080036 DZ PQ 001 R3 Pre Commissioning & Commissioning Execution Plan

PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN ARABIAN CHLOR VINYL PROJECT

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-DZ-PQ-001 ACVC ID CODE 080036-DZ-PQ-001 Sheet 1 of 45

Issue 3

Pre-Commissioning & Commissioning Execution Plan

EPC CONTRACTOR:

3

For Construction

K.S.K

Y.T.Y

D.G.S

C.W.Y

18-Jan-2012

2

For Construction

K.S.K

Y.T.Y

D.G.S

C.W.Y

05-Dec-2011

1

For Construction

K.S.K

Y.T.Y

D.G.S

C.W.Y

18-Nov-2011

0

For Construction

K.S.K

Y.T.Y

D.G.S

C.W.Y

30-Sep-2011

A

For Approval

K.S.K

Y.T.Y

D.G.S

C.W.Y

03-Aug-2011

Issue

DESCRIPTION

PREP’D

CHK’D

APPR’D

APPR’D

Date

This Document is the property of ACV and is lent without consideration other than the Borrower’s agreement that it shall not reproduced, copied, lent, or dispos ed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by pate nts.


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Table of Contents

1.

2.

General ............................................................................................................................................ 6 1.1.

Introduction ............................................................................................................................ 6

1.2.

Objectives .............................................................................................................................. 6

1.3.

Pre-commissioning & Commissioning activities ..................................................................... 6

1.4.

Units of measurement/language ............................................................................................ 7

1.5.

Standards and specifications ................................................................................................. 7

1.6.

Key project documents .......................................................................................................... 8

Plant overview................................................................................................................................. 8 2.1.

CA plant ................................................................................................................................. 9

2.2

EDC plant ............................................................................................................................. 13

2.3

Utilities ................................................................................................................................. 14

3

System definition .......................................................................................................................... 17

4

Organization. ................................................................................................................................. 17 4.1

Introduction .......................................................................................................................... 17

4.2

Preparation step (documentation step) ................................................................................ 18

4.3

Pre-commissioning step. ...................................................................................................... 20

4.4

Commissioning and start up step ........................................................................................ 21

5

Construction & pre-commissioning............................................................................................ 23

6

Mechanical completion ................................................................................................................ 25

7

Commissioning ............................................................................................................................. 26 7.1

Introduction .......................................................................................................................... 26



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7.2

Schedule .............................................................................................................................. 28

7.3

Work permit control .............................................................................................................. 28

7.4

Lock-out and tag-out ............................................................................................................ 28

7.5

Vendor commissioning activities .......................................................................................... 28

7.6

Spare parts, temporary equipment and consumables ......................................................... 29

7.7

Tightness test....................................................................................................................... 29

7.8

Drying out / inerting of lines and equipments ....................................................................... 31

7.9

System by system commissioning ....................................................................................... 32

7.10 Plant initial start up(electrolyzer energizing) ........................................................................ 36 8

Ready For Start Up (RFSU) .......................................................................................................... 38

9

Start up .......................................................................................................................................... 39

10

Testing ........................................................................................................................................... 39 10.1 Introduction .......................................................................................................................... 39 10.2 Number of tests .................................................................................................................... 39 10.3 Performance test.................................................................................................................. 40 10.4 Reliability Test ...................................................................................................................... 42

11

Hand-over ...................................................................................................................................... 43

12

Punch and Punch Control............................................................................................................ 43

13

Vendor’s training at site ............................................................................................................... 44 13.1 Vendor’s technology support. .............................................................................................. 44 13.2 Vendor’s training at site ....................................................................................................... 44

14

Communication............................................................................................................................. 44 14.1

Radio-communication .......................................................................................................... 44

14.2

Mobile phone ....................................................................................................................... 44



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15

Reporting ....................................................................................................................................... 44

16

HSE management ......................................................................................................................... 45

Attachments .......................................................................................................................................... 45 Attachment 1: Pre-commissioning / commissioning & start up schedule Attachment 2: Pre-commissioning / commissioning process and activities Attachment 3: Organisation for preparation phase Attachment 4: Organisation for pre-commissioning phase Attachment 5: Organisation for commissioning phase Attachment 6: Completion process flow chart Attachment 7: Start up flow chart Attachment 8: EDC Plant Drying & Start-Up Plan Attachment 9: List of Preparation Plan of Pre-commissioning &Commissioning Documents and Activities



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Revision Index

Rev

Date

Description

3

18-Jan-12

Revision as per SAMAPCO comments(TR-OH-DH-5406, dated on 09-Jan-12)

2

05-Dec-11

Revision as per SAMAPCO comments(TR-OH-DH-6088, dated on 04-Dec-11)

1

18-Nov-11

Revision as per SAMAPCO comments(TR-OH-DH-4884, dated on 27-Oct-11)

0

30-Sep-11

Revision as per SAMAPCO comments(TR-OH-DH-4531, dated on 12-Sep-11)

A

03-Aug-11

Issue for Approval



1. 1.1.

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General Introduction The Arabian Chlor Vinyl Plant in the Kingdom of Saudi Arabia, comprising a plant and associated facilities at Jubail Industrial City including a caustic soda and ethylene dichloride plant and associated infrastructure, along with utilities and off-sites, with the capacity to process 250,000 MTPA(100%con. Basis) of caustic soda and 300,000 MTPA of ethylene dichloride. This pre-commissioning and commissioning execution plan covers overall pre-commissioning and commissioning execution works and provides basic information to SAMAPCO. It will be used as guidance for the further development of the functional work. This commissioning execution plan describes the organization, philosophy and plans for precommissioning, commissioning, ready for initial start up (electrolyzer energizing), RFSU, start up, testing, and handover. This plan is to be read together with other plans and procedures which are written for the project. This plan is a “live” document and will be subject to further periodic review by SAMAPCO and a commissioning works to reflect project requirement changes or situations.

1.2.

Objectives The objectives of this project are to design, construct and commission the facilities and reach steady state operation within the agreed project schedule and budget, and deliver CA/EDC facilities to SAMAPCO that are mechanically complete and operationally proven within the project specifications. Contractual target dates are; Plant Initial Acceptance date : 02 Dec. 2012 Taking-Over date

: 02 Jan. 2013

For this purpose, the commissioning organization will carry out the following activities.

1.3.

Pre-commissioning & Commissioning activities (1)

Preparation of documentation - This includes management documents and procedures, check lists and system definitions.

(2) Pre-commissioning of the facilities – before Mechanical Completion (MC), pre-commissioning will be performed by each system as per approved procedures. (3) Commissioning of the utility - Each utility will be commissioned and energized according to the This Document is the property of ACV and is lent without consideration other than the Borrower’s agreement that it shall not reproduced, copied, lent, or dispos ed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by pate nts.


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approved commissioning procedures. Completion of commissioning and energizing of utilities shall be done before MC date.

(4) Once utilities are energized and process systems have been dried and inerted with nitrogen, commissioning team will carry out the following.  Pre start up safety review (PSSR)  Ready for initial start up and operation which allows energizing of the electrolyzer.  Ready for start up, which means the design rate operation of the process systems in which dynamic tuning of controllers is performed and system functions checks are completed.  Start up – this phase includes initial operation and carrying out of the performance guarantee test by Contractor to demonstrate the performance characteristics. The plant have been achieved in accordance with the procedure outlined in contract, reliability operation test of the plant and all its components are assessed and analyzed.  Reliability test - this will follow after performance guarantee test. (5) Once all basic functions of a sub-system have been functionally tested and all relevant pre-start up activities for that sub-system are completed, the sub-system will be subject to an operational test wherever applicable. This operational test brings the equipment into operation under condition as close as possible to normal. The purpose of operational test is therefore to prove that the major equipment is mechanically sound, and that each sub-system, as a whole, is ready for normal operation. ESD tests will be performed. The operating test procedure will be developed during commissioning preparation phase and submitted to SAMAPCO for approval. (6) The Contractor will conduct performance testing in accordance with the contents of the contract. The performance test procedures will be developed by the Contractor and submitted to SAMAPCO for approval prior to conducting the tests. (7) Repair and/or corrective measures, both planned, as per agreed project schedules, and unplanned break down will be performed.

1.4.

Units of measurement/language Metric system shall be used as the unit of measurement and English language will be used on all official project documents.

1.5.

Standards and specifications In general, the pre-commissioning and commissioning works will be carried out in accordance with;  Arabian law  Royal Commission Environmental Regulations (RCER-2004)


PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN ARABIAN CHLOR VINYL PROJECT       

1.6.

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ASTM / ASME /API / TEMA (Tubular Exchanger Manufacturer's Association) AD-2000 Standard / EN/DIN Standard / UBC 1997 / SMACNA SAMAPCO project standards (SPCC-M-001-01, SPCC-G-006-02, SPCC-M-004/005/006, SPCC-A-003/004/0056) International Electrotechnical Commission (IEC) SPCC-E-001/E-001-04 National Fire Protection Association (NFPA) Contractor’s codes and working standards

Key project documents Key project documents to be used in conjunction with this pre-commissioning and commissioning execution plan are shown below.  Contract  Engineering procedure  SAMAPCO Specification  Construction execution plan  Project quality plan  Work permit approval system procedure  Document/equipment numbering system  Project HSE plan  Construction HSE plan  Coordination procedure

2.

Plant overview The Arabian Chlor Vinyl Project is to produce CA/EDC product in the Kingdom of Saudi Arabia, comprising a plant and associated facilities at Jubail Industrial City including a caustic soda and ethylene dichloride plant and associated infrastructure, along with utilities and offsite ,with capacity to process 250,000 MTPA (100% con. basis) of caustic soda and 300,000 MTPA of ethylene dichloride. The CA/EDC plant is designed to make chlorine and caustic soda from salt electrolysis process and EDC by react chlorine with ethylene. The plant consists of salt handling, brine treatment, electrolyzer, chlorine cooling, drying, compression, EDC reaction, EDC purification, H2 boiler system, demineralized water system, product storage tank, package items and others. In addition to these facilities, equipment for electric power, cooling water system, process water, instrument air, nitrogen storage and vaporization, sewage and waste water treatment, fire water supply are also provided.



2.1.

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CA plant

2.1.1. Salt storage and handling Raw salt will be received at site by trucks. Salt will be unloaded into the salt unloading hoppers. Salt from unloading hoppers will be transferred to salt storage through belt conveyor. Salt is fed to saturation pit where salt is dissolved using lean brine having a concentration of app. 205 gpl.

2.1.2. Primary brine system The CA Plant has a total cell-room production capacity of 768.8 MTPD NaOH 100% as 32% solution. The primary brine system is designed to produce polished brine containing less than 0.5 ppm of suspended solids. For satisfactory operation of membrane cell electrolyzer, ultra pure brine is a must. The primary brine system comprise of the following system: brine saturation, brine precipitation and Na2CO3 preparation, brine clarification, brine filtration (anthracite media), brine polishing

2.1.3. Secondary brine purification In order to warrant trouble-free operation of the membrane cells and a long service life of the membranes, the cells must be supplied with extremely pure brine. The calcium and magnesium content in the brine is not allow to exceed a maximum level, which is less than 20 ppb, as the deposition of these ions in the membrane affects its function and leads to an increased power consumption. Such low contents can be achieved in a proven technology by using ion exchange columns. The columns are filled with a cation exchange resin, with a very high selectivity for calcium, magnesium and strontium cations. The ion exchange resin absorbs calcium and magnesium ions present in the brine. Ion exchange nozzles ensure the resin remain in the columns.

2.1.4. Brine dechlorination The considerable amount of chlorine remaining dissolved in the anolyte, which requires dechloination unit before the lean brine can be recycled to the saturator. The dechlorination is carried out in two process steps. The first step is a Cl2 desorption under vacuum. In the second step the remaining free chlorine in the brine is chemically destroyed by means of sodium bisulphite(NaHSO3). Bisulphite solution is added in slight excess to ensure that no Cl2 escapes.

2.1.5. Chlorate Decomposition Electrochemical side reactions in the cell generate the chlorates. As the electrolyte recirculates, a chlorate decomposition unit is required to prevent the accumulation of NaClO3. This unit forms mainly chlorine from the chlorate and hydrochloric acid reaction.

2.1.6. Sulphate removal Amount of sulphates in brine keeps on accumulating and if not reduced then exceeds the maximum limit for the safe operation of the membrane plant. So part stream from the lean brine pump is sent to lean brine cooler where lean brine entering cools down and lean brine leaving the Nano filtration unit This Document is the property of ACV and is lent without consideration other than the Borrower’s agreement that it shall not reproduced, copied, lent, or dispos ed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by pate nts.


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gets heated from lean brine cooler. Brine enters a series of filter for removal of suspended particles. First filter is activated carbon filter and second one is lean brine filter. After filtration brine goes to the filter feed tank from where brine goes to sulphate removal system. The reject stream from the unit is then sent to gypsum precipitation tank where sulphate is converted into gypsum by addition of calcium chloride from CaCl2 tank. The gypsum thus formed is transferred to gypsum filter by gypsum filter pump. The filtered gypsum is transferred to B.L. The permeate lean brine from the sulphate removal system and filtrate from gypsum unit is sent back to brine saturators.

2.1.7. Cell room and electrolysis The cell room is designed to produce 768.8 MTPD NaOH 100% as 32% solution and chlorine using 8 electrolyzers containing 171 bipolar cell elements each +21 spare each,. The electrolyzers normally operate at a load of 16.32KA or 6kA/m2 to produce 768.8 MTPD NaOH 100% as 32% solution. The bipolar cells are capable of very fast load changes, which are only limited by maintaining a stable chlorine and hydrogen pressure. Pure brine having a concentration of 300-310gpl flows into the electrolyzer cells Each electrolyzer cells have two chambers. The anode chamber and cathode chambers of the cell are isolated from each other by the membrane. Cl2 is liberated at the anode surface and flow to the anolyte header with depleted brine. H2 is liberated at the cathode surface and flow to catholyte header with 32% NAOH

2.1.8. Chlorine treatment In order to improve the heat balance of the electrolysis process, the energy of chlorine from electrolyzers is recovered first against the brine system, then cooling water and finally chilled water. Chlorine leaving the cells is about 88℃ and about 200mbar and is saturated with water vapor. The chlorine gas is passed through chlorine recuperator(E12103) where it exchanges heat with polished brine. Chlorine is cooled down whereas polished brine is heated. Chlorine gas at about 65℃ then passes through Chlorine cooler I(E12104) where it is cooled to 45℃ using cooling water. The gas leaving cooler I is further cooled to 15℃ in chlorine cooler II (E12105) using chilled water. Protection of membranes against too low chlorine pressure is achieved by under pressure safety vessel (D12101), which is connected to chlorine waste air header. The control valve relieving the excess chlorine pressure to waste gas dechlorination is located between coolers I and II. Temperature controller on the outlet of CL2 gas stream from chlorine cooler II controls the chilling water flow to the cooler.



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The gas leaving the cooler II is then passed through the wet chlorine filter (F12101) to remove the entrained brine aerosol. Demineralized water is continuously added to the inlet stream to flush away any salt crystals that may have deposited on the surface of the filter candles and may increase pressure drop. Part of the stream emerging from wet chlorine filter is withdrawn and sent to HCL synthesis unit as per requirement. The moist chlorine gas coming from the wet chlorine filter is dried in chlorine drying tower by means of 98% sulphuric acid to meet final moisture content of about 10ppm wt%. The chlorine leaving the drying tower flows to the chlorine compressor via a dry chlorine filter to remove entrained H2SO4 droplets.

2.1.9. Chlorine compression Dry Cl2 gas from dry chlorine filter enters suction side of Cl2 compressor at around 1.02bar(a) and 15℃ and is compressed to about 5 bar(a) and 45℃ in a three stage chlorine compression unit. After every compression stage, the compressed chlorine is cooled to prevent excessive outlet gas temperature by chilled water. The compressed chlorine is transferred to EDC plant.

2.1.10. Waste gas dechlorination The waste gas dechlorination unit serves as a safety system and removes chlorine and traces of HCl from the waste gases drawn from various parts of the plant. All chlorine bearing waste streams from the plant are led to the waste gas dechlorination system, where it is rendered free of chlorine in three stages by absorbing the chlorine in caustic soda solution. The absorption leads to the formation of sodium hypochlorite (NaOCl). The first two stages are designed with an ejector each whereas the third stage consists of a final absorber. The bleaching lye produced by the waste gas unit is collected in the bleaching lye tanks. It is then pumped to anolyte system by bleaching lye pumps.Here, NaOCL can be decomposed with HCL to NaCL and Chlorine. Chlorine will be recovered back into the chlorine system.

2.1.11. Cell work shop A cell work shop meets the requirements to assemble and dissemble the cell elements and for all manipulations necessary in the cell room

2.1.12. Rectifier transformer system Required amount of electricity at required voltage is supplied to the electrolyzers through transformerrectifier. Each electrolyzer is connected to one rectifier. Two rectifiers are connected to one transformer. Switches are provided for isolation of each electrolyzer. Thus there are 8 rectifiers and 4 transformers.



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2.1.13

Polarization Rectifier Each electrolyzer is supplied with a polarization rectifier, connected to the bus bars between switches. The polarization rectifier feeds a small amount of current to the electrolyzer to prevent damage to cathode coating in presence of chlorine. Such situation arises especially in case of shutdown. A diode prevents reverse current flow into the rectifier when the main rectifier is running.

2.1.14

Caustic concentration/ Storage tank The caustic concentration unit is designed to handle 768.8 MTPD NaOH100% as 32% solution production from electrolyzer. 32% caustic leaves the electrolyzer through an overflow pipe into the Catholyte Header along with hydrogen. Separation of H2 and Catholyte takes place in the Catholyte Header The Catholyte (32% NaOH) flows under gravity at approx. 88°C to the Catholyte Tank and transferred to the caustic concentration unit 32% caustic soda is concentrated to 50% in the caustic evaporation package unit by steam produced in the H2 boiler system. This unit is based on an optimization of investment and operation costs considering the following aspects; •Using heat recuperation of vapour, product and steam condensate to lower the steam consumtion. •Capacity of quick capacity changes. •Using special materials to increase corrosion resistance of those parts in contact with caustic soda. The caustic soda at 50% by wt. of concentration is received from the concentration unit and stored in the NaOH 50% day tank (TK13301 A/B) with a volume of 1100m3 each. The tank is located within a dike, designed to hold the content of the tank. Safety interlocks are provided to stop the feed into tank upon high liquid level and to stop transfer pumps on low level signal. From TK 13301A/B, 50% caustic is pumped to the NaOH bulk storage tank (TK35001) with a volume of 19000m3.

2.1.15

Hydrogen treatment The hydrogen cooling system is designed to handle a hydrogen load corresponding to 768 MTPD caustic soda (100%) production from electrolyzer. The system consists of the treatment section, where cooling and filtering of the gas is done, a condensate collection system and the hydrogen stack. Hydrogen gas leaving the cells is at a pressure



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of about 220 mbarg and a temperature of about 88℃. The gas is saturated with water vapors at these condition and is cooled to around 45℃ by cooling water in the hydrogen cooler, where most of water vapor condenses. The cooled gas is passed through hydrogen filter to remove mist and NaOH aerosols. Most of hydrogen gas feed to the boiler system as a fuel and a part of the gas to the HCl synthesis unit as per requirement. 2.1.16

HCl synthesis and storage This unit is designed for the production of 86MTPD of HCl 100% as 32% solution. The HCl synthesis system consists of HCl synthesis unit with scrubber column and two HCl storage tanks with transfer pumps.

2.1.17

Waste water treatment (neutralization) Waste water from process buildings are collected in pits / sumps in various process areas and pumped via pit pumps or routed via trenches to the waste water pits for chemical treatment. The waste water unit is designed to treat process effluents from the plant and to send them after PH adjustment and free chlorine removal to outside for disposal.

2.2

EDC plant

2.2.1

The process plant consists of 3 units.  Direct chlorination unit,  EDC purification,  EDC drying and waste water stripping. Direct chlorination Chlorine reacts with ethylene directly to make ethylene dichloride. The reaction is carried out in a recycle reactor which consists of the U-shaped reaction loop and the EDC vapors drum which is installed on top of the reaction loop. Reaction takes places in the upper part of the loop’s riser. In this process the required chlorine is drawn into the reactor with the ejector J21001 which is operated with a driving stream of circulation EDC. The ejector is designed in a way to ensure that the required chlorine flow is brought into the system at partial load conditions that means with reduced driving stream. Ethylene is dissolved physically in EDC in the lower part of the riser section of the reaction loop R21001. Even at partial load conditions the difference in density between the riser and the down comer section of the reaction loop ensures a constant flow of the reaction medium.

2.2.2

EDC distillation In order to achieve sales grade EDC quality, reduction of byproducts formed by side reactions in the direct chlorination process is required. To remove these components, which mainly consist of high



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boiling compounds 1.1.2-trichloroethane or 1-bromo-2-chloro-ethane, EDC is purified with two distillation columns:  EDC column system  Vacuum column system 2.2.3

EDC drying, waste water stripping and incineration This unit serves the following three purposes:  Drying of EDC (operation mode 1)  Waste water stripping (operation mode 2)  Disposal of process waste gas and waste liquid Dry EDC is required for the initial filling of equipment like vessels, filters and columns of the EDC Plant before start up of the plant. Additionally, dry EDC is required for removing moisture inside of the plant. The second application for the stripper column T27001 is the removal of EDC from contaminated surface water. This water is collected in several pits located inside the plant area The waste water enters the waste water stripper, where EDC and other steam volatile organic components are stripped off from water by heat input through reboiler. The unit is operated only discontinuously. It can be brought into service whenever it is necessary. Furthermore, the incineration package unit PK27001 is assigned. The incineration system is used for the disposal of all continuous process waste gases and non-continuous waste gases (e. g. from collecting drums system, equipment shutdown, maintenance) containing chlorinated hydrocarbons, as well as liquid chlorinated waste by-products.

2.2.4

Flare One low-pressure flare system is installed. The flare is the ignitable vent type. During normal operation, small operational intermittent releases will be vented through the flare stack. During emergency condition, the flare will self ignite to properly dispose any emergency releases.

2.2.5

Truck loading The plant includes a truck loading facilities for send-out 50% NAOH, 32% HCL and 78% H2SO4. Each loading bay is fitted with an articulated liquid loading arm.

2.3

Utilities

2.3.1

Steam & condensate system Steam will be generated as MP steam at steam boiler package to match the overall demand of both MP and LP steam users. A portion of the MP steam will be letdown and desuperheated to LP steam to balance the LP steam system demand. LP steam is also produced from MP condensate and blow down. All steam condensate recovered back and recycled.



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2.3.2

Cooling water system The closed cooling water circuit provides cooling water to the various users in the CA/EDC plant and associated utilities, and returns warm cooling water from the users to the cooling water exchanger (E4302A~H) which is installed at the outside of the plant via a set of cooling water circulation pumps in ISBL. The warm cooling water is cooled through the exchanger by sea water that is cooed by the cooling tower in the neighbor ALWAHA plant.

2.3.3

Chilled water system The chilled water circuit provides chilled water to the various users in the CA/EDC plant, and is also used to provide cooling to the safety shower water. Return water from users is chilled against refrigerant from the refrigeration unit. The circuit comprises of chilled water supply and return headers, chilled water supply (TK43501) and return tank (TK43502), circulation pumps (P43501A/B), water chiller (E43501) and chemical dosing package (PK43501).

2.3.4

Drinking water system Potable water from off-plot is treated to produce drinking quality water to supply drinking water fountains, safety showers and eye wash stations. Water is continuously circulated from the safety shower buffer tank (TK41201) through a drinking water treatment package (PK41101) around a ring main and back into the tank.

2.3.5

Process water system The process water distribution system will be supplied with potable water received from Royal Commission (RC). The water is subsequently distributed to produce demineralised water and to provide water for various process users and utility stations throughout the plant.

2.3.6

Demineralised water system The demineralised water plant will be designed to produce water of a high enough quality, which is distributed to deaerator for production of boiler feed water, the CA and EDC process units and auxiliary plants.

2.3.7

Fire water system The process water from OSBL will be used as firewater to fill the storage tank (TK49601). A looped underground firewater distribution system shall be provided for all areas of the plant. The plant will maintain a minimum quantity of fire water on site sufficiently to supply the maximum fire water demand for a specified period according to the basis of design safety philosophy. Above ground fire water piping is constructed of carbon steel. The fire water main ring is to be buried in order to minimize risk of damage from collision or explosion. 3 fire water pump P-49602A/B/C (1



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electrical and 2 diesel) and 2 fire water jockey pump P-49601A/B were installed. 2.3.8

Boiler feed water system To provide BFW to steam boiler (PK41801AB), incinerator (PK27001) and desuperheater (E41807), BFW is prepared in deaerator (D14804) with demineralised water which is preheated by condensate.

2.3.9

Instrument air system Compressed air is dried in desiccant dryer package (PK46002), to meet instrument air quality. Instrument air from PK46002 is distributed to users via the instrument air receiver (D46004).

2.3.10

Plant air system Compressed air (plant air) is generated by 2 air compressor units in the package (PK46001A/B), which operates in a duty and a standby arrangement. Compressed air is distributed to users via air receiver (D46002). Emergency air receiver (D46005) is dedicated to provide plant air to the emergency caustic tank (D12604) under upset conditions.

2.3.11

Nitrogen system A supply of gaseous nitrogen (LP nitrogen) is available at the OSBL plant battery limit via a pipeline from an external supplier. Nitrogen is supplied between 6.0 and 10.0 Bar from OSBL and is distributed to various users across the CA/EDC plant and associated utilities. Pressure may be letdown locally according to requirements of the individual users. If it is not available from external supplier, emergency nitrogen can be supplied by the liquid nitrogen package unit (PK44002), composed of a standard vertical storage drum, loaded from road tankers, associated with ambient air vaporizers.

2.3.12

Refrigeration system The refrigerant is used to cool the overhead vapor stream from the EDC column in the EDC column chiller in order to recover EDC, and to provide the cooling duty required by the chilled water system. Refrigerant is also used in the EDC vent condenser, where liquid EDC is recovered from tank vents and returned to storage. The remaining chilled vapor is routed to incineration system.

2.3.13

Fuel gas system Fuel gas is supplied to the OSBL boundary from the neighboring PP plant via a fuel gas header. Fuel gas is mainly required by the EDC incinerator located in the ISBL. It is used at start up and to meet heat input requirements during normal operation. Fuel gas shall first pass through knock-out drum (D41501) to remove any slugs of particles from the fuel gas supply. A cyclone separator (S41501) and filters (F41501A/B) are provided for removal of fine particles from the fuel gas supply.

2.3.14

Electric power system The Plant receives power from the PEA substation. Battery limit is the bus bar connection to the existing Sahara 230kV GIS Bay.



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Supply system is incoming: 230 kV, 3 phases, 3wire, 60 Hz, and 63 kA for 1 second. Two feeders from the existing Sahara 230kV GIS Bay feed power to the two (2)-230/34.5kV transformers via underground cables. The two transformers which shall have on-load tap changing capability will transform the 230kV voltage to 34.5 kV to supply power to the double -ended, indoor, air insulated 34.5kV switchgear located in the main substation The 34.5 kV switchgear is to feed power to the two (2)-34.5/4.16kV transformers which will transform the 34.5kV voltage to 4.16kV to supply power to all distribution transformers which will step down voltage to the utilization levels of 4.16kv and 0.48kv.

The 34.5 kV switchgear is also to feed power to the four (4) -34.5kV/544.4V rectifier transformers which will transform 34.5kV voltage to 544.4V voltage to supply power to the eight (8) rectifiers which will convert AC voltage to DC voltage. An emergency diesel generator is provided to start automatically and supply electric power to certain critical equipment in the event of failure of the power supplies from PEA Substation. An uninterruptible power supply (UPS) will be provided to safety critical systems.

3

System definition Designation for separate system/sub-system shall be given in order to increase the accuracy and expedition of the commissioning of each step and be marked up on P&ID. The purpose of this designation is to define the systems that will be used for the Project. These systems will be used as the basis to facilitate progressive completion of construction, precommissioning, Mechanical Completion, commissioning and RFSU of the Contract Plant. Designation for separate system/sub-system shall be completed by the commissioning team (responsible for executing pre-commissioning and commissioning). These system definitions will be detailed in a separate procedure.  System definition (080036-MZ-SD-001)

4 4.1

Organization. Introduction The Contractor shall approach step by step with careful preparations by expert on each step because this plant is a newly built CA, EDC plant which is composed of facilities which are extremely toxic and



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explosive. The Contractor will select key personnel who have experience on commissioning and operation of CA, EDC facilities with minimum five years and others who will assist the key personnel shall be trained by the key personnel. In addition, key personnel such as commissioning manager and discipline leaders shall participate in the project from the preparation step, whereby the continuity of tasks shall be secured and each step shall be transferred smoothly to next step. During the pre-commissioning, commissioning, start up and testing of the plant, an integrated commissioning team will be organized with SAMAPCO personnel if required. During commissioning, SAMAPCO’s operators shall work under Contractor supervision, but maintenance staff will only witness during Contractor’s worker do the job. Punch control team shall be organized for the control of the punch. That team shall be managed under site manager’s direction and supported by commissioning team. The timing of the joining of SAMAPCO’s personnel to the commissioning team will be based upon the staffing plan and the organization chart which will be jointly developed by the SAMAPCO and the Contractor. The operation of the Plant up to achievement of Initial Acceptance as per Contract shall be carried out by Contractor under his sole responsibility and at his expense. After reliability test operation, systems shall be completed and turned over to SAMAPCO under project manager’s direction. For the execution of the project, the organization shall be divided into three steps. Commissioning will be performed with suitable organization and manpower for each step.   

4.2

Preparation (documentation) Pre-commissioning Commissioning and start up

Preparation step (documentation step) This phase where a series of preparatory jobs will be executed includes;  Establishment of the commissioning team and set-up of master schedule with respect to the overall process  Employment and development of the organization for the commissioning project  Self-training for the commissioning staff related to process design concept and equipment



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 Development of manuals and procedures for pre-commissioning, commissioning, start up, performance test, initial operation.  System definitions, including marked up drawings. All equipment, tags, cables etc. should be allocated to a system or sub-system.  Development of system work packs for both construction and commissioning activities.  Development of specific discipline based on pre-commissioning check sheets. Key personnel will be assigned with appropriate duties according to their specialties (operation, maintenance and training). They will prepare the documentation of their own respective disciplines and provide guidance to the development of relevant procedures and documentation requiring multi discipline interface involvement. Most documentation will be prepared in home office Korea, but many technical procedures will be completed at sites by on site team members. The major duties of key personnel in the preparation step are as follows; (1)

Commissioning manager  Manage the project pre-commissioning and commissioning  Control the overall pre-commissioning and commissioning schedule of the project  Preparation for pre-commissioning dossier and hand over  Integrate commissioning schedule / activities into master schedule

(2)

Commissioning coordinator  Coordinate commissioning activities with the construction team and the SAMAPCO  Coordinate commissioning schedule with the construction team

(3)

Discipline engineer  Develop the commissioning schedule  Develop and manage all check sheets, procedures and manuals  Develop the system definition list and marked-up drawings  Develop the Vendor schedule  Develop Vendor training schedule for operations and maintenance  Prepare staff mobilization  Perform general services for commissioning control

(4)

Commissioning HSE engineer  Establishes commissioning HSE management plan/permit to work system and prepare relevant procedures/pre-start up audit check list.  Ensures that all established plan and procedures are implemented in commissioning activities  Provides information and inputs as required into the SAMAPCO's report on protective measures for operational safety  Performs training to ensure that all relevant personnel, specifically commissioning personnel



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fully understand the commissioning plan and procedures (5)

4.3

Environmental specialist  Produces and complies with an environmental monitoring and mitigation report  Prepares and implements the environmental control procedures for site  Monitors the implementation of mitigation measures during construction and commissioning period  Ensures that all environmental aspects and impacts are identified, mitigation measures are determined properly.  Manages environmental monitoring program  Manages environmental compliance inspection  Monitors the implementation of the plans for water quality protection, air quality

Pre-commissioning step. The major duties of key personnel in the Pre-commissioning step are as follows. (1)

Commissioning manager  Manage the project pre-commissioning activities  Control the pre-commissioning schedule  Manage safety and direction of the team of specialist, Vendors and the related construction work.

(2)

Commissioning coordinator  

Coordinate pre-commissioning activities with the construction team and SAMAPCO Coordinate pre-commissioning schedule with the construction team and SAMAPCO

(3) Discipline engineer  Supply consumables necessary for pre-commissioning work.  Develop the pre-commissioning schedule  Maintain records of the pre-commissioning activities (4) Operation supervisor  Supervise pre-commissioning activities  Supervise control room activities  Arrange documentation related to pre-commissioning (5) Commissioning supervisor  Perform the pre-commissioning activities  Support Vendor test runs  Perform pre-commissioning check



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(6) QA/QC manager  Plan, monitor and perform all field quality verification and inspection activities  Prepare QA-QC records  Supervise subContractors QA-QC program  Monitor adherence of work to the drawings and specifications / material control procedures  Manage the documents  Reviews generated punch list (7) Turnover coordinator  Manage the punch  Prepare turnover documents

4.4

Commissioning and start up step The major duties of key personnel in the commissioning and start up steps are as follows. (1) Commissioning manager  Manage the project commissioning and start up  Control the commissioning schedule  Manage safety and direction of the team of specialist, Vendors and the construction team  Manage operation test and performance tests  Manage the initial operation.  Manage the acceptance test and reliable test operation. (2) Commissioning coordinator  Coordinate commissioning activities with the construction team and the SAMAPCO  Coordinate commissioning schedule with the construction team and the SAMAPCO  Manage the training schedule.  Coordinate and support vendor specialists' site works in link with each relevant commissioning activities. (3) Commissioning Engineer  Supply consumables necessary for commissioning, operation test and performance tests  Develop the commissioning, operation test and performance test schedules  Input records of the commissioning, operation test and performance tests  Coordinate on-the-job training  Arrange documentation related to commissioning (4) Operation supervisor  Supervise commissioning and start up  Supervise control room activities  Perform the safe induction of hydrocarbons into the facilities to start up


PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN ARABIAN CHLOR VINYL PROJECT  

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Execute the operation test and performance test of equipment Responsible for operation test and performance test on each item of equipment and facilities of each system and the plant.

(5) Commissioning supervisor  Support Vendor test runs  Perform commissioning and start up check  Perform preventive inspection and maintenance of the plant  Support the operation  Input records of maintenance  Support operation test and performance tests on each item of equipment and facilities (6) QA-QC manager  Plan, monitor, and perform all field quality verification and inspection activities  Prepare QA-QC records  Supervise subcontractor’s QA-QC program  Monitor adherence of work to the drawings and specifications / material control procedures  Manage the documents (7) Turnover coordinator  Manage the punch  Prepare turnover documents



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Construction & pre-commissioning Construction & pre-commissioning include all those activities, as indicated in the tables of general requirements for quality checks, (3.0 division of responsibilities-project standard specification No.SPCC-G-008-02), required to achieve the mechanical completion milestone. Construction & pre-commissioning also include those activities required to execute the functional tests and performance tests (as per Annex K, part 5 Para 21, of the Contract, related to utility package units, where feasible), for the SAMAPCO to issue a test result statement in relation to the same. At or near construction completion of each system/subsystem (including process and utilities systems/subsystems), Daelim will submit official notice to the OWNER that the system/subsystem is ready for punching. OWNER’s punch team(s), including all applicable disciplines, will punch each system/subsystem, compile a master punch list, and establish the priority categories (A, B, C, etc) for each punch item and submit the list to Daelim. Daelim will then begin closing out the punch items and all “A” punch items must be closed out before pre-commissioning of the system/subsystem. All Punch Items should be defined as three Categories (“A”, “B” and “C”) and it should be included in Punch Control Procedure. Within the context of this project, pre-commissioning for the process is the term used to encompass the activities before mechanical completion. In case of utilities, pre-commissioning is the term used to encompass the activities includes start up. All categories “A” punch items shall be corrected and closed out before pre-commissioning of the system/subsystem begins At the end of construction following activities should be completed:  Contract Plant or any section of the Contract Plant should be mechanically and structurally completed in accordance with the Contract including all drawings specifications, and applicable laws, codes and standards by Contractor. Pre-commissioning activities include: 

The non-operating adjustments and cold alignment checks. It means all checks, cleaning, drying, and testing of any portion of the Contract Plant which can be implemented without introducing raw material and/or auxiliary fluids as well as permanently energizing said parts. These activities verify the completeness of the installed equipment /components.



All activities associated with preparing or operating the utilities or part thereof with auxiliary fluids,



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prior to initial start up (electrolyzer energizing). During this phase, electrical equipment will be finally energized, and equipment / circuits will be pressurized and tested to check as far as possible their performance. During this period all utilities shall be ready with quantities and qualities. All plant safety system shall be in service. Main activities of pre-commissioning are as follows and marked up in the subsequent tables. For process;  Pipe line flushing and blowing  Reinstatement  Cold alignment(final alignment and coupling of rotating equipment)

For utility;  All plant safety system , fire water and protection system etc, shall be in service  Pipe line flushing and blowing  Reinstatement  Cold alignment(final alignment and coupling of rotating equipment)  Tightness test  Testing and check-out of fire and gas detection facilities  Function testing of control systems (instruments and electrical)  Energizing and testing of switchboard  Installation of temporary strainers and permanent gaskets after reinstatement  Loading of packed bed.  Dry-out and inerting  Start up and operation before Mechanical Completion (N2, process water, drinking water, instrument air, plant air CTW, boiler, demineralized water, fire water, refrigerator, chiller, fuel gas, etc.) Detailed descriptions of each pre-commissioning activity will be prepared separately for each operational system.

Necessary documentation Effective pre-commissioning requires a variety of technical documentation, which must be up-to-date and available for the commissioning group, before pre-commissioning activities commencement. The following list is indicative of what is required.  Process flow diagrams (PFD)  Piping and instrument diagrams (P&ID)  System dry-out and inerting procedures  Vendor installation, operating and maintenance manuals This Document is the property of ACV and is lent without consideration other than the Borrower’s agreement that it shall not reproduced, copied, lent, or dispos ed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by pate nts.

PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN ARABIAN CHLOR VINYL PROJECT           •

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Instrument function testing procedures Equipment list Electrical distribution drawings Functional logic diagrams Trip and alarm summary Detailed equipment manufacturers drawings Detailed vessel internals drawings Lubrication list and schedule Material safety data sheets Instrument tag list and piping list Tightness test procedure

Mechanical completion Mechanical completion occurs when the Contract Plant or any section of the Contract Plant has finished:  All activities listed in SPCC-G-008-2-quality checks required to achieve the MC milestone.  General requirements for quality checks during pre-commissioning (including functional tests) and Mechanical Completion.  All deficiencies that could prevent safe and orderly commissioning activities and determinable without the use of feedstock have been corrected by Contractor. It is recognized that minor painting, insulation (not affecting plant safety and operations) as part of the project scope must be finished by Contractor until the issuance of a taking over certificate under the Contract. It is also possible that sections of the total Contract Plant can be mechanically complete before the entire Contract Pant is declared mechanically complete. Certificate of Mechanical Completion (MC) Certificate of Mechanical Completion will be issued by SAMAPCO for each system or sub-system once the following activities have been completed;  Constructed in accordance with project design drawings  Mechanical Completion activities have been completed.  All necessary check sheet, documents and drawings are duly filled and signed by Contractor and SAMAPCO.  All safety devices such as pressure safety valves (PSV) are tested, witnessed and certified by the representative of the Contractor and SAMAPCO.  System is punch listed and confirmed complete (punch “A”). • Completely documented and inputted into commissioning management system by the construction group or administrator



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　 At the end of the Mechanical Completion the Contractor shall submit a request to SAMAPCO for an issue of certificate. Along with it the Contractor will enclose all system definition, tag list, mark-up P&ID, calibration documents, check sheets, cleaning /flushing documents and test results documents (such as hydrostatic testing and pneumatic testing documents) duly filed and signed. Also a master blind and record of set pressure of all PSV's should be provided. These documents shall be completed by the Contractor system wise and a copy of the same shall be submitted to SAMAPCO. Once satisfied that Mechanical Completion is successfully completed, the SAMAPCO shall issue a test result statement in accordance with the Contract. If Mechanical Completion is not successfully completed, The SAMAPCO shall notify Contractor of any deficiencies. In the event of such deficiency Contractor shall promptly rectify the deficiency and the provisions of sub-clause 9.3A of the Contract shall apply. Minor works mutually agreed between the parties and listed on the punch lists, which will not hinder the start of commissioning activities, will not prevent the release of the Mechanical Completion Certificate. At plant Mechanical Completion, Contractor shall hand over as-built documentation for the Contract Plant as described in Contract appendix 215, in section C part 2.

7 7.1

Commissioning Introduction Commissioning encompasses all the required checks, tests and proving of a system that can be implemented for the introduction of process fluids or the permanent energizing or pressurizing of a system. Within the context of this project, commissioning is the term used to encompass the activities from Mechanical Completion to ready for start up (RFSU). Detailed descriptions of commissioning activity will be prepared separately for each operational system. The commissioning team is responsible for all aspects of pre-commissioning and, therefore, for preparing the plant systems and / or sub-systems for commissioning. Commissioning team will also direct the sub- Contractors (mechanical, electrical and instrument) and



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Vendor representatives involved in their activities required during the commissioning phase. Prior to commence commissioning, the commissioning team, especially turnover coordinator, will ensure that the relevant QC checks have been carried out by the construction group sufficiently to enable commissioning to commence. To enable this process works effectively there are specific documents and checks required to be confirmed which will include documentation such as Mechanical Completion check sheet, QC check sheet, discipline acceptance certificate, relevant site queries, relevant engineering queries and agreed outstanding punch list. Commissioning will follow the approved commissioning procedures together with the completion of the relevant commissioning check sheets and recording sheets. Commissioning will commence by system as follows  Issuance of Mechanical Completion certificate.  All fuels, lubricants, chemicals, preservatives, and any other consumables necessary for the operation of the entire system have been installed.  Completion of any punch “A” raised in MC stage.  All necessary documentation and permits in place “Commissioning” means all activities associated with : Preparing the Contract Plant to receive salt and 32 % NaOH for chlor-alkali plant and hydrocarbon for EDC plant such as:  drying out of lines and equipment;  tightness tests of lines and equipment at operating pressure;  Steam out and/or purging of lines and equipment with nitrogen.  Introduce process feed into the Contract Plant.  Operating the Contract Plant or part thereof with raw material /hydrocarbons charge from reduced up to design rate.  During this phase all instrumentations shall be “tuned up “for proper functioning.  The Commissioning phase terminates when the Contract Plant starts to operate at design capacity producing products (i.e. as mentioned in technology documents) matching with process specifications and the SAMAPCO issues a Test Result Statement to this effect in accordance with sub-clause 9.3B of the Contract.  At the end of commissioning phase the Contractor will notify the SAMAPCO that the Contract Plant “is ready for start up”.  During the commissioning phase the SAMAPCO will put at disposal of Contractor sufficient and qualified personnel for section and/or Contract Plant operation and maintenance. .


PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN ARABIAN CHLOR VINYL PROJECT 7.2

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Schedule Both the pre-commissioning and commissioning schedules have been integrated into the overall project schedule and attached in this plan. The commissioning team shall keep commissioning progress according to the commissioning schedule. To minimize any loss in time, the commissioning team shall submit a detailed schedule to the SAMAPCO for review. If any modification of schedule and procedure is needed due to an unexpected impact, the commissioning team shall discuss it with the SAMAPCO. Level 1 overall project schedule and level 3 detailed pre-commissioning/commissioning schedules have been developed. These schedules will be updated and submitted to reflect the actual progress of pre-commissioning/commissioning activities.

7.3

Work permit control As construction progresses the emphasis changes from completion by area to completion by system. Construction will arrive at a state of completion which will commence permit activities. At this point the system or area is barricaded and sign-posted to indicate the area is designated an "operational" area and a strict entry control is exercised. At this stage of project the system will be transferred to commissioning team with its responsibility for the system. As such the work permit control comes into effect. Work permit approval system procedure (080036-xx-xx-xxx) will be used during commissioning. This system will be controlled by the HSE manager and commissioning team.

7.4

Lock-out and tag-out Lock-out and tag-out procedure shall be used to de-energize or render inoperable any valves, switches, equipment, and/or process for the purposes of pre-commissioning, commissioning, repair, maintenance, or operation. The procedure also prevents the unplanned/unscheduled start up or operation of de-energized machinery, equipment or processes. Lock-out and tag-out procedure shall be submitted to SAMAPCO for approval. This Lock-out and tagout will be detailed in a separate procedure. Lock-out and tag-out procedure (080036-xx-xx-xxx).

7.5

Vendor commissioning activities Commissioning expertise will be required from a number of equipment Vendors. The commissioning manager will coordinate with procurement group; the requirement, timing, and duration of various Vendor representatives to the plant. These will include, but not necessarily limited to, representatives for the following equipment.



                     

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Flare stack Electrolyzer Chlorine compressor package Demiwater package Sulfuric acid concentration package Sulphate removal system. HCl synthesis unit Boiler package unit Air compressor and dryer Nitrogen storage and vaporization unit Emergency power generation package. Brine polishing filter package Ion exchange package Anthracite filter package Fire water pump package Incinerator package. Gypsum filter Sludge filter Refrigeration compressor Hydrogen compressor Caustic concentration unit Others

　 Vendor representatives’ schedule (include Vendor training schedule for operations and maintenance) shall be submitted to SAMAPCO for review.

7.6

Spare parts, temporary equipment and consumables Each specialist, as part of his duties in the preparation phase, will confirm the quantities of consumables required for the pre-commissioning, commissioning, start up, operation test, performance test and testing of various facilities as well as the initial operation phase. All spare parts, temporary equipment, measuring equipment and consumables list of oil, diesel, propylene, chemicals, etc. including the first fill of the facilities, will be prepared before commencing the pre-commissioning and commissioning. SAMAPCO will review commissioning spare parts and confirm received spare parts.

7.7

Tightness test After cleaning, the plant units may be subjected to leakage tests performed to detect and eliminate leaks. For this purpose the units are pressurized to working pressure with a suitable agent. However,



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this leak test does neither replace the pressure test stipulated by the technical supervision authorities nor the pressure test to be performed during erection. A leak test shall be performed always after the system has been dismantled on hydrostatic pressure test (e.g. removal of blinds, installation of safety valves or opening of machines for inspection) and is part of the commissioning. The leakage test can only be performed in a completely erected unit (with installed electrical equipment and instrumentation). Before putting into service the chlorine system should finally be tested in order to guarantee perfect leak tightness.

The following general instruction should be followed: 

The unit to be tested is to be isolated from other units. However, for this purpose it is not sufficient just to close the shutoff valves. The equipment is slightly pressurized to detect major leaks up to max. Pressure of 0.5 bar g for gaseous media and normal operating pressure for liquid media.



All flange connections (e.g. connections between pipes and equipment, instrumentation) are covered with a suitable leak detection solution.



In the first step the system to be checked is brought to a pressure of approx. 0.5 bar g by means of nitrogen.



Leakage can be detected by formation of bubbles in the leak detection solution (soap or special spray) and must be eliminated.



If the stuffing boxes of valves are leaky, care shall be taken to ensure that the valves may be operated easily even after tightening the stuffing boxes.



If no further leaks are detected, the unit remains pressurized over several hours. The pressure drop is recorded taking into account possible temperature differences.



Before bolts at the graphite equipment are tightened see the instructions of the manufacturer and use a torque wrench.



If liquid is used for leak testing, in the second step, the pressure is slowly increased up to the operating pressure of the system to be checked and all connections are checked for leakage.



When pressurising with gaseous agents leaks can be detected by application of a leak detection solution



During pressurising and depressurising it must be ensured that no damages occur to internals.



The gas velocity must not exceed that of normal operation inside of packing materials.

 After completion of tests, no vacuum (e.g. heat exchanger) is allowed to occur. Sufficient breathing has to be ensured.


PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN ARABIAN CHLOR VINYL PROJECT 7.8

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Drying out / inerting of lines and equipments All process systems shall be dried in accordance with the project specification dew point. The activity will be done by systems and by the individual equipment items. Dry-out will be done using dry air supplied by 100% oil free air compressors and dryer packages. All process systems shall be purged in accordance with the project specification. The activity will be done by systems and by individual equipment items. Inerting will be done by using the project nitrogen system or temporary nitrogen system to comprise a liquid nitrogen tank, nitrogen vaporizers and heating equipment capable of producing gaseous nitrogen heated to the required temperature. To assure proper dry-out and inerting, all ball, globe and gate valves shall be manipulated to open/closed position several times to displace any free water. Butterfly valves shall be thoroughly dried while being left in full open position. All bypass line shall be dried and purged. To assure bypass line dried out,block valves in main line should first be blocked or throttled to allow flows through the bypass line. When the bypasses are dried and purged, the block valves in the main line should be opened wide. Also all safety relief valve line, branch line and tubing for instrument shall be dried and purged. The dry-out and inerting procedure will be carefully planned and sequenced so that a minimum amount of air and nitrogen will be required to dry and inerting the overall piping and equipment effectively the procedures, marked-up drawings and work schedules for dry-out and purge shall be subject to the SAMAPCO’s approval. Dry-out and purge/inerting works shall be performed prior to introduction of the hydrocarbon product, and the dried and purged condition should be maintained thereafter. Dry-out and inerting for pipelines, equipment and facilities shall be executed by dry air and nitrogen gas until reaching the target dew point and oxygen limit. Once the facilities are dried out and purged, the facilities shall remain in a condition such that positive pressure of nitrogen is supplied to inhibit the entrance of foreign matter into previously purged systems. Pressures on these completed systems should be monitored on a regular schedule to assure that a positive inert pressure is being maintained. The chlorine system downstream of the drying tower must be thoroughly dried. To dry the system the chlorine compressors are started alternately and input air/ nitrogen is sucked through the drying tower and blown through the entire system purging the air out at the EDC plant. Special care is to be taken that all dead spaces and dead pipe sections are likewise dried. If this cannot be accomplished dry instrument air should be fed in. If there is a risk of water having accumulated in dead spaces of valves, fittings and other items of equipment of the dry chlorine section, the latter are to be opened, dismantled as far as necessary and then dried. Dry compressed air or nitrogen should be used for drying larger equipment.



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In the EDC Plant all systems in contact with fluids containing traces of HCl have to be dried out before the initial start up or after any shutdown in which there is a chance that the equipment has become wet, all equipment must be thoroughly dried out because the simultaneous presence of water and HCl will cause rapid corrosion. The water content in the system has to be lowered to a value < 20 ppm wt. to avoid any corrosion. 

The first step in drying out the equipment is to drain all equipment and lines at the lowest point and blow out all the vessels and lines with plant air to eliminate pools of water.



The second step is to replace possible air in the system by nitrogen and the oxygen content has to be checked.



The oxygen content must be below 0.5 % by vol. before EDC can be introduced. For drying EDC resistant hoses must be available.

7.9

System by system commissioning

7.9.1

Utility The commissioning of the utility system shall be prioritized during the latter construction stages to which they are required to be commissioned for their utilization in the Mechanical Completion and commissioning of process facilities and dry-out and inerting of the piping. The commissioning sequence of utility system is as follows; (1) Energizing of electric power receiving and distribution systems The power receiving system and distribution systems shall be energized and commissioned before Mechanical Completion of the other systems. (2) Air supply system As soon as electric power is available, air compressors and drying facilities for instrument air shall be promptly commissioned. Impurities in the pipeline for supplying instrument air will be removed, dried and pressurized. In addition, temporary air compressors and air dryers for cleaning and drying of the equipment and piping shall be prepared. (3) Nitrogen supply system As early as possible, nitrogen shall be brought in and commissioned in order to be used in drying and inerting of process facilities. Besides, in view of the necessary nitrogen unavailable, for drying, temporary nitrogen vaporizers and liquid nitrogen tanks shall be prepared. (4) Water and seawater intake system When power systems have been energized, utility systems such as utility pumps, effluent treatment systems, seawater pumps and fire water pumps shall be commissioned.



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(5) Potable and Service water Potable and service water tanks shall be cleaned and filled with fresh water. After pumps are commissioned, the distribution system of the pump outlet shall be cleaned. (6) Seawater Seawater intake and header shall be cleaned and filled with seawater. After seawater pumps are commissioned, seawater filtration and chlorination systems are commissioned. (7) Diesel oil supply system Diesel oil for fire engine pump and emergency generator shall be brought in and diesel oil storage tanks and related facilities shall be commissioned. (8) Expected consumption schedule of utilities A utilities and raw material consumption schedule for commissioning shall be prepared by the Contractor and submitted for the SAMAPCO’s approval. (9) Commissioning of boiler system Steam blowing for the steam line is necessary in the pre commissioning activities. Brine and process fluid is needed to heat up to meet pre start up condition. So boiler system shall be commissioned prior to process system commissioning. Fuel gas shall be supplied from near plant via pipe line for the commissioning and start up in accordance with manufacturer’s recommendation. (10) Demineralized water system commissioning Demineralized water is used in the process for multi-purpose. So demineralized water should be available before boiler commissioning. Start up shall be carried out in accordance with Vendor’s instruction. 7.9.2

Process commissioning (1) Brine system  Complete brine circuit as mentioned below is running at 70℃-75℃ Saturator Buffer vessel Raw brine pump Precipitation tanks Clarifier/clarifier brine pump Anthracite filters Filtered brine tank Filtered brine pump Polishing filters



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Polished brine pump Chlorine recuperator Ion exchanger Pure brine Brine heat exchanger Head tank Cell header bypass Anolyte tank Dechlorination      

All controllers will be working in auto mode. Anthracite filter sequence is streamlined. Exchanger is ready for operation; with ion exchange resin filled in and duly regenerated. Required laboratory analysis procedures for salt / brine are established along with the laboratory equipment/instrument. Regular analysis is to be carried out at various sampling points. Start up with salt: start charging salt into the brine saturator whichever is in operation.

(2) Anolyte dechlorination and chlorate destruction. Following prerequisites are to be ensured before start up of anolyte system and chlorate destruction unit:  Pure brine is available  Temperature of pure brine is maintained at 70℃ - 75°C.  NaCI concentration in pure brine is greater than 270 gpl.  18% HCI is available.  Sodium bisulphite (NaHSO3) is available  18% caustic soda is available  All controllers in auto mode. (2) Chlorine cooling & drying Prior to start up of the chlorine cooling section, following prerequisites must be fulfilled. Following systems should be in operation:  Cooling water circulation  Chilled water circulation  Demineralised water system  Instrument air  Waste gas dechlorination unit  All controllers in 'auto' mode  Process air sparging in 78% sulphuric acid day tank  H2SO4 drying tower  Dry chlorine compressor by N2 This Document is the property of ACV and is lent without consideration other than the Borrower’s agreement that it shall not reproduced, copied, lent, or dispos ed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by pate nts.


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Issue 3

Following systems should be ready for operation:  Rectifiers / electrolyzers  Chlorine downstream system like HCI synthesis unit.  Brine & catholyte cycle (4) Caustic system (catholyte) Following pre-requisites are to be ensured before start up of catholyte system.  Instrument air, nitrogen, demineralized water and low pressure steam should be in operation  Rectifier, electrolyzers should be ready for operation  All controllers are in auto-mode  Confirm the purity of demineralised water and caustic 32%. (5)

Hydrogen system Prior to start up of the hydrogen cooling section, following prerequisites must be fulfilled:  Demineralized water  Cooling water  Nitrogen and instrument air  LP steam  All controllers in "auto mode" Following systems should be ready for operation  Rectifier / Electrolyzer  HCI synthesis unit

(6)

Waste gas dechlorination Following preparations are indispensable to ensure safe and trouble free start up of the unit.  Filling of heat exchangers  Chilled water side of the heat exchangers must be filled with chilled water. Take care that exchanger is vented via vent valve.  Filling of suction tank and final absorber sumps and caustic safety tank, and emergency caustic tank with 18%NaOH. Prior to start the waste gas dechlorination system, following systems must be operating:  Chilled water cycle/chilled water unit  Instrument and plant air.  NaOH dilution system and inventory of 18% NaOH in 18% caustic safety tank.

(7)

7.9.3

Incinerator Incinerator should be in operation prior to introduction of EDC to EDC process system.

Fire fighting systems commissioning



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Issue 3

Fire fighting systems shall be proven and operational prior to introduction of fuel gas or H.C. The fire water system shall be flushed and all pumps, hydrants, monitors and sprinkler facilities shall be commissioned and certified by the authorities. Also, fire detection systems shall have been tested to satisfy local code requirements. 7.9.4

Commissioning of flare stack The flare system directs the fuel gas and process H.C to the flare stack for safe disposal. The excess gas is ignited by the flare pilots and burned at a safe distance from the plant. So, the flare stack shall be commissioned prior to the introduction of fuel gas or H.C. Ignition of the flare stack pilot shall be carried out and operated before the plant start up.

7.9.5

ESD test The Contractor shall test all of the control function tests and emergency shutdown (ESD) system. The tank high level alarms and emergency shutdown (ESD) systems will be tested during precommissioning, commissioning or operation with caustic and EDC in the system. The high level alarm of each tank shall be tested during the actual operation. ESD shutdown for the port system shall be initiated during send out operation to ensure that this system is shutdown safely and in proper sequence.

7.10

Plant initial start up(electrolyzer energizing)

7.10.1

Pre start up safety review (PSSR) As a condition of achieving initial start up(electrolyzer energizing) and prior to the introduction of any H.C into the plant, the Contractor and the SAMAPCO shall jointly conduct a pre start up safety review (PSSR) to ensure system / plant is ready for the safe introduction of chlorine and/or hydrocarbons and everyone involved in the start up of the plant is trained to understand the entire plant design, operational procedures, HSE requirements and compliance, emergency response procedures, team roles and responsibilities during start up of plant. PSSR shall be done for overall systems related to introduction of hydrocarbon and energizing of electrolyzer. The plant is ready for initial start up (electrolyzer energizing) provided that all of the following conditions have been met and checked:      

Development of all procedures plans, schedules, arrangement of personnel are made and these have been approved. All Mechanical Completion activities have been completed including all relevant testing. All commissioning activities defined in the commissioning procedures have been completed. All punch list items have been completed to satisfaction; with the exception of agreed items. Construction equipment and scaffolding removed, the plot cleared of all surplus materials and properly cleaned. Temporary connections have been removed as appropriate.


PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN ARABIAN CHLOR VINYL PROJECT        7.10.2

AL-JUBAIL K.S.A


Issue 3

Safety inspection carried out with satisfactory result Buildings, equipment and/or furniture have been installed and the buildings are ready for occupation. Ancillary systems ready for connection to a live system where appropriate. Utility systems are in operation. All safety valves (pressure safety valves, thermal safety valves, vacuum breakers) shall have been checked out, be operational and be in service prior to starting the start up activity. All construction, Mechanical Completion and commissioning dossiers have been accepted. Fire fighting system and fire detection system has been completely commissioned and operated.

Notification of initial start up(electrolyzer energizing) When the plant has fully commissioned all systems (completion of operational testing for all equipment) and the entire plant such that the process system is ready for electrolyzer energizing, the Contractor shall notify to the SAMAPCO for the initial start up (electrolyzer energizing). Notifying : (a) the plant has achieved ready for initial start up (electrolyzer energizing), (b) all priority “A” and “B” punch items related to the plant have been completed or corrected, and (c) the plant has satisfied all requirements for achievement of ready for initial start up (electrolyzer energizing). Contractor shall include any additional documentation requested by SAMAPCO or necessary to demonstrate ready for initial start up (electrolyzer energizing).

7.10.3

Acceptance of ready for initial start up(electrolyzer energizing) SAMAPCO shall review all documents of ready for initial start up (electrolyzer energizing) submitted by Contractor. If the SAMAPCO does not agree that the plant has achieved ready for initial start up (electrolyzer energizing), SAMAPCO shall notify the Contractor of the reasons that the plant has not achieved ready for initial start up (electrolyzer energizing), and Contractor shall remedy, complete or correct the relevant works as necessary to achieve ready for initial start up (electrolyzer energizing) and re-notify the ready for initial start up (electrolyzer energizing) to SAMAPCO. If SAMAPCO agrees that the plant has achieved ready for initial start up(electrolyzer energizing), either initially or upon resubmission by Contractor, then the SAMAPCO shall accept the ready for initial start up(electrolyzer energizing).

7.10.4

Initial start up (electrolyzer energizing) Once SAMAPCO accept the ready for initial start up, the Contract Plant is ready for electrolyzer energizing. Initial start up (electrolyzer energizing) shall be carried out by Contractor according to the commissioning procedure with assistance from appropriate Vendor representatives as required. Technology provider's specialists shall attend at Contract Plant start up as well. The Contractor shall develop procedures for the start up of the plant which will be provided to the



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Issue 3

SAMAPCO for review and approval. Initial start up (electrolyzer energizing) activities include  All testing activities, including the running tests of the each equipment.  Electrolyzer energizing  Introduce process feed such as brine for CA plant and chlorine/ethylene for EDC plant.  Operating the plant or part thereof with hydrocarbon charge from reduced up to design rate.  All instrument tuned up for proper functioning. During initial start up (electrolyzer energizing), the operation, maintenance, safety and security of the plant will remain under the full responsibility of Contractor. Clearance of certain punch list Items may be achieved during Initial start up (electrolyzer energizing), subject to the agreement of the SAMAPCO. The commissioning manager is responsible for establishing the project organization and job assignment in accordance with commissioning procedure. During this phase it will acquire any permission required for operation of plant prior to the hydrocarbon introduction to the system and electrolyzer energizing.

7.10.5

Operating test Operating test shall be conducted within a period of system commissioning to figure out the features and capacity. Operating test shall be carried out in accordance with commissioning procedure and acceptance criteria. The Contractor shall maintain the best condition for the test..

7.10.6

Tuning and stabilization of process Tuning shall be executed between the completion of load test and the beginning of preliminary demonstration for performance test. To achieve tuning conditions, 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. In this step, equipment shall be operated in an automatic mode. When load changes, equipment has to be stabilized for a required period of time which shall be recorded. If load tests are completed, operators shall implement tuning. All test data must be recorded and compiled.

8

Ready For Start Up (RFSU) Ready For Start Up of any section and /or Contract Plant is the event that occurs when all commissioning activities have been successfully performed by Contractor to allow commencement of the production operation and assessed /certified by SAMAPCO.



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Issue 3

The plant is fed with process feed to design rate and products, complying with the project specification, are sent to storage. At the end of the commissioning phase the Contractor will notify the SAMAPCO that the plant is ready for start- up (RSFU). Immediately after establishing that any section and/or the Contract Plant is ready for start up, SAMAPCO will issue the test result statement to Contractor. A test result statement stating that commissioning has been successfully completed and RFSU has been achieved is signed by SAMAPCO and submitted to the Contractor in accordance with sub-clause 9.3B of the Contract.

9

Start up After RFSU, the start up phase includes initial operation and carrying out of the performance test by Contractor to demonstrate the performance characteristics of the plant have been achieved in accordance with the procedures outlined in Annex-K. Start up is deemed to have been completed on the calendar day on which 100% of daily production is achieved in the Contract Plant, all performance tests have been successfully completed, and the SAMAPCO has issued a test result statement in accordance with sub-clause 9.3C of the Contract. This means Initial acceptance date is hit.

10 10.1

Testing Introduction The Contract Plant shall be tested in accordance with the standards adopted for the works as established in the approved specifications and testing procedures. No later than [three (3)] months prior to the Mechanical Completion date, the Contractor shall submit a testing protocol (an inspection and testing procedure) for the plant for review and written approval by the SAMAPCO. For situations where physical tests are not possible at the time of performance test, a proposed methodology to demonstrate the performance guarantees shall be proposed in such testing protocol.

10.2

Number of tests The Contractor may perform any number of tests simultaneously provided that test conditions and safety requirements of each test are satisfied and observed by both the SAMAPCO and the Contractor.



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Issue 3

10.3

Performance test

10.3.1

General (1) The performance Guarantees shall be proven in a Performance Test run of seventy-two (72) hours to be performed by the Contractor under SAMAPCO’s supervision and the Technology Provider’s assistance, consecutively and without interruption, producing the guaranteed quality of the products at the rated capacity with the consumption figures as detailed in the Annex K of the Early Works Agreement (2)

10.3.2

The result of each Performance Test shall be recorded in a protocol and signed by both parties immediately after the Performance Test.

Interruptions (1) If there is an interruption during the Performance Test which is equal to or less than six (6) hours, the duration of the Performance Test shall be extended by the actual duration of the interruption period and the calculation of the result of the Performance Test shall be made on the basis of the seventy-two (72) hours period during which the conditions of operation have been normal . (2)

If the period of the interruption during the Performance Tests lasts more than six (6) hours and the CA Plant and/or EDC plant (as the case may be) has been operating for less than forty eight (48) hours, the Performance Test shall be repeated by the Contractor

10.3.3

Failure to achieve Performance Guarantees In the event any Performance Guarantees cannot be reached during the Performance Test, the terms of Sub-Clause 9.3C [Result of Performance Tests and Retesting] and Sub-Clause 9.4 [Failure of Performance Tests or Reliability Test] of the Contract shall be applied.

10.3.4

Preparation for the performance guarantee test run (1) Pre-test activities After the start up of the overall units, the Contractor shall carry out the necessary fine tuning and calibrations. All facilities to be tested shall be in steady operation mode for 3 days before the performance guarantee test run commences. (2)

Feed stock definition The SAMAPCO shall furnish salt at the quality defined in the Contract and in quantity sufficient to enable the required test flow rates to be met during the performance guarantee test run period. Contractor shall submit notice test date before 90 days prior to test as minimum. In the event that the actual feed stock quality, as determined from laboratory analysis, differs substantially from the design feed stock, then the Contractor shall request the SAMAPCO to review the situation before commencing performance guarantee test run.

(3)

Utilities



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Issue 3

All required utilities shall have been made available, as required for the performance guarantee test run period. Contractor will be responsible for ensuring the required volume and quality except if utilities have already been handed over to SAMAPCO. These utilities including fire water, nitrogen, instrument air, plant air, drinking water, process water, fuel gas, electric power, demin.water, chilled water, steam, etc. (4)

Chemicals The Contractor shall make available all the chemicals required for the performance guarantee test period except if facilities have already been handed over to SAMAPCO.

(5)

Laboratory services Sufficient staff and sampling equipment shall be made available by SAMAPCO throughout the performance guarantee test run for the handling and rapid analysis of gas/ liquid samples as required during the tests. Suitable sample bombs shall be provided by SAMAPCO. Auxiliaries shall be designed and supported by Contractor. Calibration and verification of laboratory equipment to be used in sample analysis will be performed jointly between SAMAPCO and Contractor prior to start up of the performance guarantee test run. Analysis will be performed in the new laboratory building. The analysis should be signed off by SAMAPCO laboratory staff and included in the performance guarantee test run report.

10.3.5

Performance guarantee test run organization An integrated performance guarantee test team will be formed with SAMAPCO personnel and the Contractor/ other parties such as UHDE etc. Contractor shall be responsible for acting as a leader of the integrated test team so as to perform the test operation. The SAMAPCO will supervise the performance test until successfully completed. The commissioning team must liaise closely with the SAMAPCO to ensure that mutual objectives are met.

10.3.6

Performance guarantee test run procedure and schedule The performance tests procedures and schedule shall be developed by the Contractor and submitted to the SAMAPCO for approval prior to conducting the performance tests.

10.3.7

Measuring and sampling method of data All instruments that will be used for demonstration of the performance of the Contract Plant will be checked prior to start the performance guarantee test run period.



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Issue 3

Data during the testing period will be recorded at two hour intervals using the plant data historian or can be manually recorded in log sheet prepared by Contractor. DCS trend log will be provided specifically to record the performance guarantee test data. These log sheets will be retrieved from the system with SAMAPCO representative. 10.3.8

Data conversion Gas and liquid flow readings from flow meters during the performance test shall be corrected for temperature, pressure, and molecular weight wherever necessary. And general correction equation and method shall be described on performance test procedure.

10.3.9

Performance guarantee test run report After the successful completion of the performance guarantee test run, Contractor will prepare the performance guarantee test run report with all results and conclusions, which demonstrate that the performance guarantee has been fulfilled. Contractor will submit this report to SAMAPCO for approval. SAMAPCO shall communicate to the Contractor, within seven (7) days after the receipt of the report, its acceptance or its rejection and in the latter case SAMAPCO shall state its reasons in writing. In the event that the installations do not perform or fail to operate in accordance with the Contract, Contractor shall carry out appropriate remedial design and construction work and provide the necessary replacement materials in accordance with the Contract. Upon completion of such remedial works the performance guarantee test run will be repeated.

10.4

Reliability Test

10.4.1

Tests The Reliability Guarantees specified in paragraphs 20.2 and 20.3 of the Annex K shall be proven in a Reliability Test run of [thirty (30) days] to be performed by the Contractor consecutively without interruption. The result of Reliability Test shall be recorded in a protocol to be agreed between the Parties and signed both Parties immediately after the Reliability Test.

10.4.2

Reliability Guarantees for CA Plant The reliability guarantees shall be as follows; (a) [95]% of the Performance Guarantees set out in paragraph 3.1; and (b) the Minimum Performance Standards set out in paragraph 9.1.of the Contract

10.4.3

Reliability Guarantees for EDC Plant The reliability guarantees shall be as follows (a) [95]% of the Performance Guarantees set out in paragraph 15.1; and



AL-JUBAIL K.S.A


Issue 3

(b) the Minimum Performance Standards set out in paragraph 18.1.of the Contract 10.4.4

11

Reliability Performance LDs In the event that the CA Plant and/or the EDC Plant (as the case may be) fail to meet any of the Reliability Guarantee during the Reliability Test, then ANNEX K, paragraph 20.4 of the Contract shall be applied..

Hand-over Following satisfactory completion of the initial operation and performance tests, SAMAPCO shall agree to a formal hand-over of the facilities. The commissioning team shall compile a systematic hand-over package, which will include SAMAPCO approved reports demonstrating successful completion, commissioning, and acceptance of the performance and reliability tests. Hand-over is the formal transfer of the asset to SAMAPCO. This hand-over will be detailed in a separate procedure. Hand-over procedure (080036-xx-xx-xxx)

12

Punch and Punch Control

Punch-out of each of the systems/subsystems by SAMAPCO or in conjunction with SAMAPCO is critical. It should be made clear in the plan and schedule when SAMAPCO perform this critical operation. SAMAPCO shall have final decision concerning punch item categories (A, B, etc) and shall have final decision as to whether or not the punch item has been corrected and closed out. A formal “punch-out” of each system and associated sub-system will be performed by the Contractor. Owner will also perform an independent punch-out as described in sect 5, paragraph 3. All defective or incomplete items will be recorded on a punch list for the respective discipline system and associated sub-systems. Where applicable, the equipment tag number and associated drawings will be used as the prime means of identifying the defect or incompletion. Punch list items will be registered and tracked electronically by means of an electronic certification management system or database.


PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN ARABIAN CHLOR VINYL PROJECT 13 13.1

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Issue 3

Vendor’s training at site Vendor’s technology support. Vendor’s personnel will be required to support pre-commissioning and commissioning activities, and Contractor will be responsible for scheduling the presence of these specialists on site at appropriate time. Contractor shall submit Vendor’s schedule for specialist Vendor support for SAMAPCO approval for all phases. Vendor support for package equipment items containing multi-discipline equipment shall include multiple visits by different disciplines, as advised by the Vendor.

13.2

Vendor’s training at site The Vendor’s training and required related exercises will be conducted in the designated training facility and at the site respectively; they will be scheduled at the most appropriate time. The training officer will coordinate to establish course attendees and schedules to ensure that courses are arranged to meet attendees’ availability. This training schedule shall be detailed and submitted to SAMAPCO.

14 14.1

Communication Radio-communication The Contractor shall provide adequate explosion proof radios for all pre-commissioning, commissioning and start up activities. Contractor shall ensure that enough radios, and channels, are available to support simultaneous precommissioning, commissioning and start up, and are also available for Vendor representative.

14.2

Mobile phone Contractor shall be responsible for prohibiting use of non-intrinsically safe equipment in areas where flammable fluids exist prior to initial start up. This equipment includes mobiles phones, cameras, spark producing tools, electric drills etc. Use of essential tools shall be controlled by appropriate permit to work procedures. Mobile phones shall not be permitted under any circumstances after initial start up.

15

Reporting A site meeting will be held for daily and/or weekly reporting once critical activities commence. The commissioning team will provide a weekly progress report. The progress report will be submitted in a format agreed among the parties involved in this report.



16

AL-JUBAIL K.S.A


Issue 3

HSE management The Contractor generates and develops the HSE management plan for the commissioning including evacuation plans and procedures. A permit to work (PTW) system will be set up by commissioning HSE engineer and submitted to the SAMAPCO for review and approval one month before the date electrolyzer energizing. Training on PTW system, emergency shutdown, safety philosophy and safety procedures etc. will be carried out for all personnel involved in commissioning. The commissioning HSE engineer will prepare and submit commissioning HSE management plan including all HSE procedures and pre-start up safety review (PSSR) procedure to the SAMAPCO two months prior to the start of commissioning.

Attachments Attachment 1: Pre-commissioning / commissioning & start up schedule Attachment 2: Pre-commissioning / commissioning process and activities Attachment 3: Organisation for preparation phase Attachment 4: Organisation for pre-commissioning phase Attachment 5: Organisation for commissioning phase Attachment 6: Completion process flow chart Attachment 7: Start up flow chart Attachment 8: EDC Plant Drying & Start-Up Plan Attachment 9: List of Preparation Plan of Pre-commissioning &Commissioning Documents and Activities


Attachment 1

Pre-Commissioning / Commissioning & Start Up Schedule Sep/30/2011 Based on System Definition rev.A

Arabian Chlor Vinyl Project Activity

No

Mile Stone 1 2

Utility U03 Process Water System

Start

Finish

(mm/dd)

(mm/dd)

2011 Dura 12 Dec tion 1 11 21

. 02/16/2012

10/07/2012

235

02/16/2012

03/01/2012

15

02/21/2012

6

Pre-Commissioning

02/16/2012

4

Commissioning

02/22/2012

02/26/2012

5

5

PSSR

02/27/2012

02/29/2012

3

6

Start Up

03/01/2012

03/01/2012

1

02/20/2012

03/09/2012

19

02/27/2012

8

U10 Sea Water

8

Pre-Commissioning

02/20/2012

9

Commissioning

02/28/2012

03/05/2012

7

10

PSSR

03/06/2012

03/08/2012

3

11

Start Up

03/09/2012

03/09/2012

1

02/25/2012

03/14/2012

19

03/03/2012

8

12

U11 Cooling Water

13

Pre-Commissioning

02/25/2012

14

Commissioning g

03/04/2012

03/10/2012

7

15

PSSR

03/11/2012

03/13/2012

3

16

Start Up

03/14/2012

03/14/2012

1

02/22/2012

03/20/2012

28

03/02/2012

10

17

U15 PA and IA System

18

Pre-Commissioning

02/22/2012

19

Commissioning

03/03/2012

03/16/2012

14

20

PSSR

03/17/2012

03/19/2012

3

21

Start Up

03/20/2012

03/20/2012

1

03/02/2012

03/27/2012

26

03/10/2012

9

22

U17 Fire Water Pump and Distribution

23

Pre-Commissioning

03/02/2012

24

Commissioning

03/11/2012

03/23/2012

13

25

PSSR

03/24/2012

03/26/2012

3

26

Start Up

03/27/2012

03/27/2012

1

03/19/2012

04/04/2012

17

03/25/2012

7

27

U05 Drinking & Safety Shower Water

28

Pre-Commissioning

03/19/2012

29

Commissioning

03/26/2012

03/31/2012

6

30

PSSR

04/01/2012

04/03/2012

3

31

Start Up

04/04/2012

04/04/2012

1

03/19/2012

04/03/2012

16

03/23/2012

5

32

U16 Waste Water

33

Pre-Commissioning

03/19/2012

34

Commissioning

03/24/2012

03/30/2012

7

35

PSSR

03/31/2012

04/02/2012

3

36

Start Up

04/03/2012

04/03/2012

1

03/24/2012

04/10/2012

18

03/30/2012

7

37

U04 Demin. Water

38

Pre-Commissioning

03/24/2012

39

Commissioning

03/31/2012

04/06/2012

7

40

PSSR

04/07/2012

04/09/2012

3

41

Start Up

04/10/2012

04/10/2012

1

SAMAPCO CA/EDC Project

1

11

21

2 Feb 1

11

1/31 Power Energ.

3

7

2012 1 Jan

21

3 Mar 1

11

21

4 Apr 1

3/ 1 Pre-Comm. Start

2/29 DCS SAT

11

21

6 Jun

5 May 1

11

21

5/1 Boiler Start Up

1

11

21

2013 7 Jul

1

11

21

8 Aug 1

11

21

9 Sep 1

11

7/31 MC Comp. of Comm. Utility

21

10 Oct 1

11

10/1 Electro. Energiz.

21

11 Nov 1

11

21

11/2 RFSU

12 Dec 1

11

21

12/2 Initial Accept.

1 Jan 1

11

21

2 Feb 1

11

21

1/2 Reliability Test Ach. Taking Over Certi

page-1 of 7

Attachment 1



No

Mile Stone 42

U14 Nitrogen

Start

Finish

(mm/dd)

(mm/dd)

2011 Dura 12 Dec tion 1 11 21

. 03/30/2012

04/17/2012

19

Pre-Commissioning

03/30/2012

04/06/2012

8

44

Commissioning

04/07/2012

04/13/2012

7

45

PSSR

04/14/2012

04/16/2012

3

46

Start Up

04/17/2012

04/17/2012

1

47

U06 Fuel Gas

04/11/2012

04/24/2012

14

48

Pre-Commissioning

04/11/2012

04/15/2012

5

49

Commissioning

04/16/2012

04/20/2012

5

50

PSSR

04/21/2012

04/23/2012

3

Start Up

04/24/2012

04/24/2012

1

04/05/2012

05/01/2012

27

52

U02 Hot Relief and Flare System

53

Pre-Commissioning

04/05/2012

04/14/2012

10

54

Commissioning

04/15/2012

04/24/2012

10

55

PSSR

04/25/2012

04/27/2012

3

56

Pre-Start Up with Air

04/28/2012

04/30/2012

3

57

Start Up with Fuel Gas

05/01/2012

05/01/2012

1

04/10/2012

10/07/2012

23

04/17/2012

8

58

U07 Boiler system

59

Pre-Commissioning

04/10/2012

60

Commissioning

04/18/2012

04/27/2012

10

61

PSSR

04/28/2012

04/30/2012

3

62

Pre-Start Up with Fuel Gas

05/01/2012

05/01/2012

1

63

Start Up with H2

10/07/2012

10/07/2012

1

04/18/2012

05/01/2012

14

64

U08 Steam Distribution

65

Pre-Commissioning

04/18/2012

04/24/2012

7

66

Commissioning

04/25/2012

04/27/2012

3

67

PSSR

04/28/2012

04/30/2012

3

68

Start Up

05/01/2012

05/01/2012

1

04/19/2012

05/02/2012

14

69

U09 Condensate and Collection Tank

70

Pre-Commissioning

04/19/2012

04/24/2012

6

71

Commissioning

04/25/2012

04/28/2012

4

72

PSSR

04/29/2012

05/01/2012

3

73

Start Up

05/02/2012

05/02/2012

1

07/11/2012

15

74

U12 Refrigeration Unit

06/27/2012

75

Pre-Commissioning

06/27/2012

06/29/2012

3

76

Commissioning

06/30/2012

07/07/2012

8

77

PSSR

07/08/2012

07/10/2012

3

78

Start Up

07/11/2012

07/11/2012

1

07/05/2012

07/21/2012

17

79

U13 Chilled Water

80

Pre-Commissioning

07/05/2012

07/11/2012

7

81

Commissioning

07/12/2012

07/17/2012

6

82

PSSR

07/18/2012

07/20/2012

3


1

11

21

2 Feb 1

11

1/31 Power Energ.

43

51

2012 1 Jan

21

3 Mar 1

11

21

4 Apr 1


2/29 DCS SAT

11

21

6 Jun

5 May 1

11

21

5/1 Boiler Start Up

1

11

21

2013 7 Jul

1

11

21

8 Aug 1

11

21

9 Sep 1

11


21

10 Oct 1

11


21

11 Nov 1

11

21

11/2 RFSU

12 Dec 1

11

21


1 Jan 1

11

21

2 Feb 1

11

21


page-2 of 7

Attachment 1



No

Mile Stone 83 84

Start Up U01 EDC Relief and Vent System

Start

Finish

(mm/dd)

(mm/dd)

2011 Dura 12 Dec tion 1 11 21

. 07/21/2012

07/21/2012

1

07/10/2012

08/05/2012

11

07/11/2012

2

Pre-Commissioning

07/10/2012

86

Commissioning

07/28/2012

08/01/2012

5

87

PSSR

08/02/2012

08/04/2012

3

88

Start Up

08/05/2012

08/05/2012

1

03/14/2012

10/01/2012

202

03/18/2012

04/07/2012

21

90

Logistic L05 Hydrochloric Acid Storage

91

Pre-Commissioning

03/18/2012

03/24/2012

7

92

Commissioning

03/25/2012

04/03/2012

10

93

PSSR

04/04/2012

04/06/2012

3

94

Pre-Start Up

04/07/2012

04/07/2012

1

03/14/2012

04/03/2012

21

95

L04 Caustic Soda Storage

96

Pre-Commissioning g

03/14/2012

03/20/2012

7

97

Commissioning

03/21/2012

03/30/2012

10

98

PSSR

03/31/2012

04/02/2012

3

99

Pre-Start Up

04/03/2012

04/03/2012

1

06/25/2012

07/08/2012

14

100

L02 Propylene Distribution

101

Pre-Commissioning

06/25/2012

06/29/2012

5

102

Commissioning

06/30/2012

07/04/2012

5

103

PSSR

07/05/2012

07/07/2012

3

104

Pre-Start Up

07/08/2012

07/08/2012

1

09/20/2012

19

105

L03 Sulfuric Acid Storage

07/12/2012

106

Pre-Commissioning

07/12/2012

07/16/2012

5

107

Commissioning

09/07/2012

09/16/2012

10

108

PSSR

09/17/2012

09/19/2012

3

109

Pre-Start Up

09/20/2012

09/20/2012

1

110

L06 EDC Storage

07/17/2012

08/10/2012

19

111

Pre-Commissioning

07/17/2012

07/21/2012

5

112

Commissioning

07/28/2012

08/06/2012

10

113

PSSR

08/07/2012

08/09/2012

3

114

Pre-Start Up

08/10/2012

08/10/2012

1

10/01/2012

19

115

L01 Ethylene Distribution

07/22/2012

116

Pre-Commissioning

07/22/2012

07/26/2012

5

117

Commissioning

09/18/2012

09/27/2012

10

118

PSSR

09/28/2012

09/30/2012

3

119

Pre-Start Up

10/01/2012

10/01/2012

1

06/29/2012

10/01/2012

95

06/29/2012

08/10/2012

25

120 121

EDC Plant E06 Incinerator

122

Pre-Commissioning

06/29/2012

07/08/2012

10

123

Commissioning

07/27/2012

08/05/2012

10


1

11

21

2 Feb 1

11

1/31 Power Energ.

85

89

2012 1 Jan

21

3 Mar 1

11

21

4 Apr 1


2/29 DCS SAT

11

21

6 Jun

5 May 1

11

21

5/1 Boiler Start Up

1

11

21

2013 7 Jul

1

11

21

8 Aug 1

11

21

9 Sep 1

11


21

10 Oct 1

11


21

11 Nov 1

11

21

11/2 RFSU

12 Dec 1

11

21


1 Jan 1

11

21

2 Feb 1

11

21


page-3 of 7

Attachment 1



No

Mile Stone

Start

Finish

(mm/dd)

(mm/dd)

2011 Dura 12 Dec tion 1 11 21

.

PSSR

08/06/2012

08/08/2012

3

125

Pre-Start Up with Fuel Gas

08/09/2012

08/09/2012

1

126

Start Up

08/10/2012

08/10/2012

1

07/10/2012

09/16/2012

11

E05 Waste Water Collection

128

Pre-Commissioning

07/10/2012

07/12/2012

3

129

Commissioning

09/09/2012

09/12/2012

4

130

PSSR

09/13/2012

09/15/2012

3

131

Start Up

09/16/2012

09/16/2012

1

07/02/2012

10/01/2012

55

132

E01 Direct Chorination Reactor

133

Pre-Commissioning

07/02/2012

07/16/2012

15

134

Commissioning

08/23/2012

09/06/2012

15

135

PSSR

09/07/2012

09/09/2012

3

136

Dehydration (Dry with EDC)

09/10/2012

09/23/2012

14

137

Pre-Start Up p with EDC(EDC ( Fill Up) p)

09/24/2012

09/30/2012

7

Start Up with Cl2 & Ehtylene

10/01/2012

10/01/2012

1

07/11/2012

10/01/2012

59

138 139

E02 EDC Distillation Column

140

Pre-Commissioning

07/11/2012

07/20/2012

10

141

Commissioning

08/14/2012

08/23/2012

10

142

PSSR

08/24/2012

08/26/2012

3

143


08/27/2012

09/02/2012

7

144

Pre-Start Up with EDC

09/03/2012

09/30/2012

28

145

Start Up with EDC product

10/01/2012

10/01/2012

1

07/15/2012

10/01/2012

52

146

E03 Vacuum Column

147

Pre-Commissioning

07/15/2012

07/24/2012

10

148

Commissioning

08/21/2012

08/30/2012

10

149

PSSR

08/31/2012

09/02/2012

3

150


09/03/2012

09/09/2012

7

151


09/10/2012

09/30/2012

21

152


10/01/2012

10/01/2012

1

E04 EDC Drying & Stripping System

07/22/2012

10/01/2012

63

154

Pre-Commissioning

07/22/2012

07/28/2012

7

155

Commissioning

08/07/2012

08/16/2012

10

156

PSSR

08/17/2012

08/19/2012

3

157


08/20/2012

08/26/2012

7

158


08/27/2012

09/30/2012

35

159


10/01/2012

10/01/2012

1

06/27/2012

10/21/2012

117

06/27/2012

09/01/2012

19

153

160 161

CA Plant C15 Waste Water Treatment

162

Pre-Commissioning

06/27/2012

07/01/2012

5

163

Commissioning

08/19/2012

08/28/2012

10

164

PSSR

08/29/2012

08/31/2012

3


1

11

21

2 Feb 1

11

1/31 Power Energ.

124

127

2012 1 Jan

21

3 Mar 1

11

21

4 Apr 1


2/29 DCS SAT

11

21

6 Jun

5 May 1

11

21

5/1 Boiler Start Up

1

11

21

2013 7 Jul

1

11

21

8 Aug 1

11

21

9 Sep 1

11


21

10 Oct 1

11


21

11 Nov 1

11

21

11/2 RFSU

12 Dec 1

11

21


1 Jan 1

11

21

2 Feb 1

11

21


page-4 of 7

Attachment 1



No

Mile Stone 165 166

Start Up C01 Salt Handling

Start

Finish

(mm/dd)

(mm/dd)

2011 Dura 12 Dec tion 1 11 21

. 09/01/2012

09/01/2012

1

07/03/2012

09/04/2012

15

07/05/2012

3

Pre-Commissioning

07/03/2012

168

Commissioning

08/24/2012

08/31/2012

8

169

PSSR

09/01/2012

09/03/2012

3

170

Start Up

09/04/2012

09/04/2012

1

07/05/2012

09/09/2012

26

07/09/2012

5

C02 Brine Saturation

172

Pre-Commissioning

07/05/2012

173

Commissioning

08/20/2012

08/29/2012

10

174

PSSR

08/30/2012

09/01/2012

3

175

Pre-Start Up with Water & Demin-Water

09/02/2012

09/08/2012

7

176

Start Up with Brine

09/09/2012

09/09/2012

1

07/09/2012

09/14/2012

31

177

C03 Primary Brine Treatment

178

Pre-Commissioning g

07/09/2012

07/13/2012

5

179

Commissioning

08/20/2012

08/26/2012

7

180

PSSR

08/27/2012

08/29/2012

3

181

Pre-Start Up with Water & Demin Water

08/30/2012

09/13/2012

15

182

Start Up with Brine

09/14/2012

09/14/2012

1

07/13/2012

09/19/2012

31

183

C04 Secondary Brine Treatment

184

Pre-Commissioning

07/13/2012

07/17/2012

5

185

Commissioning

08/25/2012

08/31/2012

7

186

PSSR

09/01/2012

09/03/2012

3

187


09/04/2012

09/18/2012

15

188

Start Up with Brine

09/19/2012

09/19/2012

1

C05 Anolyte Dechlor.& Chlorate Decom.

07/17/2012

10/01/2012

21

190

Pre-Commissioning

07/17/2012

07/21/2012

5

191

Commissioning

09/08/2012

09/14/2012

7

192

PSSR

09/15/2012

09/17/2012

3

193


09/18/2012

09/22/2012

5

194

Start Up with Anolyte

10/01/2012

10/01/2012

1

195

C11 Catholyte Circulation

07/21/2012

10/01/2012

21

196

Pre-Commissioning

07/21/2012

07/25/2012

5

197

Commissioning

09/11/2012

09/17/2012

7

198

PSSR

09/18/2012

09/20/2012

3

199


09/21/2012

09/25/2012

5

200

Start Up with Catholyte

10/01/2012

10/01/2012

1

07/25/2012

10/01/2012

19

07/29/2012

5

189

201

C10 Waste gas Dechlorination

202

Pre-Commissioning

07/25/2012

203

Commissioning

09/16/2012

09/22/2012

7

204

PSSR

09/23/2012

09/25/2012

3

205


09/26/2012

09/28/2012

3


1

11

21

2 Feb 1

11

1/31 Power Energ.

167

171

2012 1 Jan

21

3 Mar 1

11

21

4 Apr 1


2/29 DCS SAT

11

21

6 Jun

5 May 1

11

21

5/1 Boiler Start Up

1

11

21

2013 7 Jul

1

11

21

8 Aug 1

11

21

9 Sep 1

11


21

10 Oct 1

11


21

11 Nov 1

11

21

11/2 RFSU

12 Dec 1

11

21


1 Jan 1

11

21

2 Feb 1

11

21


page-5 of 7

Attachment 1



No

Mile Stone 206 207

Start Up with Waste Gas C07 Electrolyser

Start

Finish

(mm/dd)

(mm/dd)

2011 Dura 12 Dec tion 1 11 21

. 10/01/2012

10/01/2012

1

07/22/2012

10/01/2012

35

07/28/2012

7

Pre-Commissioning

07/22/2012

209

Commissioning

09/04/2012

09/18/2012

15

210

PSSR

09/19/2012

09/25/2012

7

211

Anolyte / Catholyte Fill Up

09/26/2012

09/30/2012

5

212

Energizing

10/01/2012

10/01/2012

1

06/27/2012

10/02/2012

28

C08 Chlorine Cooling Drying and Comp.

214

Pre-Commissioning

06/27/2012

07/03/2012

7

215

Commissioning

09/10/2012

09/19/2012

10

216

PSSR

09/20/2012

09/22/2012

3

217

Pre-Start Up with Air / N2 / H2SO4

09/23/2012

09/29/2012

7

218

Start Up with recycle H2SO4

10/02/2012

10/02/2012

1

07/02/2012

10/03/2012

31

219

C12 Caustic Conc. and Distribution

220

Pre-Commissioning

07/02/2012

07/08/2012

7

221

Commissioning

09/01/2012

09/10/2012

10

222

PSSR

09/11/2012

09/13/2012

3

223

Pre-Start Up with Water / Caustic

09/14/2012

09/23/2012

10

224

Start Up with Caustic Product (32%)

10/03/2012

10/03/2012

1

C14 HCl Synthesis and Distribution

07/07/2012

10/04/2012

28

226

Pre-Commissioning

07/07/2012

07/13/2012

7

227

Commissioning

09/06/2012

09/15/2012

10

228

PSSR

09/16/2012

09/18/2012

3

229

Pre-Start Up with Water

09/19/2012

09/25/2012

7

Start Up with H2 & Cl2 Product

10/04/2012

10/04/2012

1

07/12/2012

10/04/2012

28

225

230 231

C09 H2SO4 Concentration

232

Pre-Commissioning

07/12/2012

07/18/2012

7

233

Commissioning

09/08/2012

09/14/2012

7

234

PSSR

09/15/2012

09/17/2012

3

235

Pre-Start Up with Water / H2SO4

09/18/2012

09/27/2012

10

236

Start Up with recycle H2SO4

10/04/2012

10/04/2012

1

237

C13 H2 Cooling and Compression

07/17/2012

10/06/2012

26

07/23/2012

7

238

Pre-Commissioning

07/17/2012

239

Commissioning

09/12/2012

09/21/2012

10

240

PSSR

09/22/2012

09/24/2012

3

241

Pre-Start Up with Air / N2

09/25/2012

09/29/2012

5

242

Start Up with H2 Product

10/06/2012

10/06/2012

1

07/22/2012

10/21/2012

31

243

C06 Sulfate Removal and Gyp.Filtration

244

Pre-Commissioning

07/22/2012

07/28/2012

7

245

Commissioning

09/28/2012

10/07/2012

10

246

PSSR

10/08/2012

10/10/2012

3


1

11

21

2 Feb 1

11

1/31 Power Energ.

208

213

2012 1 Jan

21

3 Mar 1

11

21

4 Apr 1


2/29 DCS SAT

11

21

6 Jun

5 May 1

11

21

5/1 Boiler Start Up

1

11

21

2013 7 Jul

1

11

21

8 Aug 1

11

21

9 Sep 1

11


21

10 Oct 1

11


21

11 Nov 1

11

21

11/2 RFSU

12 Dec 1

11

21


1 Jan 1

11

21

2 Feb 1

11

21


page-6 of 7

Attachment 1



No

Mile Stone

Start

Finish

(mm/dd)

(mm/dd)

2011 Dura 12 Dec tion 1 11 21

.

1

11

21

2 Feb 1

11

1/31 Power Energ.

247

Pre-Start Up with Water

10/11/2012

10/20/2012

248

Start Up with Lean Brine

10/21/2012

10/21/2012

1

11/01/2012

32

11/02/2012

1

21

3 Mar 1

11

21

4 Apr 1


2/29 DCS SAT

11

21

6 Jun

5 May 1

11

21

5/1 Boiler Start Up

1

11

21

2013 7 Jul

1

11

21

8 Aug 1

11

21

9 Sep 1

11


21

10 Oct 1

11


21

11 Nov 1

11

21

11/2 RFSU

12 Dec 1

11

21


1 Jan 1

11

21

2 Feb 1

11

21


10

249

Initial Start Up / Tunning

10/01/2012

250

RFSU

11/02/2012

251

Performance Test

11/02/2012

12/01/2012

30

252

Initial Acceptance Test

12/02/2012

12/02/2012

1

253

Reliability Test

12/03/2012

01/01/2013

30


2012 1 Jan

page-7 of 7

Attachment 2 :

rev. 2 Dec/5/2011

Pre-Commissioning / Commissioning Process and Activities Utility Pre-Comm. Start

Mechanical Completion

Initial Acceptance

RFSU

Reliability Test Achieved

2013.

2012. 3/1 Construction

▪ Loop Check ▪ Hydro Test of Piping ▪ Power Energizing ▪ DCS SAT ▪ PSV Popping Test ▪ Equip. Final Inspection ▪ Vessel/Tank Closing ▪ Cold Align. Check ▪ Install. of Instrument ▪ Motor Solo Run ▪ OWNER disciplines to punch all systems /subsystems, compile master punch list, and decide punch item categories. ▪ DIC shall submit pre-comm./Comm. procedure 6 months prior to precomm.

7/31 Pre-Comm.

OVERALL SYSTEM ▪ "A" Punch Cleared ▪ Pipe Cleaning ▪ Reinstatement ▪ Leak Test ▪ Functional Test (Interlock check for Process, F&G )

UTILITY SYSTEM only ▪ "A"&"B" Punch Clear ▪ PSSR ▪ Tightness Test (at Operating Pressure)

▪ Steam Boiler Refractory Dty-out ▪ Chemical Preparation and Chemical in Service for Steam Boilers ▪ Start Up & All Utility System in Service ▪ Hot Alignment ▪ Performance Test

11/2 Comm.

▪ "B" Punch Cleared ▪ PSSR ▪ Tightness Test (at Operating Pressure) ▪ System Drying Out / Inerting ▪ Catalyst Loading ▪ Initial Chemical Fill-up ▪ Refractory Dyr Out (for Incinerator)

▪ MRT ▪ Load Test (Compressor)

▪ Brine System (CA Plant)-Start Up & Operation ▪ Electrolyzer-Start Up & Operation ▪ Introduce Chlorine / Ethylene Feed for EDC Plant ▪ Control System Tunning OJT Traning

12/2 Start Up/ Operation ▪ Plant design rate Operation ▪ Complete Punch (including "C") ▪ Operational Test

▪ Performance Test

1/2 Reliability Operation ▪ Reliability test

▪ Hand Over - Special Tools - Spart Parts - Final Data Books

Attachment 3

rev. A Aug/2/2011

Organization for Preparation Phase Korean

ACVC Management

DIC Project Manager K

1

ACVC

TCN

Staff Grade Number of Staff Nationality K : Korean / T : TCN / A : ACVC S : Supervisor / L : Leader W : Worker

Comm. Manager

Construction K

1

Engineering

Total Korean

S

TCN

Comm. Coordinator K

K

Procurement

S

CA Plant

EDC Plant

Utility / Off Site

Lab

Process Engineer

Process Engineer

Process Engineer

Lab Engineer

1

S

K

Operation Supervisor K

3

1

S

K

Operation Supervisor S

K

2

1

S

Operation Supervisor S

K

2

S

K

S

Attachment 4

rev. 0 Jan/17/2012

Organization for Pre-Commissioning Phase Korean SAMAPCO

K

Construction

1

Staff Grade Number of Staff Nationality

SAMAPCO Management

DIC Site Manager S

K : Korean S : Supervisor T : TCN L : Leader A : SAMAPCO W: Worker

Comm. Manager

Punch Team K

1

TCN

Safety S/V S

K

1

Total Korean

S

TCN

Comm. Engineer

QA/QC K

1

S

K

1

Comm. Coordinator S

SAMAPCO Operation S/V

Operation S/V (Utility)

A

K

1

S

1

K

1

Turnover Coordinator

S

K

1

Safety Engineer

S

K

1

S

SAMAPCO Maint. S/V

Comm. S/V K

S

1

S

A

1

S

Operation Shift A A

Operation (Day)

Operation Shift B

Operation (Night)

Lab. (Day)

Mechanical K

1

S

Electrical K

1

S

K

1

Mechanical Engineer

Control System

Instrument S

K

1

S

A

A

Operation Shift C

Operator

Operator

K

1

S

K

1

Mechanical

Analyst

A S

K

1

S

T

2

L

T

1

Control System

Instrument

Electrical L

T

2

L

T

2

Electrical Engineer L

A

Operation Shift D A

Operation Shift E A

Operator T

3

Analyst

Operator W

T

3

W

T

2

Mechanical W

T

8

W

T

3

Instrument Engineer

Instrument

Electrical W

T

8

W

A

Attachment 5

rev. 0 Jan/17/2012

Organization for Commissioning Phase Korean SAMAPCO

K

Construction

1

Staff Grade Number of Staff Nationality

SAMAPCO Management

DIC Site Manager S

S : Supervisor K : Korean T : TCN L : Leader W: Worker A : SAMAPCO

Comm. Manager

Punch Team K

1

TCN

Safety S/V S

K

1

Total Korean

S

TCN

Comm. Engineer

QA/QC K

1

S

K

1

Comm. Coordinator S

SAMAPCO Operation S/V

Operation S/V

A

K

1

S

1

K

1

Turnover Coordinator

S

K

1

Safety Engineer

S

K

1

S

SAMAPCO Maint. S/V

Comm. S/V K

S

1

S

A

1

S

Operation Shift A A

Operation (Day)

Operation Shift B

Operation (Night)

Lab. (Day)

Mechanical T

1

S

Electrical K

1

S

K

2

Mechanical Engineer

Control System

Instrument S

K

1

S

A

A

Operation Shift C

Operator

Operator

K

8

S

K

6

Mechanical

Analyst

A S

K

2

S

T

2

L

T

1

Control System

Instrument

Electrical L

T

2

L

T

2

Electrical Engineer L

A

Operation Shift D A

Operation Shift E A

Operator T

Analyst

Operator W

T

W

T

Mechanical W

T

8

W

T

3

Instrument Engineer

Instrument

Electrical W

T

8

W

A

Completion Process Flow Chart

Attachment 6

rev.A Aug/2/2011

QC Check Sheet

Prepare QC Dossier

NDT Records Material Identification Shop Inspection Report

Prepare Pre- Comm. / Comm. Dossier

Procedure for Cleaning, Leak Test Drying, Function, etc.

Review by ACVC

Prepare Start Up, Comm., & Performence Test Dossier

ACVC Approval System Certified as Mechanically Complete

Final Issue

Construction Completion

Multi Disciplinary Punch List

Pre-Comm. Activities

Punch A Cleared

Witness / Sign Off

Punch A should be cleared before M/C sign off.

Pipe Cleaning, Function Test Utility Start Up, etc.

MECHANICAL COMPLETION

Construction Completion Check List, Site Reports

Finalize QC Dossier

Commissioning Activities

Summary of Testing & Inspection

Prepare QC Data

Witness Sign Off

Tightness Test Drying, etc.

System Comple. Dossier

Submit Sys. Dossier to ACVC

Multi Disciplinary Punch List

ACVC Approval

Punch A/B Cleared

PSSR

Initial Start Up Comm. Procedure

Energizing Electrolyser

Ready fo Start Up for Cl2 / EDC Down Stream

Comm. Acitivies Completion Product to Storage

RFSU

Inst. Tunning Load Up to Design Rate

100% Daily Production Operation Manual

START UP

Special Toos Spare Parts Hand Over

Performance Test

ACVC Approval Submit Final Data Book Performance Acceptance

ACVC Approval

Punch C Cleared

Initial Acceptance

Reliability Test

Taking Over Certificate Issued by ACVC

FINAL ACCEPTANCE

Performance Test Procedure

Start Up Flow Chart

Attachment 7

Sep/30/2011

Preparation for Commissioning PC&C Team Mobilization

▪ Prepare the precom,comm,start up procedure ▪ Prepare the performance test procedure ▪ Prepare the vendor engineer schedule ▪ Ready for tools,consumable,test equipment ▪ Ready for temp.equipment and piping installation ▪ Ready for consumable utility items

Dmin. Water Sys. Start Up

H2SO4 Con. Sys. Pre-Start Up

Boiler Pre-Start Up (Fuel Gas)

Cl2 Compressor Pre-Start Up

Salt

Cl2 Emergency Scrubber S/U Salt Handling Sys. Start Up

Control & SWGR Bld. HAVC ▪ Punch and physical checks ▪ Balance ▪ Energize & running test

Incinerator Pre-Start Up

Anthracite Filter Sys Start Up

EDC Reactor EDC Filling Up Polishing Filyer Sys. Start Up

230KV Power Incomming ▪ Punch and physical checks ▪ Cable isolation check ▪ E power available Sulfate Rem Removal oval Pre-Start U Up p 34.5KV Switch Gear ▪ Punch and physical checks ▪ E-bus isolation procedure ▪ E power available

MV/LV (4.16/0.48KV) Switch Gear ▪ Punch and physical checks ▪ E-bus isolation procedure ▪ E power available Control System (F&G) ▪ Punch ▪ Energize for F&G system ▪ Loop test ▪ Cause and effect test

Control System (SIS) ▪ Punch ▪ Energize ESD system ▪ Loop test ▪ Cause & effect test

Instrument Air ▪ Punch list ▪ Compressor runs ▪ Line blowing ▪ Air available

AC/DC UPS System ▪ Punch and physical checks ▪ Charge batteries ▪ Discharge/Recharge tests

Ion Ex. Resin Sys Start Up

EDC Purification Pre-Start Up

Electrolyser Catholyte / Anolyte Filling

Rectifier Power Ready for ON

NaOH NaOH Evaporation Pre-STart Up

INITIAL START UP (Energizing) NaOH

H2 Cl2 Cooling / Drying / Compressing Start Up

NaOH Evaporation Start Up

EDC Reactor Sys. Start Up

EDC Purification Start Up

EDC Storage

Ready for N2 ▪ N2 system service

EDC

RFSU

Performance Test Commisssioning ▪ Tightness test ▪ Drying/Inerting ▪ Functional Test

PRE START UP SAFETY REVIEW (PSSR)

Boiler Start Up (H2)

HCl Synthesis Sys. Start Up

Incinerator Sys. Start Up Instrument Tuning 100% Production

All System Pre-Com ▪ Loop check/Sequence test ▪ Valve stroke test ▪ MCC auto function test ▪ C&E test/Utility start up/run

H2 Compressor Start Up Cl2

NaOH Storage Control System (DCS) ▪ Punch ▪ Energize all system ▪ Energize checks/soft ware ▪ Checks / Function checks ▪ OPC checks ▪ Communcation check

EDC Plant Drying with EDC

Performance Acceptance

Initial Acceptance

Reliability Test

Taking Over Certificate

HCl Storage

Attachment 8

EDC PLANT DRYING & START-UP PLAN M/C

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M/C

Attachment 9 List of Preparation Plan of Pre-commissioning &Commissioning Documents and Activities

1. Preparation of pre-commissioning and commissioning documents as per Plant Completion of Project Standard Specification (SPCC - G - 008) Items 1.1

Section definition (System Definition)

1.2

Detailed pre-commissioning (including FUNCTION TESTS) procedure

Preparation Plan Preparaed and issued to Owner (Document No. 080036-MZ-SD-001)

1.2.1 Box-up procedure

Will be prepared by 29th Feb. 2012

1.2.2 Loop test procedure


1.2.3 Electrical pre-commissioning procedure


1.2.4 Motor solo run procedure


1.2.5 Pipe cleaning procedure 1) Air blowing procedure 2) Water flushing procedure

Preparaed and issued to Owner (Document No. 080036-DZ-MP-002)

3) Steam blowing procedure 4) Chemical cleaning procedure 1.2.6 Tightness test procedure with marked-up P&ID

Preparaed and issued to Owner (Document No. 080036-DZ-PQ-011)

1.2.7 Functional test procedure


1.2.8 Drying & Inerting Procedure


1.2.9 MRT procedure


1.2.10 Reliability Test procedure

Preparaed and issued to Owner (Document No. 080036-DZ-MP-003) Will be prepared by 31th Mar. 2012

1.3

Detailed pre-commissioning planning by section and discipline

1.4

Detailed commissioning / ready for start-up procedures

Will be prepared by 31th May 2012

1.5

Detailed commissioning planning by section and discipline

Will be prepared by 30th June 2012

1.6

Pre-commissioning and commissioning technical 1) Pre-commissioning : will be prepared by 31st Mar. 2012 database 2) Commissioning : will be prepared by 30 June 2012

1.7

Pre-commissioning and commissioning check & test sheets

1) Pre-commissioning : will be prepared by 31st Mar. 2012 2) Commissioning : will be prepared by 30 June 2012

1.8

Detailed pre-ready - for start-up activities procedure

Will be prepared by 30th Sep. 2012

1.11

Performance test procedure

Will be prepared by 31st Oct. 2012

1.13

Operation manual

Preparaed and issued to Owner (Document No. 080036-VZ-MP-01 / 080036-VZ-MP-002 / 080036-VZ-MP-003 / 080036-VZ-MP-OO4 / 080036-VZMP-005)

1.14

Maintenance manual

Will be prepared by 30th April 2012

1/2

Items

Preparation Plan

1.15

Turnover procedure

Will be prepared by28th Feb. 2012

1.16

List of consumable to use during precommissioning and commissioning activities

Will be prepared by 31st March 2012

1.17

Pre-commissioning and commissioning schedule Schedule have preparaed and issued to Owner, updated schedule will be issued by 30th Apr. 2012 (Document No. 080036-DZ-PQ-001) Start-up schedule Schedule have preparaed and issued to Owner, updated schedule will be issued by 30th June. 2012 (Document No. 080036-DZ-PQ-001)

1.18

2. Pre-commissioning and commissioning site activities List 2.1

Schedule for site attendance of vendor specialists

2.2

Optimize detailed pre-commissioning and commissioning procedures

2.3

Manage and execute pre-commissioning and commissioning activities in field as per detailed procedure

2.4

Coordinate vendor specialists and the TECHNOLOGY PROVIDER's site attendance during plat precommissioning, mechanical completion, commissioning and ready for start up phases.

2.5

Coordinate and execute plant start up, initial operation and performance tests with OWNER and TECHNOLOGY PROVIDER's respective personnel

2.6

Training on the job to OWNER personnel in accordance with CONTRACT.

2.7

Taking-over of the PLANT by the OWNER after successful performance test and reliability tests.

2/2

080036 DZ PQ 001 R3 Pre Commissioning & Commissioning Execution Plan

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