- Barzan Project - MHN TLP/FPU Project (on-going)
- BCP Project (on-going)

Win PCS ProCoSys Zenator


Reference Projects ENI Projects Chevron Projects
- Sakhalin Project Reference Project Reference Project
- Kizomba A Project - Goliat Project - DSO Project (on-going)
- Kizomba B Project - Gorgon Project (By Company)

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PROJECT COMPLETION
Nasr Full Field Development SYSTEM (ICAPS)
Project Package2 ADMA OPCO

ITR INDEX LIST

Mech.
Elec. Inst. Tele (Incl. HVAC,
Piping)

CCK 27 26 45 231
Precommissioning STS 26 10 5 14
PIP N/A N/A N/A 11
PRC 1 1 1 1
FTS 26 11 20 N/A
Commissioning
OTS 1 1 1 26
PVP N/A N/A N/A 4

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3. Commissioning Execution Team

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Nasr Full Field Development Project Package2 ADMA OPCO

Onshore Commissioning Schedule for NASR-2 Project


Comm'g 2017 2018
Module Remark
Period 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8

17.5/31 Temporary Equip. S/A : Apr. 24


SP ~
18.4/9 ICSS Package System Commissioning
Shore Power : 31.May.

17.8/8
GTP ~
ICSS Package System Commissioning
18.3/16
Shore Power : 8.Aug.

17.9/5
EDG Test :
AP ~ Feb. 10
ICSS Package System Commissioning
18.6/12
Shore Power : 5.Sep.

17.10/13
MFT ~ MCC Package System Commissioning
18.4/3
Shore Power : 13.Oct.

17.10/26 S/A : Apr. 20


PDP ~ MCC Package System Commissioning
18.4/5
Shore Power : 26.Oct.

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Module Lay out(Preliminary) at ULSAN Yard

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Onshore Commissioning Execution Strategy

Hand a Priority Sub Shore Power Supply Commissioning will start as per
system List to --> SWBD test --> priority sub-system List and Hot
Construction Team in UPS/Battery Charger loop test will also start
order to early start --> ICSS system test
simultaneously.
Commissioning.

MC E&I Commissioning Package Commissioning & Hot Loop test

Mechanical Completion work

Shore Power Supply SWBD on & System Test.

Preparation Works UPS/Battery Charger


for Commissioning
Start.
ICSS SAT DCS/ESD/F&G Hot Loop test in progress

Package Equipment Performance Test


Control Power Supply

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Dry Air Supply to Platform (AP, GTP, SP)


PG
AIR DRYER

capacity : 60L/min
Dew Point : -38C
Accommodation
MANIFOLD Platform


HHI Yard Air
AIR DRYER
pressure:7bar, capacity : 60L/min
Dewpoint :-38C Dew Point : -38C PG

Gas

Treatment
AIR DRYER
MANIFOLD Platform
capacity : 60L/min
Dew Point : -38C

No. Description Specification


Isolation Valve 2" PG
Separation
Isolation Valve 2"
Platform
Isolation Valve 2"
Isolation Drain Valve 1"
MANIFOLD
Isolation Valve 2"
Air Dryer 60L/min, -38C
Manifold
Isolation valve 1"
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Diesel Oil Supply to Platform ( GTP, SP & AP )



Accommodation
D.O Tank Platform
21m3

Gas

Treatment
D.O Tank
21m3 Platform

No. Description Specification


Discharge Line 1-1/4" Separation
Diesel Tank 21m3 Platform
Diesel Pump skid 15m3/h
Filling Connector 2"
Fine Mesh Strainer 40mesh
Tank Rolly

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Cooling Sea water Supply to Platform


Chemical
Tank (tote) 8"x10" Gas

Treatment
Platform

8"x10" No. Description Specification



Sea water pump 500m3/h, 11bar
Strainer 40mesh
Seawater supply line 10"
Quay Side Seawater overboard line 10"
Flow control line 3"
Chemical dosing pump
Chemical
Tank (tote) 8"x10"

Separation
Platform



8"x10"

Quay Side
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Fresh Water Supply to Deluge System


Gas
TEMPORARY FRESH TEMPORARY FRESH
Treatment
WATER TANK 30 m3 WATER TANK 30 m3
Platform

12
No. Description Specification
Supply Pump 450m3/h
Screen mesh 40mesh
HHI Yard Fresh Water
Isolation Valve(2") 2"
Isolation Valve(2") 2"
Isolation Valve(2") 2"
Temp. water tank 30m3


TEMPORARY FRESH TEMPORARY FRESH
WATER TANK 30 m3 WATER TANK 30 m3


Separation
12 Platform

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PDP Commissioning Procedure & test activities

132KV
SWGR HHI shall check and test all interlocks and
inter-trips within and between the various
33KV switchboards.
SWGR

11KV 415V UPS/Battery


LER
SWGR SWGR Charger
Shore Power
Transformer
Supply to SWGR

1. F&G
2. PA/GA
3. CCTV
Pedestal Crane HVAC Units Mechanical
Load test System test Handling Equip. test

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Shore Power Supply to GTP, Accomodation Platform

132KV SWGR

33KV SWGR Gas

Treatment
11KV SWGR
Platform
11KV ETR.

11KV SWGR
M/G
5MVA
11KV Accommodation
50HZ 11KV ETR.
Platform

POWER S TATION
13.8KV, 60HZ
T e m p orary S hore P ow er H ouse

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Shore Power Supply Scheme( SP, PDP & MFT)

6.6KV SWGR
Separation
6.6KV TR.
Platform

6.6KV ETR.

132KV SWGR

C 33KV SWGR Power


Distribution
11KV SWGR Platform
T/R T/R
11kV/6.6K V 11kV/415V
5M VA 5M VA C 415V SWGR

M/G
5MVA
11KV
11KV TR.
50HZ
Manifold

415V SWGR Tower


POWER S TATION
13.8KV, 60HZ -Upper Deck
T e m p orary S hore P ow er H ouse

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4. QA/QC

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Nasr Full Field Development Project Package2 ADMA OPCO

CONTENTS

1. Quality Management Dep't Organization

2. OPERCOM Instroduction

3. Completion Activities

4. PRECOMM/COMM Dossiers

5. PUNCHLIST

6. PRECOM/COMM Execution flow

7. ICAPS DATABASE
- APPENDIX 1, 2 and 3

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1. Quality Management Dep't Organization


DIRECTOR
T. R. Lee

QM Department
G. Mgr S. B. Kang

QA/QC Manager
G. Mgr O. J. Jeon
MC Room
Operator TBA

Quality Assurance Shop Inspection Site Inspection Material Inspection N.D.E.


Lead J. H. Shon Lead D. B. Kim Lead G. S. Jin Lead Y.G. Seong Lead J. S. Seok
Q.I J. I. Cho Q.I S. C. Oh Q.I J. S. Yoon Q.I Y. H. Kim Q.I D. R. Park
Q.I J. S. Kim Q.I J. N. Park Q.I S. R. Lee Q.I J. U. Lee Q.I T. H. Kim
Q.I M. S. Yang Q.I H. H. Im Q.I H. J. Kim Q.I Y. S. Lee
Q.I T. U. Bak Q.I K. N. Ahn
Q.I C. Jeong Q.I J. S. Kwon
Q.I S. C. Park
Q.I Y. R. Kim

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2. OPERCOM Instroduction
OPERCOM : Trademark, property of Company, designating the methodolory
of the Pre-commissioning and Commissioning activities described through
a set of four specifications : "4 Specifications is organised as follow :"
EXP 101
GS EP EXP 101 : Pre-comm. and Comm. Specification
GS EP EXP 103 : Pre-comm. and Comm. Engineering EXP 103
GS EP EXP 105 : Pre-commissioning Execution
GS EP EXP 107 : Commissioning Execution EXP 105 EXP 107

ICAPS : (Integrated Commissioning And Progress Syatem) Software, property


of Company. Designates the tool to be used during the Pre-commissioning
and commissioning activities in order to support and implement the
OPERCOM methodology
- ICAPS covers the preparation and execution of Pre-commissioning and
commissioning activities, as per the OPERCOM methodology.
- OPERCOM and ICAPS shall be the tools to reach a smooth and progressive
transfer of the plant to the Operator, Safely, in line with plans, schedule
and with full confidence.
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2. OPERCOM Instroduction
2.1 SUBSYSYSTEM Definition

Precommissioning & Commissioning shall be organized by Sub-Systems,


when Construction is working by trades, Areas and Units

An OPERCOM SubSystem is a subdivision of the installation that performs


a given operational function with no or little interference from the other
parts of the plant.

The preliminary SubSystem breakdown is done during the Basic Engineering.


It is finalized right at the beginning of the detailed engineering,
before any process engineering activities.
It is built in parallel with the Start-Up Sequence.

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3. Completion Activities
3.1 Completion Activities Definition

C om pletion A ctivities = Precom m issioning + C om m issioning


They are all the verifications to be performed after construction & QA/QC
activities, just before the plant is brought on line, to ensure that every
piece of equipment operates as per design.
of the plant.

-. Precom m issioning = Static Tests

-. C om m issioning = D ynam ic Tests

Some control(dimension of structure, quality of welding & materials,.)


are QA/QC activities, not PCC

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3. Completion Activities
3.2 OERCOM Terminology

ITEM : Smallest piece of equipment requiring one precommissioning task.

ITEMPACK : Group of ITEMS subject to a specific precommissioning


task Such as Piping Hydrotest.

BASIC FUNCTION (BF) :


Smallest equipment subject to a commissioning task.
A BF is a group of ITEMS that performs an elementary function of the plant.
only instrument, electrical and telecom BF's are subject to commissioning
FUNCTIONAL TESTS.
Ex : Switchboard, transfoemer, heater, process control loop, pump, vessel,.

PROCESS FUNCTION : Group of BF's subject to a Pre-Start-Up Activity.

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Nasr Full Field Development Project Package2 ADMA OPCO

3. Completion Activities
3.3 Commissioning Phases :
PCC ENGINEERING

- GENERAL OPERCOM PREPAREATION


SubSystem List, Start-up Sequence, MarkedUp Drawing
- PRECOMMISSIONING PREPARATION
Status Index, Precommissioning Dossiers & Procedure. Precom Tasks
- COMMISSIONING PREPARATION
Technical Database(TDB), Commissioning Dossiers & Procedure, Comm. Tasks

PCC EXECUTION

- PRECOMMISSIONING EXECUTION
Conformity Checks, Static Tests, Piping Tests Precom Dossier, RFC
- COMMISSIONING EXECUTION
Preliminary Checks, Functional Test, Operating Tests, Comm. Dossier
Pre-StartUp Actvities, Handover to Operations

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HEAVY INDUSTRIES CO., LTD.
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3. Completion Activities
3.4 Precommissioning Execution
Precommissioning shall be organized by SubSystems.
De-energized tasks performed on equipment items / itemPacks :
-. Conformity Checks(CCK) :
Systematic checks on each equipment item to verify item condition, quality,
compliance with drawings/specifications, vendor instructions, safety rules
standards and good practice.
-. Static Tests(STS) :
Cold testing performed on selected critical items to ensure quality, ie.
calibration, alignment, cable continuity,
-. Piping Tasks(PIP) :
Cleaning, gross air leak and pressure testing.
A Ready-For-Commissioning Certificate(RFCC) :
is issued at the end of precommissioning for each SubSystem.

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HEAVY INDUSTRIES CO., LTD.
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3. Completion Activities
3.5 Commissioning Execution
Commissioning shall be organized by SubSystems.
Energized tasks performed on equipment Basic / Process Functions.
-. Preliminary Checks(PRC) :
-. Site and documentation=checks
Precommissioning StaticbyTests
each discipline involved.
-. Functinal Tests(FTS) :
Hot test of each instrument, electrical and telecom basic function.
-. Operational Tests(OTP) :
Actual run-in and on-line tests of utility and major equipment.
-. Pre-StartUp Activities(PVV) :
-. Precommissioning = Static
Preparation works for startUp suchTests
as inerting, leak testing, drying-out,
chemical filling and cleaning.

A Ready-For-StartUp Certificate(RFSUC) :
is issued at the end of Commissioning for each SubSystem.

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HEAVY INDUSTRIES CO., LTD.
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4. Pre-comm. & Comm. Dossiers


4.1 Standard Precommissioning dossiers :
Ready for Commissioning Certificate.
Residual Punch List.
Descrition, Mark-up and As-Built drawings.
Status
-. Preliminary
Index. Checks :
Check = Static Tests
Lists and Test sheets.
-. Precommissioning
Vendor
-. Functinal
reports,
Tests
specific
: procedures and tests.
List of modifications.

4.2 Special Piping dossiers(Cleaning, HT, Leak test packs) :

Mark-up drawing showing pack limits.


Status Index, List of lines.
Procedures, OPERCOM datasheets.
Calibration certificate and test recorder charts

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HEAVY INDUSTRIES CO., LTD.
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4. PRECOMM/COMM Dossiers
4.3 Standard Commissioning dossiers :
Commissioning dossiers are arranged by SubSystems.
#. Each dossier should contain :

Start-Up Handover Certificates.


-. Preliminary
Residual List. :
PunchChecks
Descrition, Mark-up and
-. Precommissioning Static Tests
= Aqs-Built drawings.
-. Functinal
Technical Tests :
Database.
Check Lists and Test sheets.
Vendor reports, specific procedures and tests.
(Incl. OTP/PSA).
List of modifications.

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HEAVY INDUSTRIES CO., LTD.
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5. PUNCH LIST
5.1 Punch List Processing :
All design defects (Discrepancies, Malfunctions, Damaged
or Missing equipment, missing document,.) should be recorded
into the PUNCHLIST DATABASE.
The
-. Preliminary
way to record,
Checks
monitor
: and clear punchlist items shall be
accurately = PUNCHLIST
defined in the
-. Precommissioning Static TestsPROCEDURE.
The
-. Functinal
quality ofTests
this procedure
: is of paramount importance due to
the major impact it has on project cost and time delays.

The remaining punch lists for FAT shall be input into the ICAPS by CTR

Punch list items shall be classified as Category A, B, and C


- PL 'A' : Cleared prior to RFC(Ready for Commissioning) of the S-System
- PL 'B' : Cleared prior to RFSU(Ready for Start-Up) of the SubSystem
- PL 'C' : Cleared prior to Handover to CPY the final milestone.

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HEAVY INDUSTRIES CO., LTD.
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6. PRECOMM/COMM Execution Flow


6.1 Precommissioning Flow

Installation Completion Documents from ICAPS DWG/Documents


1) Task Sheet : "A" Sheet -P&ID / SLD
(Marked-up Drawings)
RFCC signed by HHI & CPY 2) Status Index by Discipline -Hydro Test PKG
QM/Commissioning Manager -.Structural -Wiring DWG
-.Mechanical
-.Piping
Yes -.E & I
Cat. "A" Punch -.Architecture
-.Etc.
No

RFCC signed by HHI & CPY


QM/Commissioning Manager PUNCH LIST

Hand over to Commissioning RFCC Form


Ready for commissioning Cer't RFC Dossier
Team

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HEAVY INDUSTRIES CO., LTD.
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6. PRECOMM/COMM Execution Flow


6.2 Commissioning Flow

Preliminary Check(MC) Documents from ICAPS DWG/Documents


Pre-commissioning
CCR(Comm & Check Report)
: "B" Sheet - RFC Dossier

Commissioning
FTS(Functional Test Sheets) - P&ID/ SLD
- Energization
- Dynamic Test : Dynamic Test - Loop Drawing
- Equipment Running-in - SLD
- Pre-startup Activities

Yes
Cat. "B" Punch

No
PUNCH LIST
Commissioning dossier signed
by CPY and CTR Comm. Mgr.

RFSUC Form - RFSU Dossier


Hand over to Start-up Team
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7. ICAPSDATABASE
ENGINEERING PREPARATION EXECUTION
Line List PRECOM
COMM
DOSSIER
DOSSIER
DOCUMENT
E/Q List
OPERCOM
CERTIFICATES
Cable List

Instr. List PUNCHLIST


DATABASE

Other List ICAPS PROGRESS


REPORTS

Subsystem
List PRECOM/COM
M
PLANNING
FEEDBACK
SUS REPORT
STATUS

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HEAVY INDUSTRIES CO., LTD.
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7. ICAPSDATABASE
COMMISSIONING TASKS
COUNTRY PROJECT/
SUBPROJECT

OPERATIONAL
ZONE SUBSYSTEMS
TESTS(OTS)

PROCESS
PRESTART-UP
FUNCTIONS
ACTIVITIES(PSA)

AREA PRELIMINARY
CHECKS(PRC)
FUNCTIONAL
BASIC FUNCTIONS TESTS(FTS)

ITEM PACKS ITEMPACK


TEST(PIP)

SUBAREA
ITEMS CONFORMITY
CHECKS(CCK)

Piping line
STATIC
Cable TESTS(STS)
Equipment
Instrument

ENGINEERING PRECOMMISSIONING TASKS


EQUIPMENT LISTS
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HEAVY INDUSTRIES CO., LTD.
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APPENDIX 1
READY FOR COMMISSIONING CERTIFICATE (RFCC) When all PRE-COMMISSIONING
inspections are completed within
sub-system or system with minor punches
NASR PKG 2 PROJECT
not affecting on the pre-commissioning,
Document No.
READY FOR COMMISSIONING CERTIFICATE SUPPORT MATRIX

Worksite Issued Date


RFCC shall be issued and accepted by HHI
WSUL
SUB SYSTEM No. QM and COMPANY after the PRE-
SUB SYSTEM DESCRIPTION COMMISSIONING review.
1. This Support Matrix, when comprehensively completed and signed shall be attached to the Contract
ready for Commissioning Certificate which shall be processed in accordance with the term and The PRE-COMMISSIONING Dossier will
condition of the Contract.
DISCIPLINE REPRESENTATIVE ACKNOWLEDGEMENT
contain but not limited to
CONTRACTOR COMPANY

DISCIPLINE HHI. PRECOM. PRECOM COMM Status Index



DATE / DATE / DATE /
NAME
SIGN.
NAME SIGN.
NAME SIGN. Status of any Punch List
ELECTRICAL As-Built Drawings
Opercom Pre-com Check Sheets and
INSTRUMENT
Test Sheets.
MECHANICAL
The accepted RFCC by both parties allows
PIPING & VESSEL
the commissioning activities.
OTHER

PUNCH LIST ITEMS TYPE DEFINITION as per PUNCH LIST PROCEDURE

A B C

A: To be cleared before RFCC.


B: To be cleared before RFSU.
C: Can be cleared after RFSU.

NAME DATE SIGNATURE

HHI Construction Manager

HHI Commissioning. Manager

COMPANY Construction Manager

COMPANY CSL

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HEAVY INDUSTRIES CO., LTD.
Nasr Full Field Development Project Package2 ADMA OPCO

APPENDIX 2
When all COMMISSIONING inspections
are completed within sub-system or
system with minor punches not affecting
on the pre-commissioning,

RFSUC shall be issued, and accepted by


HHI COMMISSIONING Manager and
COMPANY (Commissioning & Start-up
Manager) after COMMISSIONING.

The COMMISSIONING Dossier will contain


but not limited to

Ready for Start-Up Certificate


Status of any Punch List
As-Built Drawings
Functional Test Sheets (FTS)
Operational Test Procedure (OTP)
Piping and Vessel Preparation (PVP)

The accepted RFSUC by both parties


allows the Start-Up activities.

HYUNDAI
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HEAVY INDUSTRIES CO., LTD.
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APPENDIX 3
NASR PKG 2 PROJECT NASR PKG 2 PROJECT
PRE-COMMISSIONING DOSSIER INDEX COMMISSIONING DOSSIER INDEX
Sub System No Description TICK
Sub System No Description : TICK
AS
AS APPROPRIATE
APPROPRIATE
1. COMMISSIONING CERTIFICATE
1. PRE-COMMISSIONING CERTIFICATE 1.1 Ready For Start-up Certificate (RFSU)
1.1 READY FOR COMMISSIONING CERTIFICATE (RFCC)
2. CONSOLIDATED PUNCH LIST
1.2 STATUS INDEX SUMMARY
2.1 Punch List Report by Discipline
1.3 PUNCH LIST SUMMARY REPORT (Sorted by Discipline)

2. SUB-SYSTEM BOUNDARY MARK-UP 3. SUB-SYSTEM BOUNDARY MARK-UP


3.1 Sub-system Boundary Mark-Up Draw ings
2.1 SUB-SYSTEM BOUNDARY MARK-UP DRAWINGS

3. PIPING & VESSEL INDEX 4. PRELIMINARY CHECK SHEETS


3.1 PIPING SUB-SYSTEM STATUS INDEX AND TEST-PACK STATUS INDEX 4.1 Piping & Vessels
4.2 Electrical
3.2 MARKED UP PIPING SUB-SYSTEM P&IDS "As Pre-Commissioned"
4.3 Instrumentation
3.3 PIPNG CHECK LIST AND TEST SHEETS 4.4 Mechanical
3.4 DETAIL PUNCH LIST REPORT 4.5 Telecom.
4. ELECTRICAL INDEX 5. ELECTRICAL FUNCTIONAL TESTS
4.1 ELECTRICAL SUB-SYSTEM STATUS INDEX 5.1 Technical Data Base
4.2 MARKED UP ELECT. SINGLE LINE DIAGRAM, INTERCONNECTION DIAGRAMS, 5.2 Functional Test Sheets
GENERAL ARRANGEMENT DRAWING FOR PANEL, CABLE LIST "As Precommissioned" 5.3 Single Line Diagram
4.3 OPERCOM TASK SHEETS 5.4 Distribution Board Diagram
4.4 DETAIL PUNCH LIST REPORT 5.5 Mark-Up Draw ings "As Commissioned"
5.6 Cable List "As Commissioned"
5. INSTRUMENTATION INDEX
5.1 INSTRUMENT SUB-SYSTEM STATUS INDEX 6. INSTRUMENTATION FUNCTIONAL TESTS
5.2 MARKED UP INST. ICSS DRAWINGS AND ESD, F&G & CAUSE EFFECT DIAGRAMS ,CABLE LIST "As 6.1 Technical Data Base
Precommissioned" [INSTRUMENT LIST. LAYOUT. WIRING DIAGRAM FOR JB,TRANSMITTER AND 6.2 Functional Test Sheets
MARSHALLING. TSLD for COLD LOOP TEST] [Layout, Wiring Diagram, Logic Diagram, Interconnection Diagram, Cause & effect Chart.]
5.3 HOOK-UP DWG, DATA SHEETS AND CALIBRATION CERTIFICATES "As Precommissioned" 6.3 Loop Draw ings "As Commissioned"
5.4 OPERCOM TASK SHEETS 6.4 Cable List "As Commissioned"
5.5 DETAIL PUNCH LIST REPORT
7. TELECOM FUNCTIONAL TESTS
6. MECHANICAL INDEX 7.1 Technical Data Base
6.1 MECHANICAL SUB-SYSTEM STATUS INDEX 7.2 Functional Test Sheets
6.2 MECHANICAL PRESERVATION & LUBRICATION SCHEDULE / RECORDS 7.3 Reference Draw ings
7.4 Mark-Up Draw ings "As Commissioned"
6.3 OPERCOM TASK SHEETS
6.4 DETAIL PUNCH LIST REPORT 8. OPERATIONAL TEST PROCEDURE
8.1 Operational Test Status
7. OTHER DISCIPLINE INDEX
8.2 Mechanical Pre-Test / Record Sheets
7.1 DISCIPLINE SUB-SYSTEM STATUS INDEX
8.3 OTP Certificate
7.2 SUB-SYSTEM MARKED UP DRAWINGS (P&ID, SLDS, etc.) 8.4 OTP
7.3 OPERCOM TASK SHEETS
7.4 DETAIL PUNCH LIST REPORT 9. PIPING & VESSEL PREPARATIONS
9.1 PVP Leak Test
8. VENDOR DOCUMENTATION 9.2 PVP Inerting
8.1 FAT REPORT 9.3 PVP Drying Out
8.2 INSPECTION REPORT 9.4 PVP Chemical Loading
8.3 GENERAL ARRANGEMENT DRAWING "As Precommissioned"
8.4 CERTIFICATES 10. VENDOR REPORTS
8.5 VENDOR TASK SHEETS 10.1 SAT Report (Where applicable)
8.6 VENDOR P&ID / SLD "As Precommissioned" 10.2 Commissioning & Start-up Spare Parts & Special Tools List
10.3 Vendor Daily Commissioning Report
8.7 INSTRUMENT / EQUIPMENT LIST. WIRING DIAGRAM FOR JB , TRANSMITTER
10.4 Red Line Mark-up Vendor Draw ings
AND MARSHALLING. 10.5 ICSS Softw are / Hardw are FDS & ICSS IFAT Report
8.8 CONSOLIDATED PUNCH LIST
11. MODIFICATIONS
9. MODIFICATIONS 11.1 Modification Record Sheets
9.1 MODIFICATION RECORD SHEETS 11.2 Red Line Mark-up (P&ID, SLD)
9.2 RED LINE MARK-UP 11.3 Additional Tests / Checks

Note : 12. MISCELLANEOUS


12.1 "As Commissioned" Blind List
12.2 Lubrication Schedule
12.3 Material Safety Data Sheet
12.4 Preservation Status
12.5 Temporary Equipment List for Commissioning

HYUNDAI
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HEAVY INDUSTRIES CO., LTD.
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5. Construction Engineering

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HEAVY INDUSTRIES CO., LTD.
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JOINT NUMBERING

ITR & TAG

TRAINING
- THEORY TRAINING
- PRACTICAL TRAINING

CHECK POINT

BOLTING

SAFETY

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HEAVY INDUSTRIES CO., LTD.
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JOINT NUMBERING

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ITR ( Inspection Test Record) & TAG

14B01-GACA-UEC-TP-0001
GACA00-0E-09277.05:JT003

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THEORY TRAINING

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PRACTICAL TRAINING

- Manual Torque
- Hydraulic Torque
- Tensioning
- Hub clamp or Compact flange
- Safety

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HELMET STICKER / ID CARD

- Name
- Trainee No. (Cert. No.)
- Issue date
- Categories

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CHECK POINT

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CHECK POINT (FLANGE)

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CHECK POINT (GASKET)

Missing
Graphite

If graphite is removed from the gasket then the product should not be used.
The area of the gasket where the graphite has been removed could become a leak path or
may alter the product seating characteristics.

MISSING FILLER IS NOT ACCEPTABLE

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HEAVY INDUSTRIES CO., LTD.
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CHECK POINT (TORQUE)


2 3 THREADS ABOVE NUT

ALIGNMENT

SQUARE FLANGES

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HEAVY INDUSTRIES CO., LTD.
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CHECK POINT (TENSION)


50% Bolt Tensioning 100% Bolt Tensioning

Make sure the Stud extends a minimum of one bolt diameter

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BOLTING ACTIVITY

Hydraulic
Bolt Tensioning

Hand & Hydraulic


Torque Wrench

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BOLTING ACTIVITY (TORQUE)


1 1
8 5

4 3 4 3
1
12 5
6 7
8 9
2 2
4 3

1 - 30% Cross 10 7
2 - 60% Cross
3 - 100% Cross 6 11
2
4 - 100% Round (until nut stops rotate)

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HEAVY INDUSTRIES CO., LTD.
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BOLTING ACTIVITY (TENSION)


Pressure 'A (1ST Pass) Pressure 'B (2nd Pass)
Applied Oil Pressure

Three Times Three Times


* * * Residual
* * * Bolt Load

1st Set 2nd Set

* For Ring Type Joints, hold


Pressure longer to achieve
Gasket Compression

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SAFETY

Pinch Points
Backing Spanner Pinch Point
fully engaged

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SAFETY

Always wear full PPE

Cordon off work areas posting suitable warning notices

Do not exceed the stated maximum working pressures


for the equipment

Never stand in line with the Bolt Axis.

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6. HHI Preservation work

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Contents
* Preservation work scope in HHI
* Preservation Work Flow Chart in HHI

1. Protection work
2. Anti corrosion work
3. Lubricate equipment for preservation
5. N2 Charging work
6. Energizing anti condensation heater
7. Check insulation resistance of motor
8. Check battery voltage and recharge
9. Passivation work
10. Document management system in HHI
11. Sample of preservation weekly activity report (BCP)

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HEAVY INDUSTRIES CO., LTD.
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* Preservation work scope in HHI

<Preservation scope by each PHASE>

Storage Installation M/C Commission


Received Receiving
Inspection
Material
Preservation team Commissioning team
handling team

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* Preservation work Flow Chart in HHI

Matrial Purchasing Material Handling


Department Engineering Dep't Vendor QM Cons't Eng'g Dep't + Relevant Dep'ts Commissioning Dep't Cons't Dep't
Dep't Dep't

Initial Check/Confirm
Preservation Conditon of Equipment Maintenance preservation / De-preservation / Re-preservation
for transportation Check Initial Preservation

Work Scope

Equipment Design Vendor Equipment Storage location Receiving Preservation Preservation M/C & Preservation for
and PO issue Selection Fabrication Selection Inspection duing Storage after Installation Commissioning Sail away

VEIR IFC ATIO N O F


S U B M IS S IO N O F EQ U IP M EN T S TO R AG E R EC EIVIN G P R ES ER VATIO N B AS ED O N P R O C ED U R E
P R O JEC T B ID D IN G
VEN D O R D ATA M AN AG EM EN T IN S P EC TIO N AN D R EC O M M EN D ATIO N FR O M VEN D O R
S P EC IFIC ATIO N S
FAB R IC ATIO N AN D P R O TEC TIO N O F R EP O R T AN Y FAU LT
S P EC IFIC ATIO N S VEN D O R S ELEC TIO N M AIN TEN AN C E P R ES ER VATIO N / D E-P R ES ER VATIO N / R E-P R ES ER VATIO N
TR AN S P O R TATIO N EQ U IP M EN T(B O X ) TO C P Y /HHI
ACTION U N P AC KIN G / R EP AC KIN G
G ETHER IN G VEN D O R D ELIVER Y EQ U IP M EN T IN ITIAL
FO R R EC EIVIN G P O R FO R P R ES ER VATIO N C O N S U M AB LE
D O C U M EN T M AN AG EM EN T P R ES ER VATIO N
IN S P EC ITO N
ATTEN D IN G R EC EIVIN G
A/S
IN S P EC TIO N
FAT

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1. Protection work
One of basis preservation. Cover equipment with Vinyl, Plywood, Pvc Cover,
Rubber etc to protect equipment from rain, rust, welding scatter, paint and any
contamination as well as physical damage.
1-1) Sample of protection work for equipment

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HEAVY INDUSTRIES CO., LTD.
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1-2)Cooler Pin Tube Cover

1-3) various Gauge Cover

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1-4)Level Gauge Cover

1-5) nonferrous metal Tube Cover

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2. Anti corrosion work


Apply Denso Tape, Inhibitor(VpCI), Silica-gel(desiccant) and Grease to
exposed machined surface including electrical panels and J/B to avoid
formation of rust and condensate.
2-1) Sample of Denso Tape work

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2-2) Inhibitor installation work


a) Sample of VpCI(Vaper Corrosion Inhibitor) installation work

Install VPCI-132 for Install VPCI-105 for


electrical panel inside electrical panel inside

Sponge Type Emitter Type

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2-3) Silica gel installation work


a) Sample of Silica gel installation work

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2-4) Grease Wire Rope for Winch, Main Crane Slewing Gear
a) Sample of grease work

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HEAVY INDUSTRIES CO., LTD.
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3. Lubricate equipment for preservation


Normally, Supplier drain the lubrication oil from equipment before
shipment
to avoid over flow during the transportation. Refill the equipment a little
bit for preservation if applicable.

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HEAVY INDUSTRIES CO., LTD.
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4. Shaft rotation work


Rotate Shaft to protect shaft deflection. (in GOLIAT FPSO case, 2+1/4 turn,
once per 4 week

a) Sample of rotating work

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HEAVY INDUSTRIES CO., LTD.
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5. N2 Charging work (1)


Charge Vessel, Drum and Tank with N2 to protect inside corrosion if
applicable
Check leakage and pressure (normally, 0.5 bar)

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HEAVY INDUSTRIES CO., LTD.
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5. N2 Charging work (2)


Charge storage container with N2 for long term preservation

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HEAVY INDUSTRIES CO., LTD.
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6. Energizing
. anti condensation heater
Power up space heater to avoid formation of condensation.

a) Sample of anti condensation heater work

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HEAVY INDUSTRIES CO., LTD.
Nasr Full Field Development Project Package2 ADMA OPCO

7. Check insulation resistance of motor


Measure insulation resistance to ensure no current leakage from poor
preservation

a) Sample of measuring insulation resistance(in GOLIAT FPSO case, once per 8 week)

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8. Check battery voltage and recharge


Measure voltage and recharge battery if necessary

a) Sample of measuring voltage and recharging batteries

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7-1. Sample form(Insulation test) from HHI

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7-2. Sample form(Insulation test) from previous project

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9. Passivation work
Remove surface corrosion

a) Sample of passivation work

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10. Document management system (ICAPS)

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10-1. Document management system (ICAPS)

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10-2. Document management system (ICAPS)

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11. Sample of preservation weekly activity report(BCP)

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