SIBA Field Development Project

Client:
Kuwait Energy,
P.O. Box. 5614, Salmiya, Kuwait

PMC:
Touchstone.
P.O. Box. 72129, Sharjah, UAE

EPC Contractor: Engineering Consultant

PETROJET Mott MacDonald
P.O. Box. 2048, Horreya-Heliopolice
Cairo, EGY

Project Title:
SIBA FIELD DEVELOPMENT PROJECT
Contract No:
KEIL/SIBA/2015/C-051-REV-CPF EPC

Document Title:

Pre-Commissioning Procedure

Prepared Checked Approved Approved

Rev. Date Rev. Description PMC Rep. Client Rep.
By By By PTJ

Document No: C-051-001-PRO-000X

Format Pages

A4 1 Of 17

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Amendment Summary

Revision No Date Description

Issued for IDC / IFR

Disclaimer:- “This document is issued for the party which commissioned it and for specific purposes connected with the captioned project only. It
should not be relied upon by any other party or used for any other purpose.
We accept no responsibility for the consequences of this document being relied upon by any other party, or being used for any other purpose, or
containing any error or omission which is due to an error or omission in data supplied to us by other parties.”

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TABLE OF CONTENTS

1 Introduction.................................................................................6
Background................................................................................. 6

2 Intent of the document...............................................................8

3 Abbreviations............................................................................11

4 List of systems and Sub-systems.............................................13

5 Reference documents and drawings........................................14

6 Definitions - Stages of project completion / Pre-commissioning

and start-up...............................................................................15

7 Developing Pre - Commissioning Organization........................19

8 Roles and responsibility of Commissioning Team...................22

9 Pre- Commissioning plan..........................................................27

10 Prepare Requirement and Schedule of Commissioning Spares,

Tools, Process Material, and Consumables..............................35

11 Pre-commissioning (Aspect - Wise)..........................................37

12 Site Acceptance Procedure......................................................48

13 Pre-commissioning and Ready for start-up Procedure for Utility

………………………………………………………………………………………49

14 Pre-commissioning & ready for start-up Procedures of support

Systems.....................................................................................90

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Attachments

Attachment – 1 System and Sub-System Listing

Attachment – 2 Pre-commissioning Check lists (all systems)

Attachment – 3 Pre-Commissioning team Organization Flow chart

Attachment – 4 Mark-up PIDs (Utilities)

Attachment – 5 Commissioning Flow chart (Sequence)

Attachment – 6 Tank Commissioning Procedure

Attachment – 7 Instrument set points

Attachment – 8 Engineering and vendor documents (PIDs, SLD, Layouts,

System Architectural diagrams, Instrument index, Datasheets…etc)

Attachment – 9 Pre-commissioning sequence of supports systems

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1 Introduction

Background
The Siba gas field was discovered in 1969 and is located in southern Iraq, in the Basra
Governorate, some 30 km southeast of Basra city extending east to the Shat Al-Arab River,
as shown in Figure 1 -1. Kuwait Energy Iraq Limited (KEIL), a wholly owned subsidiary of
Kuwait Energy Company, in partnership with Turkish Petroleum (TPAO) and Missan Oil
Company signed with South Oil Company (SOC) in Iraq a Gas Development and Production
Service Contract (GDPSC) for the Siba Field, Effective Date 1 July 2011. KEIL has been
appointed the Operator for the field.
The Contract term is 20 years with an optional 5 year extension. The field has a reserve
estimated at 1.5 tcf Gas Initially in Place (Yamama C and D formations). The field is virgin
land at this point of time, however unexploded ordinance remains in place. The key
milestone dates for the Siba field development project are summarised below [Ref. 1, Article
11]:

 Effective Date: 1 July 2011.

 Preliminary Development Plan (PDP) shall be prepared and submitted no later than 6
months from Effective Date, including programs:
o To achieve First Commercial production as per below.
o For appraisal of reservoirs within the Contract Area.
o To explore undiscovered potential reservoirs.
o For construction of processing plants and related facilities/installations, upstream of
the Transfer Points and within the Contract Area, for the extraction of Natural Gas
Liquids (NGLs) from Natural Gas.
 The PDP [Ref. 2] was approved 17 July 2012.
 Final Development Plan (FDP) shall be submitted within 6 months after the completion of
the Appraisal Program. Upon approval by SOC, the FDP shall supersede the PDP.
 First commercial production at 25% of target Plateau Production shall be achieved no
later than 3 years from the approval of the PDP, i.e. by 17 July 2015.
 Plateau Production at 100 mmscfd (ADQ) of Net Dry Gas specifications shall be
produced no later than 6 years from the Effective Date for a minimum period of 9 years,
i.e. 1 July 2017.
Work to mature the PDP to the Final Development Plan for submission is ongoing in
accordance with KEIL’s project scheduling.

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Figure 1-1 – Siba Field Location

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2 Intent of the document

This document covers the various aspects of safe, efficient, and timely Pre-
commissioning (Pre Comm) and Commissioning of SIBA Field Development Project, as
covered under the EPC contract scope of PETROJET(PTJ).

The purpose of this document is to describe scope, methodology, and procedures for
carrying out Pre-Commissioning, Commissioning leading to Performance Tests activities
for the subject project scope. This manual defines the following scope and its execution:

 Equipment / System Pre-commissioning

 Equipment / System Commissioning

This document establishes the overall philosophy, plan and execution methodology of
commissioning of the facilities. However, the final details of Pre-commissioning and
commissioning shall be worked out at site and developed depending on the dynamic
status at the site. Pre-commissioning Check-list in the attached formats should be used
for the first time commissioning after completion of the construction and installation.
These check lists are expected to be redefined and developed by the facility operators
(KEIL) after any modification/ addition or wet start subsequently. Agreed and approved
Site Acceptance Test (SAT) procedures will continue to supersede these check lists for
all large integrated systems as also the Performance Guarantee Test (PGT) run
document will be the overriding document for large process packages or equipment
systems.

Also, Vendor manuals / instructions shall be strictly followed while testing,

commissioning and operating the relevant equipment and large integrated systems.

During all pre-commissioning & commissioning activities, PTJ will involve KEIL team
(nominated by the Company) and impart necessary training.

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The scope of Pre-commissioning and Commissioning work shall be as per EPC contract
and cover following units / areas:

 Hub-1 receiving Production Fluid from Wellhead S1 and S4 along with Trunk
line, Pig Launcher and Pig Receiver facilities
 Feed Gas Slug Catcher Train 1 & 2 leading to Gas Treatment Plant Train 1 & 2
 Dry Gas Export Facilities, On-spec Condensate Storage Tank and Export
Facilities along with Pig Launcher, Pig Receiver and Metering facilities
 Off-spec Condensate Storage and pumping Facilities
 LPG Mounded Storage and Export Facilities along with Pig Launcher, Pig
Receiver, and Metering facilities
 Gas Turbine Package-1, 2 &3
 Diesel and Amine Storage and pumping facilities
 Raw Water, Potable water and Demin water Tanks and Pumps
 Instrument Air and Nitrogen Distribution system
 Fire Fighting System including Fire Alarm System and Clean Agent Flooding
System
 Associated Piping, Electrical & Instrumentation for the above systems
 Integrated Control and Safety System (ICSS)
 Telecommunication System

The Pre-commissioning and Commissioning of Gas Treatment Plant, GTG’s, Potable

Water Treatment Pkg, Raw Water Treatment Pkg., Demin Water Treatment Pkg.,
Instrument Air Compressor/ Dryer Pkg are not covered in detail in this manual as the
responsibility of Pre-commissioning and commissioning of these packages lie in
Package Supplier scope.

This document should always be referred along with Technical catalogues, system
specifications and special procedures mentioned in the vendors’ manuals. This
document, therefore, does not intend to replace other engineering and project details of
system suppliers.

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3 Abbreviations
Abbreviation Description
3LPE 3 Layer Polyethylene
3LPU 3 Layer Polyurethane Foam
ADQ Average Daily Quantity
AGA Australian Gas Institute
AISC American Institute of Steel Construction
API American Petroleum Institute
ASME American Society of Mechanical Engineers
AWS American Welding Society
BGL Below Ground Level
BoD Basis of Design
BPD Barrels Per Day
BS British Standard
CAPEX Capital Expenditure
CBR California Bearing Ratio
CCB Central Control Building
CCR Central Control Room
CGR Condensate to Gas ratio
CITHP Closed In Tubing Head Pressure
CO2 Carbon Dioxide
CPF Central Processing Facility
CTS Custody Transfer System
DC Direct Current
DCS Distributed Control System
DNV Det Norske Veritas
EDG Emergency Diesel Generator
EHS Environmental Health Services
EPF Early Production Facility
ESD Emergency Shutdown
FBHP Flowing Bottom Hole Pressure
FCP First Commercial Production
FDP Final Development Plan
FEED Front End Engineering Design
FFT First Fault Tolerance
FGS Fire and Gas System
FPF Full Production Facility
FTHP Flowing Tubing Head Pressure
FTHT Flowing Tubing Head Temperature
GDPSC Gas Development Production Service Contract
GTG Gas Turbine Generator
H2S Hydrogen Sulphide
HCS Hub Control System
HMI Human Machine Interface
HP High Pressure
HPPS High Integrity Pressure Protection System
HSE Health, Safety and Environment
HWC Hard Wired Console
ICCP Impressed Current Cathodic Protection

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ICSS Integrated Control and Safety System

ID Inner Diameter
IEC International Electro technical Committee
IER Instrument Equipment Room
IFC International Finance Corporation
ISO International Standardisation Organisation
KEIL Kuwait Energy Iraq Limited
KOD Knock Out Drum
LER Local Equipment Room
LP Low Pressure
LPG Liquefied Petroleum Gas
mmscfd Million Standard Cubic Feet per Day
NACE National Association of Corrosion Engineers
NEC National Electric Code
NFPA National Fire Protection Association
NGLs Natural Gas Liquids
NNW North North West
NPSHA Net Positive Suction Head
NW-SE North West South East
OIW Oil in Water
pax Personnel
PDP Preliminary Development Plan
P&ID Piping & Instrumentation Diagram
PFD Process Flow Diagram
PLCS Pipeline Control System
PMS Power Management System
ppm Part Per Million
RSH Mercaptans
RVP Reid Vapour Pressure
RWCS Raw Water Control System
SG Specific Gravity
SIS Safety Instrumented System
SOC South Oil Company (Iraq)
SSE South South East
stbpd Standard Barrel per Day
tcf Trillion Cubic Feet
TDS Total Dissolved Solids
TPAO Turkish Petroleum (Türkiye Petrolleri Anonim Ortaklığı)
TSS Total Suspended Solids
UCP Unit Control Panel
UPS Uninterruptable Power Supply
UTM Universal Transverse Mercator
WCS Well Control System
WGR Water to Gas Ratio
World Geodetic System
WGS

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4 List of systems and Sub-systems

The Detail list of system, sub-systems and sub-sub systems with description is available in
attachment -1.

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5 Reference documents and drawings

Below is the list of Documents and Drawings required for reference during pre-
commissioning. Please refer attachment no. 5 for complete documentation.

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6 Definitions - Stages of project completion / Pre-commissioning

and start-up

6.1 Mechanical Completion

This stage is the step that verifies the design installation and ensures that
the installed facility gets ready to start Pre-commissioning activities. It
confirms that the construction and installation of equipment, piping,
mechanical components, instrumentation, electricals, communication etc.
is done and all the inspections, tests and documentation have been
completed. It represents the interface between Construction and Pre-
commissioning activities. It broadly covers following, but not limited to:

 Completion of Design, Engineering, procurement, and

Construction. Installation of facilities (Equipment, Piping,
Instrumentation, Electricals, Structural work etc.) in accordance
with ‘Approved for Construction’ documents
 Relevant Safety studies done and recommendations from Safety
studies incorporated in Design and Installation
 Testing and Inspections, including Factory acceptance tests
 Relevant approvals available
 Static Equipment are installed as per specifications
 Rotary Equipment are installed as per specifications
 Piping and piping components are installed as per drawings and
specifications
 Leak test is carried out satisfactorily
 The electrical power receipt and distribution system like Power
Distribution Control panels, Push buttons, Cables/ accessories
are installed as per specifications
 The Field instruments are duly Calibrated and installed as per
specifications

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 The connections and communication links for instruments are

laid down
 The Mechanical completion is marked by ‘Ready for Pre-
commissioning’ or ‘Provisional Handover’ of an Equipment/
Subsystem and/or System as applicable.
 Sample check sheets for various completion of above mentioned
activities are enclosed as Annexure-………

6.2 Pre - Commisioning

Pre-commissioning represents the interface between Mechanical
Completion and Commissioning activities. It is initiated after ‘Provisional
Handover’ is achieved. It involves Pre-commissioning checks and Pre-
commissioning activities. It broadly covers following, but not limited to:

 Civil, Mechanical, Electrical and Instrumentation completion are

achieved and envisaged tele communication system is available
for use.
 Static Equipment are in clean, safe and workable condition
 Rotary Equipment (Pumps, Motors, Turbines, Engines) are
subjected to Functional / no-load tests
 Piping is clean, fit and safe for handling the medium
 Leak test is carried out satisfactorily
 Piping components like valves, PSVs, TRVs etc. are functional
as per the requirements
 The relevant electrical components are functional, fit and safe
for operation
 The connections and communication for instruments are
established
 The functionality of Field and Control room instruments is as per
design

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 The indications and functions of instruments in Control room or

Remote location are as per design specifications
 The sub-systems and systems are checked for integrity and
function
 The Safety system is in place and satisfactory
 Drains and vents are in place.

6.3 Pre-start up Safety Review (PSSR)

After the pre-commissioning of all the systems is done, the facility is subjected to Pre-
Startup Safety Review (PSSR) which shall be a joint exercise by PTJ Construction,
PTJ Operations, PTJ Safety, KEIL Operations and KEIL Safety group
representatives. PTJ shall lead the team and the efforts for this review exercise.

The PSSR is aimed at achieving following goals:

• To ensure that the fabrication, construction and installation meets the
original design, specifications and the intent of the facility.
• To verify that the Safety, Operations, Maintenance and Emergency
procedures are in place and adequate.
• To ensure that the requisite Safety studies and reviews are done during
the engineering phase and all the recommendations have been
incorporated.
• Any site modifications if done, is properly authorized, controlled and
documented.
• The personnel involved are properly qualified and trained for their duties.
• To ensure that the Safety Equipment / system are in place and functional.
• To ensure that all the lifting devices are properly inspected and validated.
• To ensure that all the resources including vendor services, materials,
spares, consumables etc. are lined up and available for commissioning.

PSSR shall be conducted at least 48 hours before the Commissioning.

Only after the PSSR is duly completed and no points are left unattended, the facility is
released as ‘Ready for Commissioning’.

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6.4 Ready for Start-up

Ready for start-up mainly involves establishing utilities, ensures the
system to be ready and safe to accept Process material/ hydrocarbons

6.5 Accpetance Test and Hand-over

This phase is the phase after stabilization of operation during Process
commissioning stage. It tends to prove that the subsystems, systems and
overall facilities function as per design and exhibit following:

 Give the design outputs

 Use the design inputs
 Operate at the design conditions
 Consume the design specific consumptions

This phase is marked by ‘Final Completion’.

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7 Developing Pre - Commissioning Organization

Commissioning shall be a joint activity between PETROJET and KEIL, with PTJ in
lead role and responsible for the facility till successful Performance Test Run and
hand over.

Thus, the commissioning organization shall be led by PTJ commissioning team and
supported by KEIL commissioning manpower – duly assigned by KEIL.
The Commissioning organization shall be typically as represented in attachment #
3.
Commissioning is directed and supervised by the PTJ Commissioning Manager
who reports to the PTJ Project Manager. He has a counterpart from KEIL with
whom he coordinates the commissioning activities. He shall be assisted by two
KEIL operations Coordinators. Each KEIL Operations Coordinator is supported by
PTJ commissioning personnel and forms a dedicated group. Each Operations
Coordinator/ group is assigned particular equipment and/or system for which he is
responsible for all commissioning activities. These activities include those
performed by construction contractor and equipment vendor representatives. The
KEIL Operations Coordinators in coordination with PTJ lead makes daily progress
reports to the PTJ Commissioning Manager, who conducts a daily coordination
meeting and advises the KEIL counterpart of progress and/or issues. The PTJ
Commissioning Manager submits a Daily and Weekly report summarizing
commissioning activities to the PTJ Project Manager, who communicates with KEIL
Commissioning Manager.

It is a good practice to have the weekly and daily commissioning Plan displayed on
Chart with progress in the common meeting room for every member of the
commissioning team to note and plan activities in his area. Commissioning is
performed by teams. The Commissioning Manager has overall responsibility for the
commissioning teams.

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A commissioning team typically includes:

 Operations Coordinator
 Panel Operator
 Field Operators

Following support service personnel shall also be deployed and shared between
different commissioning teams:
 Safety Engineer
 Electrical Engineers
 Instrumentation Engineers
 Mechanical Engineers
 Vendor personnel
 Construction personnel
 Maintenance personnel

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8 Roles and responsibility of Commissioning Team

PETROJET scope of work consists of Engineering, Procurement, construction,
supply of equipment, commissioning, start-up and performance test of SIBA Field
Development Project as described under Section 2.0. PETROJET has taken the
responsibility to handover the Plant to KEIL in a clean, safe and operating condition
alongwith UOP for handing over the Gas Treatment Facilities.

During all pre-commissioning & commissioning activities, PTJ will be the lead and
responsible entity. PTJ will involve KEIL team (nominated by the Company) and
impart necessary techniques and know-how required for start-up, operation and
maintenance of the facilities.

PTJ commissioning group shall gradually take over the control of systems and
subsystems from PTJ construction group to effectively achieve completion of
erection stage, whereby KEIL team shall be part and witness.

After completion of erection, PTJ commissioning team will start Pre-commissioning

of system/ subsystem in co-ordination with KEIL. PTJ construction group shall
support these activities whereby at the end, provisional handover is achieved.

Upon satisfactory Pre-commissioning, commissioning activities and start-up is

initiated by PTJ commissioning group along with KEIL team.

Upon satisfactory Performance test run of the facilities, PTJ commissioning team
shall receive written acceptance from KEIL team. This shall be considered as
“Hand over” of the facilities.

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8.1 Responsibility of PETROJET

 Plan the total commissioning activities detailed at task level and develop
detailed schedule
 Develop commissioning organization and coordinate with KEIL commissioning
team to participate wherever applicable.
 Notify KEIL at least 24 hours in advance of any field tests to be witnessed or
inspections required.
 Ensure and verify completion of erection by Construction group
 Carry out the Pre-commissioning (Pre Comm) as per procedure, check-list
and flow chart
 Get the Mechanical completion/ Provisional handover certificate from KEIL
before pre-commissioning and commissioning
 Arrange the PSSR with KEIL to get the clearance for starting of
commissioning
 Carry out the Commissioning and Start up (CSU) as per procedure, check-list
and flow chart
 Notify and involve KEIL in Pre-commissioning and commissioning as per plan.
 Report progress on Pre-commissioning to KEIL management on Daily/
Weekly basis
 Plan and coordinate with vendors and specialists as required for tests and
commissioning of vendor items or special sections.
 Maintain documentation
 Get the work permit from KEIL which will be work wise on daily basis
 Establish the operation of the facilities and organize for demonstration of
Performance test.
 Carry out Performance Test run
 Co-ordinate with KEIL to hand over the facilities after successful Performance
Test Run

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8.2 Responsibility of KEIL

 Obtain necessary approvals from local authorities

 Assign and provide the required manpower to support for commissioning
besides erection contract workmen
 Co-ordinate with PTJ commissioning team for on-going and planned activities
 Witness completion of erection/ construction
 Participate in Pre-commissioning and witness wherever applicable
 Issue the Mechanical completion/ Provisional handover certificate
 Participation in PSSR and give clearance for commissioning
 Provision of Power supply
 Provision of Product for commissioning
 Issue the required work permit to PTJ
 Provision of Lock- Out /Tag- Out
 Participate in Process commissioning
 Award Final Completion Certificate to PTJ at the end of successful
Performance Test Run

8.3 Commissioning Manager

The Commissioning Manager shall ensure that the safety procedures for the
job are being practiced by all. He shall
 Be responsible for Risk assessment meeting prior to Commissioning
and start up.
 Establish a chain of command by announcing which individual will take
charge in the event he becomes incapacitated.
 Ensure safety supplies are available at site (i.e., hearing protection,
hard hats, safety shoes, work gloves, first aid kits, etc.).
 Institute a clear reporting procedure to ensure immediate and proper
notification in the event of sickness or accidents.

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The KEIL Operations Coordinators in coordination with PTJ commissioning

lead shall include safety in their daily progress reports to the PTJ
Commissioning Manager, who conducts a daily coordination meeting and
advises the KEIL counterpart of progress and/or issues.

8.4 Safety Officer

Safety Officer will be responsible for

 Directing the overall safety effort
 Indoctrination of new personnel in start-up and commissioning safety
considerations including the requirement to wear safety gear
 Inspection of safety equipment regarding adequacy, condition, and
availability
 Ensuring procedures such as electrical lockouts and work permits are
implemented as the time arrives
 Working with the Commissioning Manager to establish the reporting
and review procedures for issuing various work permits, vessel entry,
work in hazardous situations, accidents, near misses, etc.
 Participating in Daily progress/ planning meetings

8.5 Commissioning Personnel

Each person engaged at site for commissioning is responsible for

 Being aware of the hazardous material, areas and situations in the
facility.
 Ensuring unfinished areas or hazardous locations are properly
identified and marked.
 Constant monitoring of the site area in which the individual is working
or passing through for hazardous situations and conditions.

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 Wearing and maintaining in good condition all personal protective

equipment (PPE) appropriate to the work being performed.
 Observing the actions of co-workers and reminding them when
incorrect or unsafe actions or procedures are taking place.
 Assisting the contractor and client in checking safety equipment. If an
individual observes a problem, he/she should discuss it with the
involved workers and inform his/ her supervisor.
 Immediately reporting any unsafe conditions, unsafe equipment, or
unsafe practices.
 Promptly reporting any work-related injuries, illnesses, or “near
misses.”

However, it is a good practice to assign the role of overall safety assurance at

the commissioning site to a dedicated Safety Manager.

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9 Pre- Commissioning plan

9.1 Sequence of pre – commisioning of systems

Generic Pre-Commissioning Flow Chart is attached as Annexure – .

Pre-commissioning and Commissioning of the SIBA FIELD DEVELOPMENT
facility is envisaged and planned to be carried out in following sequence of
systems/ subsystems specific to Electrical, Cathodic Protection (CP), Electrical
Heat Tracing (EHT), Instruments, Telecom and Life Safety :
1. Electrical power establishment (Generation, Receipt, Distribution)
2. Emergency power establishment (Solar, DG Sets)
3. Lighting system
4. Earthing and Lightning system, Pipeline and bullet CP system
5. HVAC System
6. UPS (AC & DC)
7. Integrated Control and Safety System (ICSS) installation and completion
8. Well Head Control System(WHCS), HUB Control System (HCS), High
Integrity Pressure Safety System(HIPPS) and Multi Phase Flow Meter
(MPFM)
9. Telecommunication System
10. Fire water system alongwith Fire fighting network and deluge system
11. F & G system
12. NOVEC Gas based Clean Agent System
13. CF31 Rim Seal Fire Protection System
Commissioning Plan is attached as Annexure – 4, which forms the base of the
methodology. The final plan shall be the one updated at site by the Commissioning
team based on the actual site status, conditions and other factors.

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9.2 Communications
As Construction and Commissioning activities may be parallel and/ or
overlapping, a proper communication system is necessary for proper, safe
and efficient functioning.

 The Communication channel shall be typically as per commissioning

organization and Contractual obligations.
 PETROJET (PTJ) Construction Manager shall communicate with PTJ
Commissioning Manager and PTJ Project Manager about ongoing
activities, requirements, progress, offer for inspection/ provisional
handover, Punch list progress etc.
 PTJ Commissioning Manager shall communicate with KEIL
Commissioning Manager and the concerned Operations Coordinator/s
about the planned activities, progress, areas of concerns etc.
 PTJ Commissioning Manager shall communicate with his Construction
Manager and Project Manager about plans, priorities, outstanding
construction activities etc.
 PTJ Commissioning Manager shall also be responsible for
communication with Safety Officer/Manager
 PTJ Project Manager shall communicate with Home office /
Engineering Division for any engineering issues noted at the time of
commissioning.
 PTJ Project Manager shall communicate with Vendors/ Vendor
representatives.
 Operations Coordinator/s shall communicate with other Commissioning
personnel, including Panel/ Field operators, Mechanical/ Electrical/
Instrumentation Engineers etc.

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 Daily Commissioning Meetings shall be held once the Mechanical

completion stage is approached, which will be chaired by PTJ
Commissioning Manager, and attended by his Construction Manager &
Project Manager, KEIL Commissioning Manager and Operations
Coordinator, Safety Officer as minimum.

9.3 Exception List / Punch List Resolution

This procedure will establish system to identify, record and rectify the
incorrect, incomplete, damaged and/ or unsafe fabrication or installation.

 After completion of construction/ erection of an equipment/ sub-system

or system, the PTJ Construction representative shall intimate PTJ
Commissioning representative for inspection and acceptance.
 PTJ to provide inspection package or binder on each system/ sub
system (which should include but not limited to marked up each line/
equipment on latest version of P&ID and also Isometric drawing) which
shall be used by KEIL/ PTJ joint commissioning and start up team.
 PTJ/ KEIL Commissioning team shall carry out joint inspection of the
equipment/ sub-system or system with respect to Engineering
documents and/ or standard Engineering practices.
 Based on the outcome of this joint inspection / walk-down, a list of such
deficiencies is prepared by PTJ/ KEIL Commissioning team, which
shall be referred to as punch-list.
 This punch-list is submitted to the PTJ Construction Representative.
The items on the punch-list are classified under the following
categories
 Category A - Activities must be completed before pre-
commissioning the system
 Category B - Activities can be completed during pre-commissioning
the system
 Category C - Activities can be completed after pre-commissioning
the system but before commissioning

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 For each item on the punch-list, a scheduled completion date as

mutually agreed is assigned.
Punch-list shall be live document and is updated periodically by the PTJ
Construction Representative to reflect the progress of completion and the
same will be distributed to PTJ/KEIL Commissioning Representative.

9.4 Equipment/ System hand over

The Equipment/ System Hand over is done by Construction group to
Commissioning group to release them for Pre-commissioning and
Commissioning activities. This is marked by ‘Provisional Handover’ or ‘Ready
for Pre-commissioning’, and is done formally by signing relevant Provisional
Handover certificate.

 The Equipment/ Subsystems/ Systems are fabricated, constructed and

erected as per Commissioning plan and priorities.
 PETROJET Construction group offers the Equipment/ Subsystem and/
or System to Commissioning group once the stage of Completion of
Erection/ Mechanical completion is reached for that particular
Equipment/ Subsystem/ System.
 Relevant test records and certificates are also shared by Construction
group, wherever applicable. Such records may include radiography
reports, DP test, hydrostatic test, pneumatic leak test, calibration
reports, lubrication records, alignment records, inspection certificate
and records etc.
 The Commissioning group inspects the offered components and
verifies the fabrication and installation as per the Design documents,
specifications and drawings.
 If found satisfactory, the Equipment/ Sub-system/ System is accepted
as ‘Provisional Handover’ by PTJ/ KEIL Commissioning group for Pre-

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commissioning activities. This will be done by signing relevant form by

all persons concerned.
 If discrepancies are observed, a Completion exception list/ Punch list is
prepared based on the inspection and the items are listed and
categorized as described under Section 13.2 above. Category A items
are identified and attended by Construction crew as minimum before
offering for re-inspection.
 The Commissioning group shall accept ‘Provisional Handover’ once
when Category A items are attended to satisfactorily as minimum, and
a certificate with the same affect is jointly signed.
 Thus, the different Systems are gradually and progressively taken as
‘Provisional Handover’ for further Pre-commissioning activities.
 Once the system is accepted by Commissioning group, it takes control
of it and the KEIL Work permit system becomes applicable to the
components and subsystems of that System.
 However, the Completion exception list/ Punch list is maintained and
updated as the other Category items are being attended to XXX.

9.5 Engineering changes

As the Mechanical completion, Pre-commissioning and Commissioning

activities progress at site, it may be required to make some changes (usually
minor) in installation of mechanical components, piping routings, ranges of
instruments, settings of electrical components/ instruments, set-points of
instruments etc. as compared to the design specifications, documents and
drawings.

 Any proposed change to the original ‘for construction’ document/

drawing shall be through proper formal procedure of filling up
Engineering Change form.

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 The proposed change shall be described by the initiator with the details
like the nature of change, the reason, sketch/ mark-up of the change,
engineering drawings/ documents affected etc. on the form.
 The proposed change shall be seconded by PTJ Commissioning
manager if felt appropriate, and discussed with Home office Design
division.
 The Home office Design division shall approve the change if felt
appropriate and inform the Site.
 The PTJ Commissioning Manager shall convey the change required to
the concerned Construction/ Discipline representative with the relevant
approved Engineering Change form.
Such changes shall be recorded on Master document file being maintained at
site, to be incorporated later into ‘As Built’ documentation.

9.6 Work permit System

The Work permit system ensures the safety of the personnel while working on an
equipment, by complete isolation of that equipment including Lockout of
Electrical Isolation of equipment. It ensures that any safety precautions required
of the maintenance personnel are brought to their notice and enforced.

It ensures that operating personnel are aware of work in progress and do not
take any action that will affect the isolation of the equipment being worked on.

It also ensures that ‘at a glance’ record (register) of work in progress is available
and that satisfactory ‘handing back’ of equipment takes place when work is
completed.

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9.7 Electrical Safety

All equipment of Electrical Switchgear shall be locked out to protect against
accidental or inadvertent operation when such operation could cause injury to
personnel. Before lockout commences, job authorization should be obtained.
Employees authorized to perform lockout shall be certain as to which switch,
valve, or other energy isolating devices apply to the equipment being locked
out. More than one energy source may be involved.
 Electrical lock outs shall be performed under KEIL Permit to Work
control.
 The person requesting equipment to be locked-out signs should have
proper work-permit duly authorized.
 The person requesting equipment to be locked-out signs the Lockout
Logbook with his name, the date, the equipment name and number,
and the lock number.
 In the event two or more persons are required for the same piece of
equipment, two or more requests must be made and two or more locks
installed.
 All lockout of electrical equipment must be done by the electricians. No
one except the electricians is allowed to engage or disengage
equipment or add or remove locks.
 The key to each lock is retained only by the person performing the work
on the equipment. Electricians working on equipment retain the key if
they are the same person who requested the lockout and signed the
Lockout Logbook.
 Each lock shall have a unique key.
 At completion of the job, the person who signed the request provides
the key to the electrician, who removes the lock. The electrician
removes a lock only for the person who signed the request. Relief

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personnel must sign the Lockout Logbook and procure his/her own
lock. No one is allowed to accept the transfer of an issued lockout key.
 The Lockout Logbook should be signed by the person requesting the
lock to be removed, stating his work on that particular job is complete.
The final lock may not be removed without the approval of the shift
Electrical/Instrumentation Engineer.
An item cannot be powered until all locks on it are removed.

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10 Prepare Requirement and Schedule of Commissioning Spares,

Tools, Process Material, and Consumables

Following aspects are covered under general preparation for Commissioning

 All the necessary documentation is in place, viz. engineering

documents, inspection documents, certificates, approvals, manuals,
vendor literature etc.

 Sufficient and qualified manpower is available. If a specific training is

required, it should be conducted before commissioning.

 Special Equipment/ tools as necessary are made available and ready.

 Safety system in terms of installation, procedures, training etc. shall be

in place.

 Utilities like water, Instrument Air, Telecommunication, Lighting are

made available or has to be on stand-by.

 Consumables like Gaskets, Fasteners, Cable Jointing Kits, hand

Gloves etc. required for Pre-commissioning are available.

 Raw materials required for Process commissioning are available.

 Arrangements are made for logistics of Raw material, Products, By-

products and Effluents.

 Typically, Commissioning and minimum spares are supplied along with

the Equipment / Packages wherever applicable.

 It needs to be ensured at site that all the Vendor recommended and

other spares are as per the specifications, in the right quantity and
properly stored.

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 KEIL system of storage and issue of material can be followed for such
spares. Proper authorization should be assigned along with the
Commissioning team formation.

 Pre Start-up Safety Review (PSSR) is carried out jointly by

representatives of Construction, Client, Operations, and Safety groups.

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11 Pre-commissioning (Aspect - Wise)

This section describes the checks and activities to be carried out on a Mechanical
complete system which is provisionally handed over by Construction group. The
Pre-commissioning shall be conducted based on the procedures and guidelines
under this section and the relevant Annexures. These checks and activities to be
carried out cover all areas including Process areas. Normally, these aspect wise
pre-commissioning activities are carried out concurrently by different discipline
teams in all the field areas while system/ subsystem wise checks and activities are
carried out sequentially by a multidisciplinary team. Specific checks and activities
for specific system/ subsystem wise are detailed out in subsequent chapter.

Please refer to the attachment no. 9 for Pre-commissioning sequence of supports

systems. This is a high level explanation, for details individual systems must be
referred.

11.1 Safety measure

There are various Operational Hazards and Generic Hazards at any Oil & Gas
facility. While all Operational Hazards are considered by the designers and
mitigatory actions are incorporated in the Design and Operation Manuals, the
Generic Hazards prevailing mostly during Pre-commissioning and
Commissioning are addressed below:
 Fire
Where oxygen, a fuel, and an ignition source exist, there is a potential for
fire. As KEIL handles Natural Gas from SIBA field, besides LPG and
Condensate, both of which are highly flammable liquids, Fire hazard is a
very potential hazard at the facility.
 Electrocution
Electricity is for all practical purposes everywhere: in motors, switchgears,
lights, electric tools, cables, instruments, etc. Any electrical installation or
equipment has the potential to cause electrocution; therefore, they must

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be installed/erected, operated, and maintained with care. This requires

strict precautionary measures to reduce the possibility of electric shock or
electrocution. Improper grounding, use of ungrounded hand tools and
loose electrical joints are often a danger on construction sites.

 Electrical Faults
Electrical short circuits and flash overs in distribution panels, transformers,
battery banks are rare but not uncommon. These can be prevented by
proper checks performed before charging the supply distribution panels by
authorized persons only and after ensuring proper equipment grounding.

Electrostatic charges can accumulate on mechanically separated,

chargeable, non-conducting surfaces and will discharge upon contact with
personnel or in extreme cases, with gases, vapour, and dusts. Ignition is
possible if the discharge creates a spark in an explosive atmosphere.

 Heat
Working in environments with elevated temperatures can result in heat
exhaustion, cramps, and heatstroke.

Heat exhaustion results from physical exertion in hot environments and is

characterized by low skin temperature, paleness, dizziness, weak pulse,
and profuse sweating.

Heat cramps result from prolonged exposure to hot environments while

under exertion and are characterized by the cramping of skeletal and
intestinal muscles.

Heatstroke is more serious than the earlier heat conditions and occurs
when the body loses its ability to cool itself and body temperature rises to
dangerous levels. Heatstroke is characterized by hot, dry skin, severe
headache, rapid temperature rise, and possible loss of consciousness.
Because this condition can be fatal, the victim should be cooled as soon
as possible and medical personnel summoned immediately.

 Noise

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Elevated noise levels can disrupt concentration, interfere with

communication, and otherwise distract workers in the performance of their
jobs. At higher levels, noise can cause hearing loss, aural pain, nausea,
and in severe cases, reduce muscular control.

 Rotating Machinery
Rotating machinery presents a danger to nearby workers by seizing and
winding up loose clothing, belts, ties, hair, etc. Rotating machinery
(couplings, gears, chains, shafts, etc.) always should be provided with the
appropriate protection devices, such as mechanical guards and other
safety devices, and must remain in place during operation.

During commissioning of equipment, extra care must be taken to barricade

off areas where potential hazards exist, such as:

 Motors being run uncoupled

 Machinery being operated for observation without full protective

equipment in place

Unsafe situations can be reduced by a good housekeeping around the area of

activity, on every day basis. Unsafe practices should be curtailed by proper
training and awareness of all site personnel.
Every day activities during Pre-commissioning should be analysed daily, in the
morning for any eventual safety problem and mitigatory measures discussed
and taken before start of the work. This could be use of Personal Protective
Equipment (PPE), positing of Fire Tenders as a standby at critical junctures of
work and following the Safety work Permit system at an appropriate stage.
Emergency Handling system, specific to each site, should be in place and
shared with all personnel at site in the morning safety talk for 10 minutes. Use
of proper platform or support for working at heights, working inside the
confined environment are some of the critical aspects which must be
addressed sufficiently to prevent accidents.
Owner’s Safety Manager plays a pivotal role in ensuring safety at site.

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11.2 Cleaning and House Keeping:

 Clean all equipment internals of oil & grease, rags, forgotten tools and
tackles, personal belonging of inspection personnel etc.
 Clean all tanks and LPG bullet from inside. Clean the water draw off drain
sump, check the hose/swivel joints for roof hose drain are not leaking,
emergency drains are filled with water, control system for venting the tank
are correctly installed, level and temperature instruments are installed.
 Remove scaffolding, temporary supports, bracing that were installed on
equipment, piping, rotating machinery etc.
 Provide continuous clean-up of the construction and operational area.
 Remove excess materials, temporary facilities and pick-up trash.
 Perform washing for further clean-up as required.

11.3 Weather Protection

 Protect equipment from normal weather conditions, corrosion, or damage

before commissioning. This shall also include monsoon tapes to all
instruments, applying anti seize compound to all threaded covers, applying
sealant compound to all cable gland entries etc. Provide all installation and
commissioning spares.

11.4 Flushing and Drying

 Flushing to be carried out system/sub system wise.

 Dry out all equipment and piping by water draining from all low points and
blowing with air.
 Flushing to be carried out with air blowing/cardboard bursting for all above
and underground piping to remove dirt, welding slag etc. after hydrotesting.
 For lines in water service, use water as the flushing medium.
 Following to be noted for flushing of lines:
1) Orifice plates, control valves, thermo wells, vortex flow meters
and any other online instruments, pressure relieving devices
should not be installed before testing and flushing. If installed,
they shall be removed and necessary spool pieces shall be

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provided in their place wherever required during flushing to

avoid damage.
2) Disconnect inlet/outlet connections to equipment (heat
exchangers, process vessels, heaters etc). Also disconnect
pump suction/discharge piping. Always flush through equipment
by-pass to an open end.
3) Remove all pump strainers.
4) Instrument lines should be closed off or disconnected
5) Flush pump suction and discharge piping while disconnected
6) Flush through open end lines. Do not restrict flow
7) Regulate rate of flushing medium from it’s source. For example,
for water from a tower, regulate at the tower outlet; for
compressed air, at the valve in the supply to the line being blown
8) Flush through all drains and vents
9) Where possible, flush downward or horizontally
10)First, flush or blow each main header from the source to end
11)Second, flush or blow each lateral header from the main to end
12)Third, flush or blow each final pipe from the lateral to end
13) Flushing operation is deemed to be complete when pipe flushing stop
coming out from open pipe ends.

11.5 Dewatering Piggable flow lines after Hydro test

 The pipeline shall be dewatered by launching series of appropriate pigs

pushed by air/Nitrogen.
 Dewatering shall deem to be completed when no water is received at the
receiving terminal during the travel of pig and the last pig received is “touch
dry”.
 After complete dewatering, the entire pipeline shall be purged with nitrogen.
 Carry out leak test with nitrogen as per procedure given below and maintain
a positive nitrogen pressure thereafter, till the line is ready to be
commissioned.

11.6 Leak and Pressure testing

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 After flushing operation has been completed, install all valves, pipe fittings,
control valves, online instruments, safety devices etc., which were removed
prior to flushing operation, for each process system.
 Connect all equipment like heat exchangers, process vessels, rotating
equipment, and other process equipment with the piping system. Keep all
atmospheric storage tanks isolated from pressure testing loop.
 Conduct leak and pressure test in accordance with applicable statutory
/safety/other applicable design codes and specifications.
 For hydrocarbon lines, leak test is to be carried out after flushing and
inerting the line with nitrogen. The test pressure will be air or nitrogen
system pressure or the section design pressure, whichever is lower. For non
hydrocarbon lines, leak test is to be conducted with air. For lines in water
service, test pressure will be the rated discharge pressure of the pump.
Follow API 1110 or equivalent for leak test pressure.
 For the purpose of leak tests the unit will be divided into sections of
approximately the same design pressure. Air (or Nitrogen) will be injected at
different locations depending upon check valve locations.
 Leak tests up to 5 kg/cm2g pressure is to be conducted after
purging/flushing. Leak test at higher pressure shall be carried out in steps of
5/10 kg/cm2.
 The pressure rise must be monitored at several points and preferably
recorded. The leak test is satisfactory if the drop is pressure is less than
0.05kg/cm2/hr over a period of 4 continuous hours.
 Rectify all leaks detected during leak test by tightening or other methods.
 During leak test, disconnect all instrument air piping and tubing, and all
impulse piping and tubing.
 After leak test has been completed, maintain a positive pressure of 0.5
kg/cm2g with nitrogen in all hydrocarbon lines till commencement of
commissioning activities.
 Flushing, drying and leak testing Pre Commissioning Checklist for all the 18
systems and Sub Systems are given in Attachment I.

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11.7 Storage Tanks

 Calibrate tanks and LPG bullet: calibrate storage tanks and LPG bullets and
obtain certification from the concerned authorities for the calibration charts.

 Caution while filling empty tanks, following should be adhered to:

1) Always fill the tank slowly.
2) For filling tanks with hydrocarbons, initial filling velocity should
be less than 1 m/s, till the inlet nozzle is submerged.

11.8 Piping systems

 Check pipe hangers, supports, guides and pipe specialties for hot settings
and make minor adjustments as necessary.
 Install seals on valves where necessary. Replacing dried up graphite seals
with fresh ones
 Correct support, vibration and thermal expansion problems detected during
commissioning

11.9 Rotating machinery

 Install mechanical seals, permanent packing and accessories wherever

required.
 Level base plates and sole plates. Alleviate any excess piping stresses that
may be imposed on pumps and drivers. Chemically clean complete lube and
seal oil system when specified. Dispose of waste and cleaning media as per
site instructions.
 It is important to make sure that the inside of piping (especially suction
piping) around the compressor has been cleaned. The lube oil lines and
compressor suction lines downstream of the suction filter should be acid
cleaned and pickled, if necessary, as per OEM manuals.

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 Obtain service engineer for technical assistance during installation. Pre

commissioning and commissioning of rotating equipment should be done in
presence of the manufacturer.
 Check for correct direction of rotation and freeness of the rotor.
 Do cold alignment
 Check correct quality and quantity of lubricants are filled.
 Conduct no load test of motors and turbines.
 Check bearing temperatures, vibration, over speed trip functions and other
safety devices.
 Make hot alignment and any adjustments required when the rotating
equipment is put into operation.

11.10 Electrical Equipment / Systems (Also includes HVAC, EHT &

CP)
 Testing and checking of electrical equipment for proper earthling, continuity,
insulation resistance and secondary injection testing of relays after
insulation resistance test, ratio test of transformer, stability check of different
relays, high voltage test of cables, illumination level checking.
 Checking of CP system, Battery capacity.
 After obtaining clearance from hydro testing lines and equipment, start
insulation and electrical tracing as per design requirements, to achieve
completion prior to commissioning. Commence this activity after completion
of leak testing.

11.11 Instrument Systems

 Carry out all non-operating checks that will ensure instrument operability i.e
remove all shipping stops, check pointer travels, and verify instrument
capability to measure, operate and stroke in the direction and manner
required by the process application. Clean all impulse lines by blowing with
cooled and filtered clean air compatible with instrument components.

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 After commissioning the air compressor and dryer system, clean all air
supply headers by blowing with clean air and check them for tightness. Also,
clean service air header with air from service air receiver.
 Leak test pneumatic control circuits.
 Hydro testing of impulse tubing and other associated tubing
 Check piping from instruments to process piping for tightness.
 Install and connect all system components and verify their conformance to
specifications and design criteria for functional and range using dummy
transmission signals as needed.
 Check all electrical signals and alarm wiring for continuity, correct source of
power and polarity.
 Check thermocouple for proper joining of wires, position of elements in
wells, proper polarity and continuity of receiving instruments.
 Identify orifice plates by tagging and check for proper installation of
upstream side of plates.
 Isolate or remove if necessary, the components such as control valves,
positive displacement meters, and turbine meters for pressure testing.
Reinstall these items after testing the system.
 Check bores of orifice plates and install these plates after completion of
flushing operations.
 Calibrate instruments with standard test equipment and make all required
adjustments and control point settings. Fully pressurize and energize the
transmitting and control signal systems by opening process connections at
primary sensors and final regulators and by making control mode settings
for automatic operation of equipment as the process facility is charged and
brought on stream.
 Check setting of all alarm and shutdown switches.
 Check all shutdown systems before commissioning.
 Arrange for testing and recalibration of all the safety valves settings at site.
Ensure that safety valve isolation valves are locked open as per drawings.

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 Check each field-bus segment for compliance with respect to design

guidelines like availability of minimum voltage at each instrument end,
communication with hand held terminal, measuring noise level, checking
configuration of each device etc.
 Wet leg/dry leg calibration of all DP type level instrument including zero
level/suppression.
 Calibration/ setting of radar/RF type level instruments installed on the
vessel/tank
 Installation and proving of partial stroke testing circuitry of shutdown valves.
 Check that orifice plate has been installed with proper tightness before going
ahead with welding /installation of pre-fabricated hook-ups.
 Check that all Dampers used for control are operating both in manual mode
(winch operation mode) and automatic mode (pneumatic mode)
 Check that opening/closing time of dampers are within stipulated period (As
required by design conditions)
 Check that all skin type thermocouples are installed as per installation
drawings.

11.12 Life Safety Equipment’s

 Ensure all safety devices are installed after calibration test and adjustments.
 Ensure partial stroke testing of all shut down valves.

11.13 Fire and Gas System

After completion of pre-commissioning checks for F&G system, pre-commissioning
activities are initiated which are aimed at checking the functionality.
• Check if cable continuity and megger test results are okay.
• Verify the power supply to the system.
• Verify the Battery condition and check the system on Battery back-up.
• Simulate each Gas detector and check that connections to F&G panel are
checked for connectivity by simulating the signal.

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• Field Manual switches and Manual Call Points are simulated by making/
breaking contacts and verifying the signals in F&G panel.
• Check for operation of all Flashing Beacon and Alarm Sounders
functionality.
• Deluge valves operation is checked as per Vendor instructions.
• NOVEC Gas based Clean Agent System installation is verified for
completion.

11.14 Telecom Systems

After completion of Telecommunications work including the cabling and termination,

pre-commissioning activities are initiated for checking the functionality. It would be a
good idea to follow the following guidelines:
 All Telecom sub system vendors should be present to certify the satisfactory
completion of the work as per the envisaged schemes.
 Telecom Service Integrator (TSI) shall also be present to check the two way
inter communication between different systems including proper termination of
the backbone- network cables.
 Functionality like power failure back up, standby system automatic taking over
and critical communication of emergency to manned locations are some of the
essential checks to be performed.

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12 Site Acceptance Procedure

After the hydrocarbon has been introduced in the process plant and treatment
process results into production of on-grade products, the process is scaled up to the
design capacity operation. A stable stage is reached when products are available on
a sustained basis for storage and despatch. All the associated support systems
should have also been put to use by that time. Performance Guarantee Test Run
(PGTR) for the main process of Gas Treatment is carried out by the Process
Licensor ensuring the measurement of all guaranteed figures. Once this document
has been prepared and signed, it demonstrates Site Acceptance of the process plant
areas as designed, engineered, erected and commissioned by all the concerned
agencies.
As a sub set to the total process Site Acceptance, Site Acceptance for all
subsystems are also carried near to its full design capacity while noting the
significant observations. The achieved parameters are required to be extrapolated
based on the design conditions and related to achieved conditions. This set of
document becomes the basis for Site Acceptance of each subsystem for meeting the
contractual obligations by respective vendors.

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13 Pre-commissioning and Ready for start-up Procedure for Utility

13.1 Sub-System: SYS-020-01 Diesel Storage and Supply System

 System Description

 Sub-Sub-system: SYS-020-01-01 Tanker unloading to Diesel Storage Tank

 Receipt of Diesel in Diesel Storage Tank 02-TK-2601 from road tankers using
Diesel Transfer Pump 20-P-2601A/S.
 Sub-sub-system: SYS-020-01-01 Diesel supply from Diesel Storage Tank to Fire Water
Pumps, GTG Diesel Day Tank and Essential Generator

 Supply of Diesel by Diesel Transfer Pump 02-2601A/S through Diesel

Filter/Coalescer Package 02-Z-2601 to:
a) Fire water Pumps 02-P-5001B/C/D
b) GTG Diesel Day Tank
c) Essential Generator 02-DG-6201A/B

 Note:
Pre-Commissioning SYS-020-01 will enable the following:
 Enable commissioning of the two 1.2 MVA Essential Generators 02-DG-
 6201A/B. At this stage, it is envisaged to transfer Diesel only to Essential
Generators.
 With the Essential Generators, it will be possible to commission Instrument Air
Compressors 02-Z-3701A/B/C.
 With the Essential Generators, it will be possible to commission Fire Water Jockey
Electrical Pump 02-P-5002A/B and Fire Water Pump Electrical 02-P-5001A.
 DCS, SIS, FGS, UCP, Communications Systems, emergency lighting will be
available.

Refer ATTACMENT-4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

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 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-01-01 Tanker unloading to Diesel Storage Tank

 Flush, purge, leak test and keep under nitrogen pressure tanker unloading line
carrying Diesel as per the general procedure up to Diesel Storage Tank 02-TK-
2601, including suction side of 02-P-2601A/S and 02-P-2601A/S discharge side up
to Diesel Storage Tank 02-TK-2601. Keep Diesel Storage Tank 02-TK-2601
isolated to retain nitrogen pressure. Ensure strainers on the tanker receipt and
pump suction lines are clean.
 Clean, inspect and Commission Diesel Storage Tank 02-TK-2601 as per general
Petroleum Product Storage Tanks–Commissioning Procedure given in Attachment-
6.
 Ensure following instruments are in line:
a. PDG 0104
b. PDG 0105
c. ESD 2601A/B/LZA 0103
d. ESD 2601C/PZIA 0106
e. LIA 0101
f. PVRV 0102
g. FI 0109
h. PG 0107
i. RO 0108

 Set the instruments where applicable as per Instrument Set Points given in
Attachment – 7 Instrument set points
 Complete pre commissioning activities for 02-P-2601A/S, as per the general pre
commissioning procedure. Refer ATTACHMENT XX for OEM manual for 02-P-
2601A/S for vendor’s pre commissioning procedure.
 Mobile fire tender is stationed at the site with foam storage.
 Swing spectacle blind in open position at nozzle N6. Station a vacuum truck to
remove any excess Diesel filled.
 Ensure 3” valve at nozzle N1 is closed.
 Portable generator to operate 02-P-2601A/S.

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 Ready for start-up for SYS-020-01-01 Tanker unloading to Diesel Storage Tank

 Connect the tanker unloading line to the tanker unloading connection. Connect the
crocodile clip to the tanker unloading line and to earthing at the other end.
 Line out 02-P-2601A/S suction line up to pump suction. Open the valve at the hose
connection and allow Diesel from the tanker to fill the suction line of 02-P-2601A/S.
 Carefully open the vent of 02-P-2601A/S to displace the nitrogen and fill the pump
casing with Diesel. Small quantity of Diesel overflowing from the pump vest will
collect in the Drip Tray of the pump for priming the pump. To achieve a flooded
suction, the tanker should be at a higher elevation with respect to the pump
suction, or the tanker should be positioned on a ramp.
 Line out the discharge side of 02-P-2601A/S to Diesel Storage Tank 02-TK-2601 at
nozzle N2, via the bypass of RO 0108.
 Start 02-P-2601A/S as per the OEM manual given in ATTACHMENT XX with a
portable portable DG set to be made available at site. Receive Diesel in 02-TK-
2601, ensuring that the velocity of Diesel at nozzle N2 is less than I m/s. The
nitrogen from the discharge piping will be vented from PVRV 0102.
 Ensure that PDG 0104 and PDG 0105 show normal readings.
 Ensure there are no leaks in the line. If leaks are found, the pump should be
stopped and the leaks attended. Mobile fire tender is stationed at the site with foam
storage as a precautionary measure.
 Diesel inventory in the tank should not exceed that required to commission and run
the Essential Generator 02-DG-6201A/B and commission the air compressors and
electrical fire water pumps. If excess Diesel is filled, remove by evacuation with
vacuum truck, as high Diesel inventory in the tank in absence of yet to be
commissioned firefighting facilities can pose a high risk beyond the capability of the
mobile fire tender with foam storage.
 LZAHH 0103 will trip the pump in case of HHLL in the tank.
 While transferring the Diesel from the tanker keep watch on the level of Diesel in
the tanker, so that 20-P-2601A/S does not loose suction.
 Make up Diesel from tanker as it is consumed for initiating plant startup, following
the above procedure.

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 Pre-commissioning of SYS-020-01-02 Diesel supply from Diesel Storage Tank to Fire

Water Pumps, GTG Diesel Day Tank, and Essential Generator

As SYS-020-01-02 is contiguous to SYS-020-01-01, it is recommended that pre

commissioning activities of this Sub-Sub-System be taken up with Sub System SYS-020-01-
01 with respect to the following:

 Flush, purge, leak test and keep under nitrogen pressure the section starting from
2” valve downstream of FE 0109 up to:
i. Diesel supply to Fire Water Pumps 02-P-5001B/C/D day tank inlet.
ii. GTG Diesel Day Tank
iii. Essential Generator 02-DG-6201A/B up to hose connection.
 Complete pre commissioning activities of Diesel Filter/Coalescer Package 02-Z-
2601 as per OEM manual given in Attachment XX.
 Mobile fire tender is stationed at the site with foam storage.
 Station a vacuum truck to route Diesel, if required, from 02-Z-2601

 Ready for start-up for SYS-020-01-01 Tanker unloading to Diesel Storage Tank

 Close the tanker unloading 3” valve at the tanker unloading connection.

 Keep open the 3” valve on tanker unloading line and close 2” valve on RO 0108
bypass. This is to ensure that the tanker unloading line does get pressurized due to
incidence of solar radiation when it is blocked in during periods of no unloading.
 Crack open the 3” valve at nozzle N1 and ensure the 02-P-2601A/S is primed by
overflowing some Diesel from the pump vent. Once the pump is primed, open the
3” suction valve.
 Line out Diesel supply line to Fire Water Pumps day tank, GTG Diesel Day Tank
and Essential Generator. Diesel should be transferred to each destination, one
destination at a time. When transferring Diesel to a particular destination, it is to be
ensured that velocity at the entry to the destination tank is below 1 m/s, till the entry
nozzle is submerged. There should not any free fall Diesel in the destination tank.
 Start commissioning 02-Z-2601 as per OEM manual given in ATTACHMENT XX,
the operation of the 2” line to local drain pit.
 Start 02-P-2601A/S with power from portable generator, and route Diesel to the
destination tank one at a time, under coordination with operating personnel in the
destination tank area, so that the destination tank does not overflow. Stop 02-P-
2601A/S when the required quantity of Diesel is filled in the destination tank.
 In case of low low level in 02-TK-2601, LZIALL 0103 will trip 02-P-2601A/S.

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13.2 Sub-System SYS-020-02 Air Compressor and Dryer; Air and

Nitrogen distribution system

 System description

 Sub-Sub-system: SYS-020-02-01 Instrument Air Compressor Package

 Comprises of three Instrument Air Compressors supplied as a package item. Two

are working and one is standby. The compressors discharge to a common 3”
header to Wet Air Receiver 02-V-3702.

 Sub-Sub-system: SYS-020-02-02 Wet Air Receiver, Instrument Air Dryer and Filter
Package, Dry Air Receiver and Instrument/Plant Air Distribution

 Comprises of Wet Air Receiver 02-V-3702, Instrument Air Dryer and Filter Package
02 Z-3702A/B, Dry Air Receiver 02-V-3601 and Instrument Air Distribution System,
all part Sub System 2.1. The compressed air is routed to Wet Air Receiver 02-V-
3702. The stream from Wet Air Receiver 02-V-3702 is routed to Instrument Air
Dryer and Filter Package 02-Z-3702A/B, and then to Dry Air Receiver 02-Y-3601.
The dry air air from is routed to the instrument air distribution header.
 Wet Air Receiver 02-V-3702 is protected by PSV 0103 and Dry Air Receiver 02-V-
3601 si protected by PSV 0107. In case of high consumption of plant air, PICA
0106 shuts XV 0102 on the plant air line.
 A parallel stream from the outlet of Wet Air Receiver 02-V-3702 is routed to plant
air distribution header, If instrument air header pressure drops below 7.8 barg, XV-
0102 closes, and it is reset when the pressure increases to 8 barg, under control of
PICA-0106.
 PZIALL 0105 on instrument air header initiates Level 2 ESD.

 Sub-sub-System: SYS-020-020-03 Nitrogen Cylinder Rack Package and Nitrogen

distribution

 Comprises of 2 sets of nitrogen cylinder racks supplied as a package. Nitrogen

supply from Nitrogen Cylinder Rack Package 02-Z-3502 after pressure reduction in
PRV-XXX is routed to Amine Storage Tank 02-TK-1601 blanketing system and to
Fuel Gas Header. The header downstream of PRV-XXX is protected by PSV-XXX.
FIA 0110 is provided with high and low flow alarms.

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Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-02-01 Instrument Air Compressor Package

 This is a package supply, and vendor’s documents are given in ATTACHMENT XX.
Pre commissioning of Sub System 2.1 to be carried out as per vendor’s procedure.

 Ready for start-up for SYS-020-02-01 Instrument Air Compressor Package

 This is a package supply, and vendor’s documents are given in ATTACHMENT XX.
Commissioning of this system to be carried out as per vendor’s procedure. Power
for commissioning this system will be from Essential Generator. Essential
Generator 02-DG-8201A/B is part of Gas Turbine Package 02-Z-6001A/B/C and is
given in ATTACHMENT XX. With the commissioning of System 1.0, Diesel will
become available to Essential Generator. Essential Generator to be pre
commissioned and commissioned as per procedures given in ATTACHMENT XX
for supplying power to commission Instrument Air Compressor Package. Since Air
Compressor Package SYS-020-02-01 is a contiguous part of SYS-020-02-02, it is
recommended to commission both Sub-sub-systems at the same time.

 Pre-commissioning of SYS-020-02-02 Wet Air Receiver, Instrument Air Dryer and Filter
Package, Dry Air Receiver and Instrument Air Distribution

 Wet Air Receiver, Instrument Air Dryer and Filter Package and Dry Air Receiver are
a part of the Instrument Air Compressor Package described in ATTACHMENT XX
(part of Sub System 2.2). Plant air and instrument air distribution and safety reliefs
are not a part of the package.
 Pre commissioning of Wet Air Receiver, Instrument Air Dryer and Filter Package
and Dry Air Receiver is to be done as per procedure given in ATTACHMENT XX.
 Follow the procedure given below for pre commissioning SYS-020-02-02 which is
not a part of the package:

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 Ensure following are operational and correctly set as per ATTACHMENT XX:
i. PSV 0103 and PSV 0107 is set as per test certificate. Ensure bird screens at
PSV outlet are clean.
ii. XV 0102/ZL 0102/HS 0102.
iii. PG 0101 and PG 0104 are checked as per test certificate.
iv. PZIA 0105 and PICA 0106.
v.
 Flush the instrument air and plant air headers and tubing with air from a portable
compressor. Leak test all air supply headers and pneumatic control circuits.
Connect back all the instrument air lines to their respective instruments. Follow
general pre commissioning procedure.

 Ready for start-up for SYS-020-02-02 Wet Air Receiver, Instrument Air Dryer and Filter
Package, Dry Air Receiver and Instrument Air Distribution

 Commissioning of the package for Sub System SYS-020-02-01 and 02 is

recommended to be taken up together along with the plant air and instrument
distribution system which are outside the package. Follow the procedure given
below:
i. Manually close XV 0102 to isolate the plant air system.
ii. Line out Wet Air Receiver 02-V-3702, Air Dryer and Filter Package 02-Z-
3702A/B and Dry Air Receiver 02-V-3601.
iii. Commission Instrument Air Compressor Package 02-Z-3701A/B/C one at a
time as per procedure given in ATTACHMENT 7.
iv. Commission the Air Dryer and Filter Package 02-Z-3702A/B as per procedure
given in ATTACHMENT XX.

 As soon as the instrument air header gets pressurized to 8 barg, commission PICA
0106, reset XV 0102 and route plant air to the plant air header.
 The instrument and plant air system is now commissioned. The plant air can be
take from different hose stations spread across the plant. If the instrument air
header pressure is below set point of PICA 0106 of 7.8 barg, XV 0102 shuts off
plant air supply.
 If instrument air header pressure goes low low, PZIALL 0105 initiates LEVEL 2
ESD.

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 Pre-commissioning of SYS-020-02-03 Nitrogen Cylinder Rack Package and Nitrogen

Distribution

 Pre commissioning of Nitrogen Cylinder Rack Package is to be carried out as per

procedure given in ATTACHMENT 9.
 For pre commissioning the nitrogen header, flush the nitrogen header with filtered
and dry air using a temporary hose connection from the instrument air header to
flush dirt from open ends. Follow the general pre commissioning procedure for
flushing.
 Ensure following instruments are installed and set, as applicable, by referring to
ATTACHMENT XX.
i. PG 0109
ii. FIA 0110

 Ready for start-up for SYS-020-02-03 Nitrogen Cylinder Rack Package and Nitrogen
Distribution

 Commission the Nitrogen Cylinder Rack Package as per procedure given in

ATTACHMENT XX.
 Purge the nitrogen header with nitrogen from Nitrogen Cylinder Rack Package at
about 15 m/s velocity to purge out the air. FIA 0110 can be used to check the
nitrogen rate.
 Continue purging till oxygen content in the nitrogen is less than 0.5% by vol.
 Leak test the header by closing the valves at Amine Storage Tank 02-TK-1601 and
Fuel Gas Header as per general pre commissioning procedure.
 After completion of the leak test, keep the nitrogen header pressurized to 0.5
kg/cm2g, till there is a demand for the nitrogen from Amine Storage Tank/Fuel Gas
header.

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13.3 Sub-System SYS-020-03 Raw Water System

 System description

 Sub-Sub-system: SYS-020-03-01 Raw water from Shat Al-Arab River to Raw Water
Storage Tank

 Raw water, from Shat Al-Arab River, is supplied by the Raw Water Intake Pump 01-
P-3101A/B and is routed to the Raw Water Storage Tank 02-TK-3101 at CPF. 01-
P-3101A/B is provided with automatic recirculation valve and FGT 0104. 02-TK-
3101 can also receive water from water tanker by the Tanker Unloading
Connection. Raw water is received in Raw Water Tank 02-TK-3101. 02-TK-3101 is
a cone roof tank with a goose neck vent and bird screen. The tank is provided with
an overflow line to open trench and LI 0106 with high and low level alarms.
 Raw Water Intake Well 01-TK-3102 is provided with a coarse screen and a fine
screen mounted in separate chambers and sumps provided for each chamber.
 Raw water line from the intake sump area to CPF area is provided with temporary
pig launcher and pig receiver facility, to be operated by contractor.
 Raw Water Intake Pump 01-P-3101A/B to be commissioned with power from
Essential Generator (refer ATTACHMENT XX).

 Sub-Sub-system: SYS-020-03-02 Raw water Chemical Injection Package

 Raw water Chemical Injection Package 02-Z-2805 injects chemicals to raw water in
Raw water intake well. The drains from chemical injection package shall be
collected in barrels.

 Sub-Sub-system: SYS-020-03-03 Raw water supply from Water Storage Tank to

Potable Water Treatment Package, Raw water Distribution and Utility Station

 Raw water from 02-TK-3101 is pumped by Raw Water Transfer Pumps 02-P-
3101A/B to Raw Water Distribution, Utility Station, and Potable Water Treatment
Package 02-Z-3301. 02-P-3101A/B is provided with a recirculation line under flow
control of FIQC 0114. Overflow and drains from 02-TK-3101 and 02-P-3101A/B are
routed to storm water via open trench. 02-P-3101A/B trips on LZIALL 0107.
 Raw Water Transfer Pumps 02-P-3101A/B to be commissioned with portable DG
set, which is to be made available prior to commissioning SYS-020-03-03.

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Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-03-01 Raw water from Shat Al-Arab River to Raw

Water Storage Tank

 Ensure following instruments are operational and required instruments are set as
per ATTACHMENT XX:
i. HS 0105 A/B , XL 0105 A/B
ii. ARV (set as per 01-P-3101A/B vendor).
iii. PG 0101, PG 0102
iv. FT 0104 (to be used after flushing operation).
v. LSL 0101 / LSLL 0102
vi. LICA 0106
vii. LI 0106A
viii. LZIA 0107

 Ensure that the inlet screens of 01-P-3101A/B clean.

 Ensure there is adequate water level in 01-P-3101A/B sump.
 With the discharge valve crack open, start the pump ensuring that the pump is
developing shut off pressure as indicated by PG 0101/0102. If there is an air lock in
the pump casing, remove it by opening the 3/4” discharge bleeder. Slowly open the
discharge valve, recirculating the minimum flow back to the sump through the ARV.
Run the pump for some time to ensure stable operation. Ensure that the pump runs
with crack open discharge valve for a very short time.
 Flush the raw water line up to inlet of Raw Water Storage Tank 02-TK-3101 and
leak test the line with full pump pressure of 01-P-3101A/B after closing the open
end. Follow general procedure.
 After completion of flushing, install back FT 0104.
 Carry out pre commissioning checks on 02-TK-3101 as per ATTACHMENT-6.
 To enable the storm water drain to handle tank drains during commissioning,
physically clean the entire storm water drain of construction debris.

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 Ready for start-up for SYS-020-03-01 Raw water from Shat Al-Arab River to Raw Water
Storage Tank

 With 01-P-3101A/B running, receive raw water in Raw Water Tank 02-TK-3101, 02-
TK-3101 is provided with LICA 0106 with high and low level alarms for monitoring
level and an overflow line. Verify the water level in tank by taking dips through the
gauge hatch. Check for leaks in the tank.
 Fill the tank up to HLL. Back flush the Demin Water Generation Package 02-Z-3402
reject line with water from 02-TK-3101 up to 02-Z-3402 and drain to storm water
drain channel. Maintain water level in 02-TK-3101 for subsequent activities, and
manually stop 01-P-3101A/B.
 Any excess water filled be drained through the overflow line. Also ensure that the
1” drain lines from the tank sump is clear by draining some water.

 Pre-commissioning of SYS-020-03-02 Raw water Chemical Injection Package

 Raw water Chemical Injection Package 02-Z-2805 is a package item and is to pre
commissioned as per ATTACHMENT XX.

 Ready for start-up for SYS-020-03-02 Raw water Chemical Injection Package
 Raw water Chemical Injection Package 02-Z-2805 is a package item and is to
commissioned as per ATTACHMENT XX.

 Pre-commissioning of SYS-020-03-03 Raw water supply from Water Storage Tank to

Potable Water Treatment Package, Raw water Distribution and Utility Station

 To enable the storm water drain to handle equipment drains during commissioning,
ensure storm water drain is cleaned as per pre commissioning procedure of Sub
System SYS-020-03-03.
 With water level in Raw Water Tank 02-TK-3101 at HLL, flush the 02-P-3101A/B
suction line by draining the water from the open end into storm water drain. After
closing the open ends, leak test the suction line under full hydrostatic pressure of
02-TK-3101.
 Clean pump suction strainers.

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 Ensure following instruments are operational and required instruments are set as
per ATTACHMENT-7:
I. PDG 0106
II. PG 0109/0112
III. PG 0110/0113FIQC 0114

 Ready for start-up for SYS-020-03-03 Raw water supply from Water Storage Tank to
Potable Water Treatment Package, Raw water Distribution and Utility Station
 Line out Raw Water Transfer Pumps 02-P-3101A/B suction line and fill the pump
casing with water. Ensure 02-TK-3101 is filled up to HLL. Prime the pump by
opening the vent on the pump discharge.
 Commission Raw Water Transfer Pumps 02-P-3101A/B with power from portable
DG set as per procedure given in ATTACHMENT 11. Maintain a minimum
recirculation flow with FIQC 0114 for pump protection.
 Flush the discharge line of 02-P-3101A/B up to Potable Water Treatment Package
02-Z-3301 and Raw Water Distribution header and recirculation line with full flow
from Raw Water Transfer Pumps 02-P-3101A/B and draining the water from open
ends of pipe into the storm water drain. Follow the general flushing procedure. After
closing all open ends, leak test the line with full pressure from 02-P-3101A/B.
 Route the raw water to Potable Water Treatment Package 02-Z-3301 and to Raw
Water Distribution under control of FIQC 0114. Raw Water Transfer Pumps 02-P-
3101A/B is provided with LZIA 0107 to trip 02-P-3101A/B on low low level in Raw
Water Tank 02-TK-3101.

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13.4 Sub-System SYS-020-04 Potable water system

 System description

 Sub-Sub-System SYS-020-04-01 Potable Water Treatment Package

 Raw water from 02-P-3101A/B is routed to Potable Water Treatment Package 01-Z-
3301. Instrument air is also routed to Potable Water Treatment Package 01-Z-3301 as
a utility, and drain routed to storm water drain.

 Sub-Sub-System SYS-020-04-02 Potable water supply to Potable Water Tank after

treatment of raw water in Potable Water Treatment Package

 Potable water from Potable Water Treatment Package 02-Z-3301 is routed to Potable
Water Tank 02-TK-3301, under level control of LICA 0103. 02-TK-3301 has an
overflow to storm water drain. It is also taken as fire water make up to Fire Water Tank
02-TK-5001A/B. Another stream is routed to Make Up for Cooling Water System. LICA
0103 is provided with high, high high and low level alarms. LZIA 0104 trips potable
water generation package at high high level in 02-TK-3301. LZIA 0104 trips 02-P-
3301A/B on low low level in 02-TK-3301.

 Sub-Sub-System SYS-020-04-03 Potable water supply from Potable Water Tank to

consumers
 Potable water from Potable Water Tank 02-TK-3301 is pumped by Potable Water
Pumps 02-P-3301A/B, with recirculation line with RO 0112, and flow measurement on
the discharge with FIA 0111.
 Portable DG set to be available for supplying power to Potable Water Pumps 02-P-
3301A/B.
 The potable water is sent to the following destinations:
i. Potable water distribution to Safety Showers at Demin Water Generation
Package & Amine Storage Tank, GTP I & II, Diesel Storage, Workshop,
Chemical Storage & warehouse.
ii. DM Water Treatment Package 02-Z-3402.
iii. GTP I & II.
iv. Potable Water Treatment Package 01-Z-3301

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Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-04-01 Potable Water Treatment Package

 Complete pre commissioning activities as per OEM manual of Potable Water

Treatment Package given in ATTACHMENT XX.

 Ready for start-up for SYS-020-04-01 Potable Water Treatment Package

 Complete commissioning activities as per OEM manual of Potable Water Treatment

Package given in ATTACHMENT 12. After commissioning of Potable Water Treatment
Package, potable water will start flowing to:
i. Fire water tank 02-TK-5001A/B
ii. Potable water tank 02-TK-3301
iii. Make up for cooling water system

 Pre-commissioning of SYS-020-04-02 Potable water supply to Potable Water Tank

after treatment of raw water in Potable Water Treatment Package

 Carry out pre commissioning activities of Potable water Tank 02-TK-3301 as per
ATTACHMENT-6.
 Commission Potable Water Tank 02-TK-3301 and receive water from Potable Water
Treatment Package 01-Z-3301. Fill up 02-TK-3301 up to HLL under level control of
LICA 0103. Check for leaks. LICA L/H 0103 are provided to monitor levels. In case of
HH level sensed by LICA 0104 LICA 0103, potable water generation package shall trip.
Overflow line is also provided to storm water drain. Also verify level manually through
the gage hatch.
 Back flush the potable water line from Potable Water Treatment Package 01-Z-3301
through the bypass of LCV 0102, through an open end at 01-Z-3301, to clean the line
and drain to storm water drain. After the line is cleaned, leak test the line at full
hydrostatic pressure of 02-TK-3301.
 Again fill up 02-TK-3301 up to HLL under level control of LICA 0103 and flush the
suction line of Potable Water Pumps 02-P-3301A/B, by opening the line at the suction

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of 02-P-3301A/B, and draining the water to storm water drain. After flushing is
complete, close the line and leak test at full hydrostatic pressure of 02-TK-3301.
 Clean pump suction strainers and RO 0112.
 Commission Potable Water Pumps 02-P-3301A/B with portable Diesel power
generator as per OEM manual given in ATTACHMENT 13. Recirculation line with RO
0112 is provided to ensure minimum flow through the pump, and FIA 011 with low flow
alarm is provided on the common pump discharge line.
 Flush 02-P-3301A/B recirculation line and discharge line to potable water distribution
safety showers, DM Water Treatment Package 02-Z-3402 and GTP I & II. Flush
through the open ends of above circuits to clean the pipelines, following the general
flushing procedure, and drain to storm water drain. After completion of flushing, close
all open ends in the piping, and leak test the piping at full pressure of 02-P-3301A/B.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT-7:
i. LICA 0103
ii. LZIA 0104
iii. PDG 0105/0108
iv. PG 0106/0109

 Ready for start-up for SYS-020-04-02 Potable water supply to Potable Water Tank after
treatment of raw water in Potable Water Treatment Package

??????????????????????????????????????????????

 Pre-commissioning of SYS-020-04-03 Potable water supply from Potable Water Tank

to consumers

 Carry out pre commissioning as per the procedure given in pre commissioning of Sub
System SYS-020-04-02.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT-7:
i. PG 0107/0110
ii. RO 0112
iii. FIA 0111

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 Ready for start-up for SYS-020-04-03 Potable water supply from Potable Water Tank to
consumers

 Line out suction of 02-P-3301A/B. Ensure 02-TK-3301 is filled up to HLL. Fill the pump
suction line and pump casing with water and prime the pump by removing trapped air
from the ½” pump discharge bleeder. Line out the pump recirculation line through RO
0112. Close the 2” valve down stream of FE 0111.
 Start the portable DG set.
 Commission 02-P-3301A/B as per OEM manual given in ATTACHMENT XX.
Recirculate the flow through RO 0112 ensure stable operation of the pumps, one at
time.
 Open the valve down stream of FE 0111, after lining out the potable water line to:
i. Fire water tank 02-TK-5001A/B
ii. Potable water tank 02-TK-3301
iii. Make up for cooling water system

 Adjust the potable water flow to the consumers by monitoring FIA 0111 and
manipulating respective valves at the consumer end, ensuring that the recirculation line
to 01-TK-3301 is lined out.

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13.5 Sub-System SYS-020-05 Fire water system

 System description

 Sub-Sub-System SYS-020-05-01 Fire Water Tanks

 Fire water make up from Potable Water Treatment Package 02-Z-3301 is routed to Fire
Water Tanks 02-TK-5001A/B. 02-TK-5001A/B is provided with LI - 0101/0111 with high
and low level alarms and tank overflow lines to storm water drain. Local level gages LG
0223/0224 are also provided. When 02-TK-5001A/B falls to HLL, it is filled with potable
water from the outlet of potable water package. When the level reached HHLL, filling is
manually stopped. Firewater from Fire Water Tanks 02-TK-5001A/B is routed to Fire
Water Jockey Pump 02-P-5002A/B, Fire Water Main Pump 02-P-5001A/B, and Fire
Water Diesel Pump 02-P-5001C/D.

 Sub-Sub-System SYS-020-05-02 Fire Water Jockey Pumps

 Fire Water Jockey Electric Motor Driven Pump 02-P-5002A/B, discharges to Fire Water
Ring Main, and are self-venting and capable of auto start on open discharge. The
selected duty jockey pump maintains the system pressure at 11 barg. If the system
pressure drops to 10.5 barg, Duty pump (02-P-5002A) shall start automatically. If the
duty pump does not start, standby jockey pump (02-P-5002B) at 10 barg starts
automatically till pressure reaches 11 barg. Jockey Pump discharge pressure is
indicated on PI 00007A/B.

 Sub-Sub-System SYS-020-05-03 Fire Water Main Pumps

 Electric Motor Driven Fire Water Main Pump 02-P-5001A takes suction from Fire Water
Tanks 02-TK-5001A/B and discharges into the fire water ring main. PSV 00003A is
provided to protect the casing from overpressure, the discharge being routed to floor
drain pit. The discharge of 02-P-5001A is routed to the fire water ring main and to Fire
Water Tanks 02-TK-5001A/B via the Test Header.
 Diesel Engine Driven Fire Water Pump 02-P-5001B/C/D takes suction from Fire Water
Tanks 02-TK-5001A/B and discharges into the fire water ring main. PSV 00003B/C/D
relieves any overpressure in the discharge line of the diesel engine driven pumps, and

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the PSV discharges are routed back to the Fire Water Tanks 02-TK-5001A/B. FI
00008 is provided on the test header to measure the recirculation flow back to 02-TK-
5001A/B. Diesel from Diesel Filter Coalescer Package 02-Z-2601 is routed to Diesel
Tank of each Diesel Engine Driven Fire Water Pump 02-P-5001B/C/D.
02-P-5001B/C/D discharge is also routed to Fire Water Diesel Pump Cooler; the cooler
outlet being routed back to Fire Water Tanks 02-TK-5001A/B. PI 00004B/C/D is
provided for indication of pump discharge pressure.
 Pressure transmitter PIALL 0104/0114 located in the ring main sense the fire water
system pressure. If anyone pressure transmitter senses 9.5 barg, the lead pump 02-P-
5001A shall start immediately. If the ring main pressure fails to reach 10 barg in 15
seconds, 2nd. Pump 02-P-5001C shall start. If the ring main pressure still fails to reach
10 barg within 30 seconds, 3rd. pump 02-P-5001B shall start. If the ring mail pressure
fails to reach 10 barg within 45 seconds, the 4th. Pump 02-P-5001D shall start.

 Sub-Sub-System SYS-020-05-04 Fire Water Distribution Header

 The Fire Water Ring Main is connected to fire hydrants, monitors, sprinklers, deluge
valves located in the facility. F&G system is provided, which can activate deluge valves
on detection of fire. On Spec and Off Spec Condensate Tanks 02-TK-1802 and 02-TK-
1803 respectively are provided with foam pourers.

 Sub-Sub-System SYS-020-05-05 Foam Proportioning System

 A Foam Proportioning Unit, Foam Concentrate Tank 02-TK-5002 and Foam

Concentrate Gear Pump 02-P-5003A/B are provided for supply of foam solution to
foam makers to supply foam to 02-TK-1802 and 02-TK-1803 in case of a fire exigency.
 Pressure transmitter located in the ring main sense the fire water system pressure. If
anyone pressure transmitter senses 9.5 barg, the lead pump 02-P-5001A shall start
immediately. If the ring main pressure fails to reach 10 barg in 15 seconds, 2nd. Pump
02-P-5001C shall start. If the ring main pressure still fails to reach 10 barg within 30
seconds, 3rd. pump 02-P-5001B shall start. If the ring mail pressure fails to reach 10
barg within 45 seconds, the 4th. Pump 02-P-5001D shall start.

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Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-05-01/02/03/04/05 Fire water system

 Since the above systems are in the same vendor package, it is recommended to take
up pre commissioning activities all the sub systems together.
 Complete pre commissioning activities of Fire Water Tanks 02-TK-5001A/B as per
procedure given in ATTACHMENT-6.
 Commission Fire Water Tanks 02-TK-5001A/B and receive water from Potable Water
Treatment Package 01-Z-3301. Fill up Fire Water Tanks 02-TK-5001A/B up to HLL.
Test the tanks for leaks.
 Back flush the makeup water line from Potable Water Treatment Package 01-Z-3301,
through an open end at 02-TK-5001A/B, to clean the line and drain to storm water
drain. After the line is cleaned, leak test the line at full hydrostatic pressure of 02-TK-
5001A/B.
 Flush the suction lines of Fire Water Jockey Electric Motor Driven Pump
01-P-5001A/B, Electric Motor Driven Fire Water Main Pump 01-P-5001A and Diesel
Engine Driven Fire Water Pump 02-P-5001B/C/D. 02-P-5001B/C/D under hydrostatic
pressure of Fire Water Tanks 02-TK-5001A/B up to HLL. Follow general flushing
procedure by opening the piping near the respective pump suctions. After completion
of flushing, box up the open ends and leak test the piping under hydrostatic pressure of
water in 02-TK-5001A/B up to HHLL.
 Box up the suction piping of Fire Water Jockey Electric Motor Driven Pump 02-P-
5001A/B, and commission 02-P-5001A/B as per OEM manual given in ATTACHMENT
14. Flush the discharge piping of Fire Water Jockey Electric Motor Driven Pump 02-P-
5001A/B by opening the piping on Fire Water Ring Main, fire hydrants, monitors,
sprinklers, deluge valves, so as not to leave any dead ends in the piping. During
flushing of the suction lines. Clean pump suction strainers as required. After completion
of flushing, box up all open ends and leak test the discharge piping at full pressure of
Fire Water Jockey Electric Motor Driven Pump 02-P-5001A/B.
 Commission Electric Motor Driven Fire Water Main Pump 02-P-5001A as per OEM
manual GIVEN IN ATTACHMENT XX. PDI 0125 with high alarm is provided to indicate

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pump suction strainer 02-S-5001A, which can be cleaned prior to commissioning the
pump. During commissioning, establish flow through the pump via the test header. FI
00008 is provided to indicate the flow through the test header. After satisfactory
commissioning, stop 02-P-5001A, and keep the fire water ring main pressurized with
the Fire Water Jockey Electric Motor Driven Pump 02-P-5001A/B. Reduce the fire
water ring main pressure below 9.5 barg by opening a hydrant valve, and ensure that
the Electric Motor Driven Fire Water Main Pump 02-P-5001A picks up.
 Manually clean the storm water drain. During the flushing and pump testing, drain the
fire water to storm water drain.
 With the fire water ring main commissioned, top up Diesel in the Diesel Storage Tank
02-TK-2601 and transfer the Diesel from the Diesel Filter/Coalscer Package 02-Z-2601
to the Diesel Tanks of Diesel Engine Driven Fire Water Pump 02-P-5001B/C/D.
 Commission Diesel Tanks of Diesel Engine Driven Fire Water Pump 02-P-5001B/C/D,
one by one, as per OEM manual given in ATTACHMENT 14. Diesel to be taken from
Sub System 1.0, which should be commissioned in a prior step. PDI 0126/7/8 with high
alarm is provided to indicate pump suction strainer 02-S-5001B/C/D, which should be
cleaned prior to commissioning. During commissioning, establish flow through the
pump via the test header. FI 00008 is provided to indicate the flow through the test
header.
 Test each of Diesel Driven Fire Water Pump 02-P-5001B/C/D to ensure that each
pump picks up at the preset pressure transmitter settings when the fire water ring main
pressure is dropped by opening one or more fire hydrants.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT-7:
i. LI 0101/0111
ii. LG 0223/0224
iii. PI 00007A/B
iv. PI 00004A/B/C/D
v. PIA 0104/0114
vi. LIT 00012B/C/D

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 Ready for start-up for SYS-020-05-01/02/03/04/05 Fire water system

 As the sub systems are in the same vendor package given in ATTACHMENT XX, it is
recommended to take up commissioning activities together.
 After completion of pre commissioning of the fire water pump suction and discharge
piping, the lines are filled with water and can be put in service once fire water pumps
are commissioned.
 Commissioning of the 02-P-5002A/B and 02-P-5001A/B/C/D have already been
covered in the pre commissioning step given above. Follow ATTACHMENT XX for
operation of the pumps as required.

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13.6 Sub-System SYS-020-06 Gas Turbine

 System Description

 Sub-Sub-System SYS-020-06-01 Diesel from Filter/Coalescer Package

 Diesel from Filter/Coalescer Package 02-Z-2601 is routed to GTG Diesel Day Tank 02-
TK-6101, and Fuel Forwarding Unit 02-Z-6102, both part of Gas Turbine Package 02-
Z-6001A/B/C, given in ATTACHMENT 8. The Diesel from the Fuel Forwarding Unit 02-
Z-6102 is routed to GTG Liquid Fuel Module 1,2 & 3 (FI 0104/0110/0116 and
respective Liquid Fuel Block Valve, part of Gas Turbine Package) for initial running of
GTG. Diesel Day Tank 02-TK-6101 is provided with vacuum truck connection.
 Instrument air connection is supplied to each of the three Liquid Fuel Block Valve.

 Sub-Sub-System SYS-020-06-02 Gas Turbine Package

 3 nos. GTG, each of 7.8 MVA @ 50C, two working and one standby are provided to
meet the power requirements.
 Essential Diesel Generator 02-DG-6201A/B (2x50%), 1.2 MVA each, are provided for
plant start up and safe shutdown of the plant, and GTG auxiliaries.
 Instrument air is supplied as a utility to Gas Turbine Package 02-Z-6001A/B/C.

 Sub-Sub-System SYS-020-06-03 Fuel Gas Block & Vent Assembly

 Raw fuel gas is routed to FI 0103/0109/0115 and respective Fuel Gas Block & Vent
Assembly (one for each GTG), prior to use as GTG fuel before availability of dry gas.
 Dry fuel gas is SDV 0121/0122/0123, PCV 0101/0107/0103 and PCV 0102/0106/0114,
prior to routing to FI 0103/0109/0115 and respective Fuel Gas Block & Vent Assembly.
PIA 0118/0119/0120 is provided for each Gas Turbine to monitor pressure on the dry
fuel gas header upstream of Fuel Gas Block & Vent Assembly.
 Instrument air connection is supplied to each of the three Fuel Gas Block & Vent
Assembly.

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Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-06-01/02/03 for Gas Turbines

 Since the three sub systems are part of the same Gas Turbine Package
02-Z-6001A/B/C, given in ATTACHMENT-XX, carry out pre commissioning of all the
sub systems taken together.
 Flush all hydrocarbon and instrument air lines by air blowing/cardboard bursting, as per
general flushing procedure.
 After flushing is complete, close all open ends and purge all hydrocarbon lines with
nitrogen to inertize.
 Leak test hydrocarbon lines with nitrogen at design pressure. Leak test instrument air
lines with air pressure.

 Ready for start-up for SYS-020-06-01/02/03 for Gas Turbines

 Since the three sub systems are part of the same Gas Turbine Package
02-Z-6001A/B/C, given in ATTACHMENT-XX, carry out commissioning of all the sub
systems taken together.
 Commission Diesel Day Tank 02-TK-6101, Fuel Forwarding Unit 02-Z-6102 and the
Liquid Fuel Module 1,2 & 3,as per OEM manual of Gas Turbine Package 02-Z-
6001A/B/C, given in ATTACHMENT-XX, and bleed nitrogen out of the system through
bleeders. Commission the instrument air header.
 Commission Gas Turbine Package 02-Z-6001A/B/C one by one on Diesel fuel, as per
OEM manual given in ATTACHMENT-XX.
 When GTG operation is stable, discontinue operation of Essential Generator 02-DG-
6201A/B.
 When raw gas becomes available, change GTG fuel from Diesel to raw gas, as per
OEM manual given in ATTACHMENT-XX.
 When dry gas becomes available, change GTG fuel from raw gas to dry gas, as per
OEM manual given in ATTACHMENT-XX.

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13.7 Sub-System SYS-020-07 Demin Water Package

 System Description

 Sub-Sub-System SYS-020-07-01 Demin Water Treatment Package

 Potable water from 01-P-3301A/B is routed to Demin Water Generation Package 02-Z-
3402. Reject water from 02-Z-3402 is sent back to Raw Water Tank 02-TK-
3101.Instrument air and plant air are also supplied to this package as utilities. Drain
from 02-Z-3402 is routed to a local drain pit.

 Sub-Sub-System SYS-020-07-02 Demin water supply to Demin Water Tank after

treatment of potable water in Demin Water Generation Package

 Demin water from 02-Z-3402 is routed to Demin Water Tank 02-TK-3402 under level
control by LICA 0103, which is provided with high and low level alarms. 02-TK-3402 is
sized for seven days storage. A drain line provided for draining tank to storm water
drain.
 02-TK-3402 is provided with PIA 0106 with high and low alarms. LZIA 0108 is provided
with HH and LL trips. PVRV 0107 is provided as conservation vent.

 Sub-Sub-System SYS-020-07-03 Demin water supply system.

 Demin Water Pumps 02-P-3402A/B takes suction from 02-TK-3402 and discharges to
Amine Storage Tank 02-TK-1601 and Gas Treatment Plant I & II.
 02-P-3402A/B is provided with FIA 0115 with low flow alarm, for measuring the total
flow to 02-TK-1601 and Gas Treatment Plant I & II.
 02-P-3402A/B is also provided with a recirculation line with RO 0116.
 02-P-3402A/B suction line is provided with PDG 0109/0112 and PG 0110/0113. 02-P-
3402A/B discharge line is provided with PG 0111/0114.
 02-P-3402A/B trip on LZIALL 0108.

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Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-07-01 of Demin Water Treatment Package

 As the Demin Water Treatment Package is supplied as a vendor supplied package,

follow pre commissioning procedure given in ATTACHMENT XX

 Ready for start-up for SYS-020-07-01 Demin Water Treatment Package

 As the Demin Water Treatment Package is supplied as a vendor supplied package,

follow commissioning procedure given in ATTACHMENT XX. After commissioning,
route the reject water to 02-TK-3101.

 Pre-commissioning of SYS-020-07-02 of Demin water supply to Demin Water Tank

after treatment of potable water in Demin Water Generation Package

 Carry out pre commissioning activities for Demin Water Tank 01-TK-3402 as per
procedure given in ATTACHMENT 3.
 Commission the Demin Water Generation Package 02-Z-3402 as per ATTACHMENT
15.
 Once 02-Z-3402 starts to produce demin water, flush the demin water line from 02-Z-
3402 to 02-TK-3402 by opening the bypass of LCV 0102 and opening the line at 02-
TK-3402 inlet. After completion of flushing, leak test the line at full pressure. Follow
general flushing and leak test procedure.
 Similarly, flush and leak test the reject water line by backing up water from the Raw
Water Tank 02-TK-3101, and follow general flushing and leak test procedure.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT 5:
I. LICA 0103/LI 0103A
II. PIA 0106
III. LZIA 0106
IV. PVRV 0107

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 Ready for start-up for SYS-020-07-02 Demin water supply to Demin Water Tank after
treatment of potable water in Demin Water Generation Package

 Commission LICA 0103 and close the LCV 0102 bypass valve. Fill the Demin Water
Tank 02-TK-3402 up to HLL under level control of LICA 0103. Monitor the tank level
with with LI 0103A and manually check the level with the gage hatch. Ensure there are
no leaks. LZIAHH 0108 TRIPS Demin water generation package.

 Pre-commissioning of SYS-020-07-03 of Demin water supply system

 With 02-TK-3402 water level at HLL, flush and leak test 02-P-3402A/B suction line with
full hydrostatic pressure, as per general procedure.
 Clean suction strainers of Demin Water Pumps 02-P-3402A/B.
 Commission Demin Water Pumps 02-P-3402A/B as per procedure given in vendor
package, which is attached as ATTACHMENT 16. Recirculate through recirculation line
after dropping RO 0116 and discharging the water at an open flange. After flushing and
leak test under normal flow is complete, install RO 0116. While recirculating during
flushing operation, ensure pump does not get overloaded. Ensure stable operation of
the pump after installing RO 0116.
 With 02-P-3402A/B in operation, flush and leak test line to Amine Storage Tank 02-TK-
1601 and line to Gas Treatment Plant I & II, as per general procedure. Install FE 0115
after flushing and leak testing is complete.

 Ready for start-up for SYS-020-07-03 Demin water supply system

 After flushing and leak test, operate the 02-P-3402A/B at normal flow. FIA 0115 with
low flow alarm is provided for total flow, and LZIA 0108 with low level trip is provided
for protection of 02-P-3402A/B. Ensure PDG 0109/0112 readings are normal.

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13.8 Sub-System SYS-020-08 Oily Water System

 System Description

 Sub-Sub-System SYS-020-08-01 Open Drain Distribution Header

 Oily water generated in condensate storage tank area dyke, condensate pump house
collection pit, GTP I and GTP II is routed to oily water treatment package.
 The oily water distribution system consists of a network of underground sewer lines
interconnected with vented seal boxes

 Sub-Sub-System SYS-020-08-02 Oily Water Treatment Package

 The final outflow from Sub System 8.1 is routed to Oily Water Treatment Package 02-
Z-2401. After treatment of the oily water, the treated water is routed to the Evaporation
Pond 02-BA-2402 for evaporation through common collection pit 02-BA-2405.
 Catch Basin 02-BA-2403 is provided for sludge drains from Oily Water Treatment
Package 02-Z-2401, with provision of connecting a vacuum truck to dispose of the
liquids.
Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-08-01 of Open Drain Distribution Header

 Run Fire Water Jockey Electric Motor Driven Pump 02-P-5001A/B as described in
procedures of System 5.0. Connect fire hoses to fire hydrants, and route the hoses to
following oily water system collection pits:
I. Condensate storage tank area dyke collection pit.
II. Collection Pit for Condensate Pump house
III. Collection pits for GTP I and GTP II.

 Flush Open Drain Distribution Header originating from each of above collection pits,
one pit at a time, so as not to overload the Fire Water Jockey Electric Motor Driven
Pump 01-P-5001A/B. Ensure entire network is flushed to the inlet section of the Oily

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Water Treatment Package 02-Z-2401, from where the collected debris is to be

manually removed. All the flushing water will drain to the Oily Water Treatment
Package 02-Z-2401, from where it is to be disposed off as per the operating procedure
of the package, described in the next section.
 Ensure the vent pipes of each vented seal box are clean and there is no obstruction to
vapor flow from the seal box.

 Ready for start-up for SYS-020-08-01 Open Drain Distribution Header

 Ensure that water seal is maintained at each vented seal box.
 The network of underground sewer pipes are now ready to receive oily water effluent
from the plant.

 Pre-commissioning of SYS-020-08-02 of Oily Water Treatment Package

 Manually clean the Common collection pit 02-BA-2405, Evaporation Pond 02-BA-2402
and Catch Basin 02-BA-2403.
 Ensure the 6”and 2”line from oily water treatment package to Evaporation Pond 02-BA-
2402 are flushed with fire water. Also, 3” sludge line from oily water treatment package
to Catch Basin 02-BA-2403 is flushed with fire water. The vent pipe and screen of
Catch Basin 02-BA-2403 are free of obstruction.
 Carry out pre commissioning activities of Oily Water Treatment Package 02-Z-2401 as
per vendor manual given in ATTACHMENT XX.

 Ready for start-up for SYS-020-08-02 Oily Water Treatment Package

 Commission Oily Water Treatment Package 02-Z-2401 as per vendor manual given in
ATTACHMENT 17 with fire water. When oily water effluent starts to be received in 02-
Z-2401, commission each section of the package as per procedures given in
ATTACHMENT 17.
 When treated effluent gets generated from the package, run down to the Evaporation
Pond 02-BA-2402 and allow the water to evaporate as per design intent of the pond.
 Route any sludge draining from the Oily Water Treatment Package to Catch Basin 02-
BA-2403.
 Periodically evacuate the draining by vacuum truck as required.

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 All safety precautions as per plant safety manual to be followed during these manual
operations

13.9 Sub-System SYS-020-09 Cooling Water System

 System Description

 Sub-Sub-System SYS-020-09-01 Cooling Tower Package & Cooling Water Filter

Package

 Make up water from Potable Water Treatment Package 02-Z-3301 is routed to the
Cooling Tower Package 02-CT-2001 under level control of 02-CT-2001 by LCV 0102,
and flow measurement by FIA 0101, provided with high and low flow alarms.
 The Cooling Tower Package 02-CT-2001 is provided with pH meter, Chloro meter and
conductivity meter, and can be drained to storm water drain.
 Cooling Water Filter Package 02-S-2001A/B is also a part of cooling tower vendor’s
supply. The waste water stream from 02-S-2001A/B is routed as blowdown to
evaporation pond.

 Sub-Sub-System SYS-020-09-02 Cooling Water Supply and Return System

 Cooling water Circulation Pumps 02-P-2001A/B/C take suction from the Cooling Tower
Package 02-CT-2001, under flow control of FICA 0109 with high and low flow alarms,
and temperature indicator TIA 0110 with high alarm. FI 0109A and TI 0110A are
provided for local indication. The electric motor drives of 02-P-2001A/B/C are provided
with ESD. The cooling water discharge from 02-P-2001A/B/C is routed to:
I. Gas Treatment Plant
II. LPG Export Trim Cooler 02-E-1801.
III. LPG Export Pumps 02-P-1801A/B.
 Pump casing and baseplate drain are routed to local drain pit.
 Cooling water return from the above users is routed back to Cooling Tower Package
02-CT-2001. The cooling water return lines are provided with motor operated valves,
which are a part of Cooling Tower Package 02-CT-2001.

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 A cooling water recirculation stream is taken upstream of FCV 0113 and routed back to
Cooling Tower Package 02-CT-2001 for routing the recirculation stream to Cooling
Water Filter Package 02-S-2001A/B when required.

Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-09-01 of Cooling Tower Package & Cooling Water

Filter Package

 Flush the makeup water line from Potable Water Treatment Package 02-Z-3301
through the bypass of LCV 0102. Follow general flushing procedure. After flushing is
complete, leak test the line under pressure from 02-Z-3301.
 Carry out pre commissioning activities of the Cooling Tower Package 02-CT-2001 and
Cooling Water Filter Package 02-S-2001A/B as per OEM manual given in
ATTACHMENT XX.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT 5:
I. LCV 0102
II. FIA 0101

 Ready for start-up for SYS-020-09-01 of Cooling Tower Package & Cooling Water
Filter Package

 Commission the Cooling Tower Package 02-CT-2001 and Cooling Water Filter
Package 02-S-2001A/B as per OEM manual given in ATTACHMENT 18. Ensure the
cooling tower basis is filled with water from Potable Water Treatment Package under
level control of LCV 0102.

 Pre-commissioning of SYS-020-09-02 of Cooling Water Supply and Return System

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 Carry out pre commissioning of the Cooling Water Circulation Pumps 02-P-2001A/B/C
as per OEM manual given in ATTACHMENT 19.
 Clean suction strainers of Cooling Water Circulation Pumps 02-P-2001A/B/C.
 Flush Cooling Water Circulation Pumps 02-P-2001A/B/C suction lines up to 02-P-
2001A/B/C suction flange as per general procedure. Box up the suction lines and
ensure there are no leaks.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT XX:
i. PIA 0106/0107/0108
ii. FICA 0109
iii. TIA 0110

 Ready for start-up SYS-020-09-02 of Cooling Water Supply and Return System

 Close the cooling water supply line up to Gas Treatment Plant, LPG Export Trim
Cooler 02-E-1801 and LPG Export pumps 02-P-1801A/B. Line out 02-P-2001A/B/C via
4” recirculation line back to Cooling Tower Package 02-CT-2001 (Vendor to check
yellow highlighted portion. Cooling water pump capacity is 580 m3/hr and it will not be
possible to line out cooling water through 4” line. Velocity shall be on higher side.
Vendor to check and revise accordingly). MMM may please advise the purpose of the
recirculation line. To our mind, recirculation line to protect the pump against minimum
flow, due to process reason, as seen from PIA 0106/0107/0108. A high pressure alarm
on PIA 0106/0107/0108 can be a good indicator.
 Commission the Cooling Water Circulation Pumps 02-P-2001A/B/C as per OEM
manual given in ATTACHMENT 19, one at a time, circulating the flow back to 02-CT-
2001. Manipulate the 4” valve on recirculation line so as not to overload the pumps.
 Flush the recirculation line and leak test at full pump pressure by closing the open end
as per general procedure.
 For flushing cooling water supply and return lines, make the following temporary jump
overs:
 At GTP I, connect TP53 to TP50 with a temporary jump over.
 Make a temporary jump over from cooling water supply to 02-E-1801 to cooling water
return line from 02-E-1801.
 For LPG Export Pumps 02-P-1801A/B, make temporary jump over as follows:

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i. For 02-P-1801A, connect TP369 to TP368 & TP370.

ii. For 02-P-1801B, connect TP379 to TP378 & TP380.
 Open the valve on the cooling water supply line one at a time for flushing and leak
testing.
 Flush the cooling water supply and return headers with open end in cooling water
return piping at Cooling Tower Package 02-CT-2001, via FCV0113 bypass. After
completion of flushing, close the open ends and leak test at full pump pressure.
 Remove the temporary jump over, and establish cooling water circulation through Gas
Treatment Plant package, LPG Export Trim Cooler 02-E-1801 and LPG Export pump
package.

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13.10 Sub-System SYS-020-10 Closed Drain System

 System Description

 Sub-Sub-System SYS-020-10-01 Closed Drain Distribution Header

 The closed drain system collects process drains from the GTP I & II, Feed Gas Slug
Catcher for Train I & II, production manifold, fuel gas header, LPG export launcher,
condensate export launcher, raw fuel gas scrubber, On Spec Condensate Storage tank
02-TK-1802, Pipe Separators, HP Flare Pumps 02-P-2201A/B, LP Flare KOD.
 Fuel gas header is also connected with the closed drain header under pressure control
of PCV 0001 along with a pressure indicator PG 0107 for flushing the header.
 The closed drain streams are routed to the Closed Drains Vessel 02-V-2301.

 Sub-Sub-System SYS-020-10-02 Closed Drains Vessel and Pump

 Closed Drain Vessel 02-V-2301 collects the closed drains from process and off site
units, and any gas flashed off is routed to LP flare header. 02-V-2301 is maintained at
a positive pressure by introducing fuel gas through PCV 0101 and venting the gas
through PCV 0102 located on the line to LP flare header. FI 0107 monitors fuel gas
flow. PG 0106 is provided on the inlet fuel gas line for monitoring 02-V-2301 pressure.
 Closed Drain Vessel 02-V-2301 is provided with LIA 0106, with LAHHH to alert the
operator to line up vacuum truck to evacuate the vessel. 02-P-2301-A/S is provided to
pump collected liquid to Off Spec Condensate Storage Tank 02-TK-1803. LZIA 0105
with ESD2301 is provided to trip 02-P-2301A/S on low low level. LICA 0103 auto
starts/stops the pump on level. PIA 0102 monitors 02-V-2301 pressure with a high
pressure alarm. PSV 0101 is provided for protecting 02-V-2301 against overpressure
due to blocked outlet. Closed Drains Vessel 02-V-2301 is located in a sump below
grade with HC and H2S detectors.

Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

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 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-10-01 of Closed Drain Distribution Header

 Flush all close drain header lines downstream of isolation valves separating the closed
drain header from the process vessels/piping including fuel gas header downstream of
PCV 0001, up to inlet of Closed Drain Vessels 02-V-2301. Flush with air as per general
flushing procedure with air blowing/card board bursting.
 Flush the fuel gas header downstream of PCV 0001 with air as per general flushing
procedure with air blowing/card board bursting.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT-7:
I. PCV 0001
II. PG 0107

 Ready for start-up for SYS-020-10-01 of Closed Drain Distribution Header

 Since Sub Systems SYS-020-10-01 and 02 are contiguous, nitrogen inerting and
commissioning is recommended to be taken up together to ensure process safety.

 Pre-commissioning of SYS-020-10-02 of Closed Drains Vessel and Pump

 Clean Closed Drain Vessels 02-V-2301 and ensure all instruments, safety devices and
Closed Drains, Pump 02-P-2301A/S are correctly installed.
 Flush the Fuel Gas Header after closing the downstream and bypass isolation valves
of FI 0107 and PSV 0101 upstream and bypass isolation valves, up to fuel gas inlet to
Closed Drain Vessels 02-V-2301, with air blowing/ cardboard bursting.
 Flush Closed Drains Pump 02-P-2301A/S discharge up to inlet of Off Spec
Condensate Tank 02-TK-1803, with air blowing/ cardboard bursting.
 Flush 02-V-2301 pump out line with air blowing/ cardboard bursting.
 Complete pre commission of Closed Drains Pump 02-P-2301A/S as per OEM manual,
which is given in ATTACHMENT 20.

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 Flush the line downstream of nozzle N11 and the line from the sump up to vacuum
truck connection point, with air blowing/ cardboard bursting. It is not necessary to
nitrogen purge these lines.
 Ensure following instruments/safety equipment are operational and required
instruments are set as per ATTACHMENT-7:
i. FI 0107
ii. PCV 0101
iii. PG 0106
iv. PSV 0101
v. LIA 0106
vi. LZIA0105
vii. PCV 0102
viii. LICA 0103
ix. PIA 0102
x. PG 0101

 Ready for start-up for SYS-020-10-02 of Closed Drains Vessel and Pump

 Close all openings and purge with nitrogen to flare header till air is completely purged
out of the system comprising of the following:
i. The entire closed drain header and fuel gas header downstream of PCV
0001, which are a part of Sub System 10.1.
ii. Fuel gas header downstream of FI 0107, PSV 0101 inlet line up to PSV
0101 inlet and bypass isolation valve.
iii. Purge 01-V-2301 outlet line to flare.
iv. (Steps 5 1 a, b & c to be taken up while nitrogen purging of System 11.0, as
entire Sub System 10.1 & 10.2 are vented to LP flare). (There are no steps
as 5 a,b,c. Vendor to check and confirm).closed.
 Leak test the system with nitrogen at 1.0 kg/cm2g by closing 02-V-2301 outlet valve at
nozzle N4 and the NC valves at nozzles N10 and N11. After the leak test is
satisfactorily completed, commission PCV 0101 and PCV 0102, and hold a positive
pressure of 0.5 kg/cm2g in the system, by adjusting the set point of PCV 0101/0102.
 Purge 02-P-2301A/S discharge line up to Off Spec Condensate Tank 02-TK-1803, and
leak test as per general procedure.

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 System 10.0 should be commissioned along with System 11.0. Take PSV 0101 in line
by opening inlet/outlet isolation valves. As liquid level starts to build up in 02-V-2301,
flash gases will vent to LP flare.
 Commission Sub System 17.4 prior to commissioning Closed Drain Pumps 01-P-
2301A/S.
 Line out 02-P-2301A/S discharge up to Off Spec Condensate Tank 02-TK-1803.
 As level builds up in 02-V-2301, commission Closed Drains Pump 02-P-2301A/S as
per OEM manual given in ATTACHMENT 20, and route the discharge to Off Spec
Condensate Tank 02-TK-1803.
 Follow the commissioning procedure given below:
i. Override auto start of 02-P-2301A/S.
ii. Keep the low low level trip for 02-P-2301A/S in line.
iii. Ensure at least 50% level in 02-V-2301.
iv. Line out discharge line to 02-TK-1803.
v. Crack open the 2” discharge valve, and start the pump. Check whether pump
is developing shut off pressure and there are no leaks.
vi. With 50% level in 02-V-2301, the pump can run for approximately 2.5 hrs,
which is sufficient time to test the pump operation.
vii. When stable operating is obtained, open the discharge valve to route the
closed drain liquid to 02-TK-1803.
viii. Put the pump auto start in line.

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13.11 Sub-System SYS-020-11 Fuel Gas System

 System Description

 Sub-Sub-System SYS-020-11-01 Dry fuel gas distribution

 After commissioning of GTP I & II (by others), dry gas is routed upstream of Dry Gas
Export Launcher 02-U-1801 to dry fuel gas system. PICA 0108A/B controls the dry fuel
gas pressure to consumers as follows:
i. Flare Package 02-Z-2201
ii. Off Spec Condensate Tank 02-T-1803
iii. Closed Drains Vessel 02-V-2301
iv. PW Surge Drum (not in scope of this commissioning procedure)
v. Thermal Oxidizer (not in scope of this commissioning procedure)
vi. CBD Header
vii. HP/LP Flare Header Purge.
 PSV 0109/0110 venting to HP flare is provided to protect the dry fuel gas header.
 Dry fuel gas is routed to Gas Turbine Generator 1,2 & 3 upstream of PCV 0106/0107.
 FIA 0105 is provided to measure dry fuel gas flow with pressure (PI 0103) and
temperature (TI 0104) compensation. PIHH 0102 actuates SDV 0101.
 In case of dry fuel gas failure, nitrogen automatically cuts in as HP/LP flare purge
instead of dry fuel gas. PIAL 108A/B opens XV 0112 and closes XV 0111. XV 0111
closes after XV 0112 has opened.

 Sub-Sub-System SYS-020-11-02 Raw fuel gas conditioning & distribution system

 The gas from CPF Manifold is routed to Feed Slug Catcher SC 1100/2100 (operation
of SC 1100/2100 not in the scope of this commissioning manual), and the raw gas from

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the slug catcher is routed to Raw Fuel Gas Scrubber 02-V-2501, under pressure
control of PCV 0117/0124 by PICA 0123, with high and low pressure alarms.
 PZT 0118 activates ESD 2502, which closes SDV 0116. PZIA 0116 has alarms at L, H
& HH.
 Liquid level in 02-V-2501 is controlled by LICA 0143, with high and low alarms, and
LZIA 0120 activates SDV 0116 and SDV 0127 in case of HH and LL in 02-V-2501 by
ESD 2503A/B and indicated by PZIA 0118 with L, H & HH alarms. 02-V-2501 is
protected by PSV 0125/0126 venting to HP flare. The liquid outlet is routed to closed
drain header. LG 0121 is provided for local level indication.
 PG 0122 and TG 0119 are provided for local monitoring of 02-V-2501 pressure and
temperature.
 The raw gas from Raw Fuel Gas Scrubber 02-V-2501 is routed to GTP I & II to meet
their fuel requirement under pressure control by PICA 0134 with high pressure alarm.
The raw fuel gas header to GTP I & II is protected by PSV 0135/0136, venting to HP
flare.
 Raw Fuel Gas in a parallel stream is routed to Raw Fuel Gas Heater 02-E-2501A/B to
heat the gas prior to use as gas turbine fuel during start up. The raw gas is electrically
heated in 02-E-2501A/B and filtered in Duplex Filter 02-F-2501A/B prior to use in gas
turbines. 02-E-2501A/B. 02-E-2501A/B is protected by PSV 0132/0139 venting to HP
flare.
 TIA 0201/0204 with HH and LL trips are provided to to trip 02-E-2501A/B in case of
high/low element temperature by ESD 2505A/B and ESD 2506A/B. TZT
0130/0131/0137/0138 are provided to monitor the element temperature.
TT0202/0203/0205/0206 have been provided on heater inlet & outlet line to monitor the
respective temperatures. MMM may please confirm all tag nos. against P&ID 2503.
 TIA 0142 with HH and LL alarms are provided on the common raw fuel gas header. TG
0140 and PG 0141 are provided for local monitoring of temperature and pressure on
common raw fuel gas header.
 PDG 0164 is provided to monitor the differential pressure across Duplex Filter 02-F-
2501A/B.

Refer ATTACMENT- 4 for the marked of P&IDs for the system and sub system.

Refer Commissioning flow chart given in ATTACHMENT-5 for sequence in the

commissioning process of Systems.

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 Pre-commissioning & Ready for start-up Procedure

 Pre-commissioning of SYS-020-11-01 of Closed Drains Vessel and Pump

 Flush all dry fuel gas lines and the nitrogen line up to the last block valve on each
consumer by air blowing/cardboard bursting as per general procedure.
 After flushing of dry fuel gas headers are complete, box up all openings and purge with
nitrogen to inertize the system. After inertization, leak test the system at design
pressure as per general procedure.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT-7:
i. PI 0103
ii. TI 0104
iii. FIA 0105
iv. PICA 0108A and PICA 0108B
v. SDV 0101
vi. XV 0111/XV 0112
vii. PSV 0109/0110

 Ready for start-up for SYS-020-11-01 of Closed Drains Vessel and Pump

 Ensure all trips are inline.

 Ensure PSV outlets are lined out to HP flare.
 Commission PCV 0117/0124.
 When dry gas is available, commission PICA 0108A/B, SDV 0101.
 For commissioning System 12.0 given in the next section close XV 0111 and open XV
0112. This will allow nitrogen purge gas to flow in the HP/LP flare header necessary for
commissioning System 12.0. Also ensure gas is not taken into Flare package (by
closing the 2” valve on the line in Sub System 12.5).

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 After the flare pilots are lighted, as described in Sub System 12.5, continue nitrogen as
purge gas.
 Receive dry gas into the system from Dry gas Export header, up to the first block vale
to each consumer. When respective block valves are opened based on demand from
consumers, dry gas (initially mixed with nitrogen) will flow to each consumer.
 Open XV 0111 and close XV 0112 to enable changing purge gas from nitrogen to dry
gas.
 Open the 2” valve on the line in Sub System 12.5 to admit dry gas to Flare Package.
Propane pilot gas will be changed to dry gas due to high back pressure on PRV XXXX.
 Total dry gas flow is measured by FIA 0105. PICA 0108A and PICA 0108B controls the
dry gas header pressure. Two pressure control valves PCV 0106 and PCV 0107 are
provided to ensure dry gas availability without any interruption.

 Pre-commissioning of SYS-020-11-02 of Raw fuel gas conditioning & distribution

system
 Isolate and physically clean Raw Fuel Gas Scrubber 02-V-2501, Raw Fuel Gas Heater
02-E-2501A/B and Duplex Filter 02-F-2501A/B. Ensure all instruments, trips and safety
devices are operational.
 Flush incoming and outgoing lines of Raw Fuel Gas Scrubber 02-V-2501, Raw Fuel
Gas Heater 02-E-2501A/B and Duplex Filter 02-F-2501A/B by air blowing/cardboard
bursting. Use bypass of PCV 0117/0124 during this operation. Do not include Raw Fuel
Gas Scrubber 02-V-2501, Raw Fuel Gas Heater 02-E-2501A/B and Duplex Filter 02-F-
2501A/B in the flushing circuit.
 After flushing of raw fuel gas headers are complete, box up all openings and purge with
nitrogen to inertize the system. All control valves and equipment not included in the
flushing circuit to reinstalled back. After inertization, leak test the system at design
pressure as per general procedure.
 Carry out pre commissioning activities for Raw Fuel Gas Heater 01-E-2501A/B as per
OEM manual given in ATTACHMENT-XX.
 Ensure following instruments are operational and required instruments are set as per
ATTACHMENT-7:
i. SDV 0116
ii. PICA 0123 including PCV 0117 & PCV 0124.
iii. PZIA 0118/ESD 2502

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iv. PG 0122
v. LZIA 0120/ESD 2503A/B
vi. LICA 0143/LG 0121
vii. SDV 0127
viii. TCIA 0129
ix. PCIA 0134
x. PSV 0135/0136
xi. TZT 0201/ESD 2505A/B
xii. TIA 0204/ESD 2506A/B
xiii. TIA0202/0203/0205/0206
xiv. TIA 0130/0137
xv. PSV 0132/0139
xvi. TIA 0142/TG 0140/PG 0141
xvii. PDG 0164

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14 Pre-commissioning & ready for start-up Procedures of support

Systems
Detailed activities of System / subsystem wise is listed in this chapter. The systems
based on their priority are taken up sequentially along with their sub-systems .

 ELECTRICAL SYSTEM

14.1 EARTHING & LIGHITING PROTECTION SYSTEM, No. SYS-070-

01

 System Description

Earthing system has been designed and built on three types of Earths:
1. Protective Earth/ Dirty Earth (PE)- designed for protection of
personnel and covers Equipment cabinets, cable armours, metal
frames (Structural frames, Junction Boxes etc.)
2. Instrument Earth / Clean Earth (IE)- Insulated earthing system
used for Voltage reference of Electronic Systems and covers
cable Shields/ screens of Intrinsically and non-Intrinsically safe
devices. This earth is isolated from PE
3. Earth Bar of Telecom system- isolated from PE and IE
Refer the overall Earthing Layout Doc No. C-051-0002-02F-070-LAD-0008
and installation details Document No. C-051-0000-00-070-DTL-0003.

Lightning Protection System is supplied by INDELEC consisting of Air

Terminal Rod and Early Stream Lightning Conductor PREVECTRON 2. The
system has mounted Digital Counter (for minimum Detectable Current as 1
KA and maximum Detectable current as 100 KA) and a small Solar Panel for
operation of the system. No external power is required for operation of the
system.
There are 12 Nos Lightning Arrestors in the CPF area models S6.60 T/ Pole
of 9 Mtr, 12, 15, 18, 30 Mtrs and S3.40T/ Pole 9 Mtr. Wellhead S1, Wellhead
S4, Hub-1, Condensate Metering Station and Dry Gas/ LPG Metering Station
are designed for installation of one Lightning Arrestor each of model TS 2.25/
Tower 6 Mtrs.
Earthing of the Lightning Conductor is achieved by following Triangle Earthing
System with three Earth Electrodes (copper coated steel rods) each.

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Installation of Lightning Arrestor is to be completed as per Installation details

provided by the Vendor in its manual under Document No C-051-VP-070-LIG-
E19-0001.

 Pre-commissioning checks/ activities of Earthing & Lightning System

1.Obtain Mechanical Completion (MC) certificate.

2.Obtain cold Work Permit.
3.Clean the entire area around the earthing chambers.
4.Barricade the area to avoid unwanted entry.
5.Ensure that the Earthing components are installed as per specifications
6.Check the earthing strips for proper condition and installation
7.Ensure that the electrodes have clean surface
8.Check level of earth pits with reference to grade level
9.Ensure the layout of earthing grid as per project drawings referred above
10.Check for installation of Lightning arrestor with reference to specifications
11.Verify that the Cable connections/ dressings are proper
12.Verify that the contacts are clean.
13.Ensure earth pits are as per drawings.
14.Take the reading of earthing resistance by three pin method and show it to
the client (The earthing resistance shall be less than 10 Ohms for PE and less
than 1 Ohm for IE and Communication Earth. Resistance of earth pits shall be
measured individually and recorded after disconnecting from the earth grid.
Overall Earth Grid total resistance shall then be measured and recorded after
connecting all the earth pits in the grid.
15. Lightning System self-check is performed by using vendor supplied
PREVECTRON 2 Tester as per the verification points given in the
Maintenance chapter of the Vendor manual.

Obtain approval for commissioning by taking all the readings of earth pits and
show that the grid is active and is ready to receive static charge.

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14.2 Pre-commissioning of 11 KV Generators System No. SYS-070-

02

 Brief Description of 11 KV Generators

Three Gas Turbine Generators (GTG’s) GTG- 6001 A/B/C, have been
supplied by M/s Siemens for installation at CPF and meeting the total power
requirement of facilities. Each Generator of 7.8 MVA capacity with power
generation at 11 KV, 3 phase is tested at works (FAT) prior to despatch. The
Gas Turbines are designed for operation on Liquid Fuel (Diesel) as start-up
fuel and Natural Gas as normal fuel. All the Liquid Fuel Forwarding Skid
(LFFS), Gas Control Manifold Valves along with associated instruments are
also supplied by the GTG supplier for installation and connection to Generator
Control Panel for operational controls.
Refer the SIEMENS Document No. 1CS147614 (Customer Doc No. 2014-01-
037-E08-005) for all the list of equipment and Signal Exchange list.

Each Generator is also supplied with a Generator Control Panel and a

Common Synchronising Panel, installed in GTG Local Equipment Room
(GTG- LER) for parallel operation of the generators. GTG-LER also houses
the local panel for Fire Protection system of GTG. Each Generator is capable
of meeting 50% of power requirement in full load operating mode.
Refer the operating philosophy Document No. 1CS162674 given by Siemens.
The Gas Turbine Generators are also enclosed in a sound proof metal
enclosure, which is also equipped with Fire & Gas Controllers monitoring the
system for a fire condition and initiate release of fire extinguishing media
when detected. The system also monitors the field devices for presence of
combustible gases in the ventilation ducts entering and exiting the turbine
enclosure and fire in the turbine inlet duct.

 Pre-commissioning Checks

After installation of GTG’s and its sub-assemblies is complete, it is prepared

for first start and checks. The Generator control power required for Black Start
(with no power generation from GTG) will be provided by running Essential
DG set. On one of the GTG’s reaching power generation stage, Essential DG
set is stopped and GTG control power is provided internally trough Auxiliary
transformer of operating GTG.

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GTG being highly integrated power generating equipment, it is advisable to

have the vendor’s representative performing a thorough check of
completeness of installation and assisting the client in first few starts on Liquid
Fuel including Synchronisation. A general check list is being provided here as
a guide but FAT documents and approved SAT (Site Acceptance Test)
documents shall be the overriding criteria:

1. Check that all the sub-assemblies supplied by the vendor has been received
and installed as per the relevant document.
2. Check that all the control circuit cables have been connected as per the
Signal Exchange list document.

3. Check that the Fuel supply systems (Liquid and Gas) are commissioned and
ready for trial of GTG.
4. Check that Essential DG set is ready for use and connected to the Power
distribution system.
5. Check that 11 KV switch gear system is checked and ready for energising on
starting GTG including 400 V PCC sections for evacuation of power to
Auxiliaries of GTG’s
6. Ensure that all GTG internal instruments loop checks have been performed,
indications on Unit Control Panel (UCP) been verified on the turbine Control
panel and communication system connections have also been verified.
7. All Fire and safety equipment have been installed and checked for proper
functioning including release of fire extinguishing media.

On completion of the above checking and first successful trial, the GTG’s are ready
for final commissioning and use.

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14.3 Pre-commissioning of 11 KV SWITCHGEAR / OUTDOOR

ISOLATORS System No. SYS- 070-03

 Brief Description of the 11 KV System

Power at 11 KV is generated by GTG’s alone and is directly received at 11 KV

switchgear panels for further utilisation. 11 KV panel (02-SP-6101) is a High Voltage
(HV) panel located in the Substation building in CPF area under controlled
atmosphere of HVAC with appropriate Fire alarm and Protection system (Clean
Agent flooding) The switchgear panel is supplied by M/s Eaton and consists of 3 Bus
sections for three GTG’s, one on each bus with a bus coupler arrangement. GTG’s
can be synchronised to run in parallel for meeting the power requirement. Panels for
outgoing feeders are only transformer feeders as there is no electrical drive directly
on 11 KV. There are some spare panels and dummy panels for future use.
Refer the Single Line Diagram vide Doc No. C-051-VP-070-11KV-SLD-001
Each panel has its own Protective relays, selector switches, lamp indications and
Multifunction meter in the top LV compartment, a Vacuum Circuit Breaker (VCB)
withdrawable compartment in the middle and Potential Transformer (PT)
withdrawable compartment in the bottom section. Insulated Bus Bar is located
behind the LV compartment in the top portion of the panels. Auxiliary Power supply
of 230 V AC is distributed in the panels for Circuit Breakers Motor charging and
panel heaters. 110 V DC power is received from 110V DC UPS for Control &
Protection systems (Relays, alarm, lamp indication etc.). The panels also
communicate important parameters to PMS system and ICSS through MODBUS RS
485 communication port. All the power incoming and outgoing cables are going
through the bottom plate of the panels and passing through cable cellar below the
ground floor in the substation building.
In addition to the 11 KV switchboard panels described above and located in the Sub-
Station Building, two outdoor panels (free standing) each are installed near the
transformers 02-TR-6104, 02-TR-6105, 02-TR-6106, and 03-TR-6101 located in
Workshop, Security Compound, Accommodation Camp, and Condensate Metering
Areas respectively. One panel houses the 11KV Vacuum Circuit Breaker (VCB) with
a 3 pole earth/ busbar disconnector and the other houses the 11 KV Vacuum Load
Break Switch (LBS) with a 3 pole earth/ busbar disconnector for earthing of the
power cables during outage of Transformers for maintenance.
11 KV switch board panels in the Substation Bldg, are also provided with Key switch
system for circuit breakers of each bus section. These mechanical keys provide a
mechanical lock disabling the earthing switch to be put On when Circuit Breaker is
closed or vice versa disabling the closing of any Circuit Breaker when earth switch is
On. This is achieved through use of Castell Key Exchange Box for each bus section
where inadvertent removal and use of keys is inhibited.

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 Pre-commissioning checks

After the installation of all panels (including alignment, grouting of the base frames
and inter panel bolting) along with its sub-assemblies are completed, following
checks shall be performed before switching on the power:
1. Ensure that all the nut bolts on the bus bars, cable alley supports and internal
mounting brackets are fully tightened. All unused cable entries at the gland plates
are closed with caps. No seepage of water in the substation building is expected.
2. Ensure completion of Panels’ earthing system to be complete and tested as per
system requirements.
3. Ensure good housekeeping with area completely clean. Preferably HVAC System
should be operational maintaining clean air circulation.
4. Insulation resistance shall be checked with a 5000 V DC meggar. Hi-pot test on
all the incoming and outgoing cables shall also be done by applying 23 KV AC for
60 seconds and insulation resistance shall be recorded again after the Hi-pot
test. The Insulation resistance is expected to be around 5 Giga ohms. Hi-pot test
readings should be max 25 mA.
5. Ensure that only authorised personnel are present in the substation and entry of
personnel is regulated in the area.
6. Ensure that Single Line Diagram (SLD) of 11 KV system is displayed in the
substation and all the statutory permissions for charging the panels have been
obtained.
7. Auxiliary power supply of 230 V AC and 110 V DC shall be switched On after
seeking necessary permission. Control fuses shall also be of proper rating.
8. Check and ensure the lamp indications on each panel. With the circuit breakers
in TEST position, check the operation of closing and tripping.
9. Check the functioning of few protection relays and its settings as per data sheet
by using portable tools.

After satisfactory completion of the above work, 11 KV panels are ready (section by
section) to be charged with power when available.
Panel power Bus shall be charged after ensuring proper termination of Feeder
cables. Ensure that Panel heaters are OFF after the Bus is charged. Keep the Bus
charged at No Load condition for observation.
All the Transformer feeders can also be charged, one by one, once the transformer
is ready for commissioning.

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14.4 Pre-commissioning of TRANSFORMERS System No. SYS-070-

04

 Brief Description of the Transformers

Following Transformers are installed in the CPF area/ facility:

Transformer No. Prim/Sec Volt Size Loc Service

1. 02-TR-6101 A/B 11KV/ 424 V 2500KVA SubStn Train1/Utility/AuxPwr
2. 02-TR-6102 A/B 11KV/ 424 V 2500KVA SubStn Train2/Utility/AuxPwr
3. 02-TR-6103 A/B 11KV/ 3.45 KV 4000KVA SubStn 3.3 KV Panels
4. 02-TR-6104 11KV/ 424 V 625KVA W/shop Laydown area
5. 02-TR-6105 11KV/ 424 V 1000KVA Accom. Camp
6. 02-TR-6106 11KV/ 424 V 125KVA Main Gate Security/ Plant Ltng
7. 02-TR-6201 A/B 11KV/ 424 V 2500KVA SubStn Essential Pwr/UPS etc
8. 03-TR-6101 11KV/ 424 V 63KVA Cond. Mtrg. Stn.
9. 03-TR-6107 33KV/ 424 V 63KVA DryGas/LPG Mtrg Area

(Power receipt from Overhead line from Khor-Al-Zubair)

10. 02-TR-6401 A/B 424 V/ 400V 62.5KVA Main Gate Lighting

All the above transformers are for outdoor installation and supplied by M/s Schneider.
The two transformers of 4000 KVA installed at the substation yard are the largest
transformers and are provided with High Velocity Water Sprinkler for protection against
fire situation. All the transformers are with Natural Oil and Natural air (ONAN) cooling
except the last one, Lighting Transformer, which is a dry type. The transformers are
connected to the HV/ LV panels located in the adjoining substation building. HV cables
are laid through the cable cellar and LV connection is through enclosed Bus Duct to the
respective panels.

 Pre-commissioning Checks on Transformers

After the installation of the transformers is complete, following checks shall be

performed:

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1. After proper installation of the transformers, start filling the Transformer oil in the
Transformer by using hand pump or portable electric pump. The Radiators of the
transformers should have been connected and connecting valves opened for
filling the oil through the radiators with suitable air release periodically. This
operation shall be done under a temporary shed to avoid ingress of water during
rain or snowfall situation.
2. After the oil is filled to the level marked, a portable Centrifuge machine with built
in heater should be connected for oil filtration and removing any entrapped
moisture in the oil. This operation shall be continued till the Transformer oil
sampled becomes clear original colour.
3. Check the oil level in the Transformer Conservator.
4. Ensure that Transformer Oil is adequate in the tank and quality of oil (Break
Down Voltage – BDV, Colour & appearance and water content) is verified before
electrical charging of the transformer.
5. The oil drain channel should also be checked for completeness in case of need.
6. All other portable and installed Fire Protection equipment (like sand bucket, Fire
extinguishers and Sprinklers where provided) should be ready for any eventuality.
7. Check the continuity of the earth connection. The transformer must be solidly
connected to the earth.
8. Check that the cables are independently supported and supported neither by the
transformer terminals nor by the cable glands.
9. Match the name plate details (Tag No., Size etc.) with respective connected
panel name plate to avoid any mismatch installation and connection.
10. HV cables laid are meggered and cleared for connection. Ensure proper
termination and tightening of incoming cables on the Transformer HV bushing.
11. Ensure proper tightening of LV Bus bar in the Bus Duct maintaining the design
phase segregation. The Hi-pot test and insulation resistance measurement
should also be carried out and values recorded. All duct top covers should then
be securely fastened.
12. Ensure all the alarm signal cables from Transformer Control Panel is properly
connected as per schematic for alarm indication in the panel.
13. Refer Vendor’s manual TCR/ONAN/225220 for expected results.
14. Ensure proper housekeeping and presence of authorised personnel only in the
area. Area should be barricaded temporarily with Caution Boards.

After the above checks are completed, obtain the Safety Work Permit to charge
the Transformer and allow it to run on No Load for few hours of observation. The
Transformer is then ready to be put on Load and conducting Site Acceptance
Test by the vendor.

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14.5 Pre-commissioning of 3.3 KV SWITCHGEAR AND POWER

CABLES System No.SYS-070-05

 Brief Description of 3.3 KV System

3.3 KV panels (02-SP-6102) is a two bus Medium Voltage (MV) panel,

supplied by M/s Eaton and located in the Substation building under controlled
atmosphere of HVAC with appropriate Fire alarm and Protection system
(Clean Agent flooding). The MV panel incoming feeders are from two
Transformers 02-TR-6103 A/B- 11KV/ 3.3KV. The outgoing feeders are for
two sets of electrical drives- Refrigeration Compressor A/B – 500 KW and
Stabilised Overhead Compressor -933 KW for each train 1 &2 of Gas
Treatment Plant at CPF. There are some feeder panels for future 3.3 KV
motor drives also.

Refer the Single Line Diagram (SLD) document no. C-051-VP-070-3.3 KV-
SLD-0001 for the detail schematic.
Each panel has got its own Protective relays, selector switches, lamp
indications and Multifunction meter in the top LV compartment, a Vacuum
Circuit Breaker (VCB) withdrawable compartment in the middle and Potential
Transformer (PT) withdrawable compartment in the bottom section. Insulated
Bus Bar is located behind the LV compartment in the top portion of the
panels. Auxiliary Power supply of 230 V AC is distributed in the panels for
Circuit Breakers Motor charging and panel heaters. 110 V DC power is
received from 110V DC UPS for Control & Protection systems (Relays, alarm,
lamp indication etc.). The panels also communicate important parameters to
PMS system and ICSS through RS 485 MODBUS communication port. All the
power incoming and outgoing cables are going through the bottom plate of the
panels and passing through cable cellar below the ground floor in the
substation building.
3.3 KV switch board panels are also provided with Key switch system for
circuit breakers of each bus section. These mechanical keys provide a
mechanical lock disabling the earthing switch to be put On when Circuit
Breaker is closed or vice versa disabling the closing of any Circuit Breaker
when earth switch is On. This is achieved through use of Castell Key
Exchange Box for each bus section where inadvertent removal and use of
keys is inhibited.

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 Pre-commissioning checks

After the installation of all panels (including alignment, grouting of the base
frames and inter panel bolting) along with its sub-assemblies are completed,
following checks shall be performed before switching on the power:

1.Ensure that all the nut bolts on the bus bars, cable alleys supports and
internal mounting brackets are fully tightened. All unused cable entries at the
gland plates are closed with caps. No seepage of water in the substation
building should be there.
2.Ensure completion of Panels’ earthing system to be complete and tested as
per system requirements.
3.Ensure good housekeeping with area completely clean. Preferably HVAC
System should be operational maintaining clean air circulation.
4.Insulation resistance of Bus bar shall be checked with a 5000 V DC meggar.
Hi-pot test on all the incoming and outgoing cables shall also be done by
applying 8000V AC for 60 seconds and insulation resistance shall be
recorded again after the Hi-pot test. The Insulation resistance is expected to
be around 5 Giga ohms. Hi-pot test readings should be max 25 mA.
5.Ensure that only authorised personnel are present in the substation and
entry of personnel is regulated in the area.
6.Ensure that Single Line Diagram (SLD) of 3.3 KV system is displayed in the
substation and all the statutory permissions for charging the panels have been
obtained.
7.Auxiliary power supply of 230 V AC and 110 V DC shall be switched On
after seeking necessary permission. Control fuses shall also be of proper
rating.
8.Check and ensure the lamp indications on each panel. With the circuit
breakers in TEST position, check the operation of closing and tripping.
9.Check the functioning of few protection relays and its settings as per data
sheet by using portable tools.
After satisfactory completion of the above work, 3.3 KV panels are ready
(section by section) to be charged with power when available.
Panel power Bus shall be charged after ensuring proper termination of Feeder
cables/ Bus. Ensure that Panel heaters are OFF after the Bus is charged.
Keep the Bus charged at No Load condition for observation.
All the Motor feeders can also be charged once the motors are ready for
commissioning.

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14.6 Pre-commissioning of NEUTRAL EARTHING REGISTER (NER)

SYS-070-06

 Brief Description of 3.3 KV Neutral Earthing/ Grounding Resistor

Neutral Earthing Resistor supplied by M/s Schnieder Electric is installed in

transformer yard at the Neutral point of Star connected 3.3 KV transformers. These
NER’s are used for grounding the High and Medium Voltage system equipment after
electrical isolation to ground the residual voltage stored in inductive/ capacitive
circuits. These are basically Off line grounding switches with low resistance
assemblies for operation on high voltage applications.
The system is enclosed inside an outdoor panel with an off-line isolator to safely
connect the isolated Transformer secondary terminals to ground for maintenance
personnel to work on the circuit. The Grounding Resistor is a 19.1 ohm, SS AISI-304,
multi element assembly to withstand the full line voltage and max. temperature rise
upto 400o C at the time of rated earthing current flow.
Refer the data sheet of NER vide Document No. C-051-VP-070-Trafo-NER-0001
Similar NER is supplied by Siemens and connected at each GTG for 11 KV
Generator Neutral terminal earthing when it is non-operational.

 Pre-commissioning check

Neutral Earthing Panel is supplied for two Transformers after Factory test and test
results are furnished in the data sheet. Only checks required at site after installation
and connection are:
1. Insulation measurement (between grids and frame) under 500 V DC- Insulation
resistance must be higher than 200 MΩ
2. Earthing Grid for the NER shall be tested for completed work and recording of
earthing pit test values as described in Earthing System

After checking, the NER system stays commissioned for use all the time the power
outage is taken from the energised state.

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14.7 Pre-commissioning of 400V SWITCHBOARD / DISTRIBUTION

BOARD System No. SYS-070-05/13

 Brief Description of 400 V Power Panels & Distribution Boards

Following 400 V 3phase power supply panels are installed at site and their particular
Single Line Diagram (SLD) as mentioned below may be referred for understanding
the loads connected:
Panel No. Tag No Loc/ Installation SLD No.
1. PMCC-1 02-SP-6103 Substn Bldg (HVAC) C-051-0002-00-070-0003
2. PMCC-2 02-SP-6104 SubStn Bldg (HVAC) C-051-0002-00-070-0004
3. PMCC-3 02-SP-6201 SubStn Bldg (HVAC) C-051-0002-00-070-0005
4. Security Compound 02-SP-6106 Security Compound C-051-0002-00-070-0013
(outdoor-safe area)
5. Condensate Mtrg 03-SP-6101 Cond. Mtrg Area C-051-0003-3A-070-0013
(Outdoor-safe area)
6. Dry Gas/LPG Mtrg 03-SP-6102 LPG Mtrg Area C-051-0003-3B-070-0013
(outdoor-Ex-d)
7. Warehouse/Chem Stg02-SP-6105 Warehouse C-051-0002-2F-070-0033
(Indoor-safe)
In the above list, first two Power/Motor Control Centres (PMCC) are routine Low
Voltage motor supply systems receiving power from 11 KV/0.424 V transformers, the
third PMCC-3 is for Essential Loads like AC /DC UPS feeders, HVAC feeders,
Instrument Air Compressor/ Dryer Package, Fire Water Pkg. Distribution Boards, HP/
LP flare Pkg, GTG and Essential DG Control supply, F&G system pkg, Electrical
Heat Tracing (EHT) and Plant/ Road Lighting through its own Distribution Boards.
PMCC-3 also receives back up power from Essential DG sets in case of normal
Power failure.These Power panels are supplied by M/s Eaton along with all
associated Protection system, Metering and Communication Interface system duly
tested for the specified operation.

 Pre-commissioning Checks on 400 V AC PMCC/ PDB’s

1.Obtain Mechanical Completion. Ensure that all unused cable entries are sealed
from the cable cellar

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2.Confirm that electrical switch gear, start/stop switches and other items are labelled
properly
3.Clean the entire area around the MCC panels. HVAC should preferably be started
for maintaining the air quality as clean.
4.Barricade the area to avoid unwanted entry and authorised personnel alone should
be present.
5.Ensure that the MCC panel earthing components are installed as per specifications
and the earthing strips are in proper condition.
6.Check for availability of as-built electrical Single Line Diagram (SLD) in the Building
7. Ensure that the Electrical equipment / components in the MCC panel are installed
and tested as per specifications and the test records are readily available.
8.Check for lock-out provisions for the switch gear where provided.
9.Ensure availability of all safety gadgets in MCC Panel room.
10.Check protective wears are worn by the electrical supervisor.
11.Obtain Work Permit to charge the panel one by one.
12.Put the Incoming feeders ON. Wait for few minutes and check for healthy
situation all around.

After satisfactory completion of the above checks, motors and other electrical boards
are ready to be charged one by one for start up.

 Pre-commissioning Checks on 400 Volt, 3phase motors (driving pumps/ fans etc.)

1.Ensure that power supply from the power panel is available and power cable to the
motor and the control cables connections have been made as per the schematic
after meggering. Ensure that all motor earthing is also properly connected.
2.Pump and Motor are decoupled.
3.Motor is ‘bumped’ for a moment by pressing ‘start’ button to check the Direction of
rotation.
4.If the direction of rotation is okay, the Motor is started again and if not, the
rectification is done with the terminals.
5.Ensure that the area around the motor is barricaded for avoiding injury to any other
person working nearby.
6.Once the Motor is started solo, it is intended to keep it running, preferably for 3-4
hours.
7.The parameters like No Load current, temperature rise, vibration, bearing or fan
noise for the solo run are noted.

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If found satisfactory, the Motor is cleared for coupling with Pump for further tests.
The necessary documents are filled and signed
All other motors (VFD, Soft Start etc.) are covered subsequently in the manual.

14.8 Pre-commissioning of VARIABLE SPEED DRIVES SYS-070-08

 Description in brief

Variable Speed drives have been chosen as one of the Energy saving devices in
some of the LV motors used for fans or varying duty pumps in Gas Treatment Plant
of CPF area. Varying speed is achieved by reducing the applied power frequency
maintaining Voltage/ Frequency (V/f) constant. The saving of power is achieved till
the motor along with the drive is required to run near the rated speed due to process
requiremen.t. The list of such drives are given below:

Tag Number Rating Service

02-VFD- 5.5 KW, 400V, Stabiliser O/H Condenser A-1310 / A-2310,
6108/6118 3Ph Train1 /2
02-VFD- 7.5 KW, 400V, Refrig. Condenser Fan A-1361A/ A-2361A,
6107/6117 3Ph Train1/2
02-VFD- 11 KW, 400V, Deb. Reflux Cooler Condenser Fan
6105/6115 3Ph A-1338A/A-2338A
02-VFD- 11 KW, 400V, Regen Gas Cooler A-1341/A-2341B, Train 1/2
6106/6116 3Ph
02-VFD- 15 KW, 400V, Amine Still Reflux Cooler A-1322A/A-2322A
6104/6114 3Ph
02-VFD- 15 KW, 400V, Stab O/H Condens. Cooler A-1311B/A-2311B
6109/6119 3Ph
02-VFD- 30 KW, 400V, Lean Amine Cooler A-1321A/ A-2321A,
6110/6120 3Ph Train1/Train2
02-VFD- 160 KW, 400V, Fan Motors
6101/6111 3Ph
02-VFD- 160 KW, 400V, Fan Motors
6102/6112 3Ph
02-VFD- 160 KW, 400V, Fan Motors
6103/6113 3Ph

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All these VFD panels have been supplied by M/s Eaton after conducting Factory
Acceptance Test (FAT) to meet the design requirements. The small panels are wall
mounted while the large capacity drives’ panels are free standing with Local Push
Buttons for Start, Stop, Speed Raise and Lower command PB’s besides provision for
remote operation from ICSS operator stations. The panels house Power Electronic
components like Diode Bridge, Silicon Control Rectifiers (SCR) and inverters besides
its complex control circuit. These parts are heat generating components and hence
require its own panel cooling fans system. The process control variables (Process
Temperature or flow) of the corresponding application and the Motor current
indication in the controller also enable the operator to put the Speed Control on Auto
Control mode.
Refer the corresponding Vendor Drawing and Catalogue to familiarise with the
control circuits.

 Pre-commissioning Checks

The panels are self-contained, pre-wired and ready to use type and does not require
mounting any loose supplied item. This being a Power Electronic Panel, Vendor
presence at the time of trial run is recommended. All the check procedures specified
by the vendor must be followed. However, following general checks shall be
performed at site before starting the motors:
1. Obtain the Mechanical Completion Certificate (Motor installation, Cable
connections to and from VFD panel, all the control cables termination to interface
panels including Communication cables)
2. Ensure that Motor earthing, Panel earthing and cables screening earthing has
been properly terminated with completion of earthing grid job.
3. Only authorised personnel shall be present near the VFD panel and area around
the motor is barricaded for trial.
4. After the first kick start, ensure proper cable connection to achieve proper
direction of rotation, else change the Phase connections of the motor.
5. After the initial checks are found satisfactory, the motor may be started on No-
load following all the guidelines and instructions of Vendor. Preferably, the vendor
representative should be present in the initial trial. No load operation may be
continued for 3-4 hours and important parameters of the motor may be noted.
6. The operation of the motor from remote location may also be tested along with
process indication and control parameters

Once the No Load operation is satisfactory, Motor may be coupled with the
Fan/pump/compressor and full trial be conducted as given in the LV Motor
section of the manual.

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14.9 Pre-commissioning of SOFT STARTER MOTORS SYS-070-09

 Brief Description of Soft Start System

Soft Starters are used in some of the LV / MV motors as per the list below for smooth
start of the motors by reducing the applied voltage thus reducing the starting current
drawn from the power supply system. This ensures better stability of Electrical Power
distribution circuit besides increased life of motors. The Soft Starter function is over
after the start of the motor and the circuit performs like any other direct start circuit
during the run of the motors. Soft Start feature is thus used only at the time of each
start of the motor.

Tag No. Motor Rating Service

02-C- 55 KW, 400V, 3 Phase Regeneration Gas Compressor Train
1141/2142 1/2
02-P- 150 KW, 400V, 3 Phase HMO Pump Train1/2
1681/2681
02-P- 150 KW, 400V, 3Phase HMO Pump Train 1/2
1682/2682
02-C- 500 KW, 3.3KV, 3Phase Refrigeration Compressor-A Train 1/2
1161/2161
02-C- 500 KW, 3.3KV, 3Phase Refrigeration Compressor-B Train 1/2
1162/2162
02-C- 933 KW, 3.3 KV, 3Phase Stabilised Overhead Compressor Train
1110/2110 1/2

The starters have been supplied by M/s Eaton along with necessary electronics pre-
assembled in free standing panels along with local start/ stop PB. The panels have
been tested at Factory (FAT) and does not require any field connection except Motor
regular Power and control cable connection.
Refer the Vendor manual supplied along with the system.

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 Pre-commissioning Check

After the panels have been installed and connected, following general checks shall
be carried out:

1. Obtain the Mechanical Completion Certificate (Motor installation, Cable

connections to and from Starter panel, all the control cables termination to interface
panels including Communication cables)
2.Ensure that Motor earthing, Panel earthing and cables screening earthing has
been properly terminated with completion of earthing grid job.
3.Only authorised personnel shall be present near the Starter panel and area around
the motor should be barricaded for trial.
4.After the first kick start, ensure proper cable connection to achieve proper direction
of rotation, else change the Phase connections of the motor.
5.After the initial checks are found satisfactory, the motor may be started on No-load
following all the guidelines and instructions of Vendor. No load operation may be
continued for 3-4 hours and important parameters of the motor may be noted.
The operation of the motor from remote location may also be tested along with
process indication and control parameters.

Once the No Load operation is satisfactory, Motor may be coupled with the
Pump/Compressor and full trial be conducted as given in the LV Motor section of the
manual.

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14.10 Pre-commissioning of LIGHTING SYSTEM SYS-070-10

 Brief Description of the system

Single phase 230V AC lighting has been carried out in all the buildings, Plot
area and Plant areas of CPF and Metering Stations.
Refer the Layout Drg. Document Nos as below:
Overall Plot Lighting C-051-0002-2F-070-LAD-0012
CPF Train 1/2 C-051-0002-2B-070-LAD-0003
Metering Stations C-051-0003-3A/3B-070-LAD-0002
Security Compound C-051-0000-00-070-LAD-0001
Substation Bldg. C-051-0002-2F-070-LAD-0005
CCBldg. C-051-0002-2F-070-LAD-0012
Workshop C-051-0002-2F-070-LAD-0016
Inst LER C-051-0002-2F-070-LAD-0020
Fire Stn/ Ambulance C-051-0002-2F-070-LAD-0023
Admn. Bldg. C-051-0002-2F-070-LAD-0026
Warehouse C-051-0002-2F-070-LAD-0030
The above drawings give the complete layout and mounting details of lighting
fixtures installed in the buildings, roads/ passages and Plant areas. While the
fittings inside the buildings are chosen as per the ceiling design (Fluorescent
Tube light) , the area lighting consists of Poles and bracket mounted HPSV
fittings (150 W, 250 W, 400 W etc.) with Explosion Proof fixtures in
Hazardous areas. All the lighting circuits are distributed in separate phase
and neutral wire for a designated series of fittings with a group switch in a
loop-in loop-out fashion and individual switch for individual connection. These
lights Distribution Boards are fed from Lighting Transformer in the Security
Compound and nearby lighting boards.
Emergency escape route, Exit Gate, Exit Sign and Wind sock lighting is a
fluorescent LED lighting powered from pole/structure mounted Solar panels
including Ex proof Control Gear.

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 Pre-commissioning of Lighting System

Lighting systems when completed can be checked circuit wise by following

methods:
1. Ensure that all the control gear boxes are properly fastened and covers
tightened, particularly in Explosion Proof areas.
2. Ensure that structure mounted lighting brackets or pole mounted brackets
are firmly clamped or grouted to become loose during wind blowing or
personnel movement.
3. Ensure that all the earthing from the Control Gear boxes are properly
terminated. All the cables are properly clamped or laid in conduit as
specified.
4. Switch On the lights, circuit by circuit and see that lights come on without
flickering or sparks due to loose fitting and any fused/ broken bulbs/lights
must be replaced.
The lights after checking can be switched off for switching On as per the
need.

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14.11 Pre-commissioning of CONTINUOUS RATED DG SET System

No. SYS-070-11

 Brief Description of the DG set System

Diesel Generating sets as per the table have been provided at remote
locations as a back up to Solar Power or normal power for powering the
electrical and control equipment located in this areas:

DG No. Generation Volt Size Location Service

1. 02-DG-6001 400 V, 3phase 60KVA Gath. Hub-1 HCS panel
2. 03-DG-6002 400 V, 3phase 80KVA Cond.Mtrg Metering Skid

3. 02-DG-6003 400 V, 3phase 60KVA WellheadS1

WHCS panel
4. 02-DG-6004 400 V, 3phase 60KVA WellheadS4
WHCS panel
5. 02-DG-6002 400 V, 3phase 150KVA Security
CPF area Ltng
6. 03-DG-6001 400 V, 3phase 100KVA DryGas/LPG
Metering Skid

Refer the corresponding Single Line Diagram (SLD) for each area- C-051-0001-
1A/1B/1C/1D-070-SLD-0001.
The DG sets are self-contained, pre-assembled, factory tested, and ready to use
systems on installation and connection to powered equipment. For remote locations,
these DG’s can be started manually or get started automatically on Low-Low Battery
(24 V) alarm for the respective control system and Chemical Injection System. In the
normal course, these DG’s are required to be started for Methanol Injection, as the
System has got 400 V motors and also for charging Solar Panel Batteries when low
voltage is encountered. Diesel Fuel tanks for these continuous rated DG sets are
self-contained in the skid itself, requiring occasional topping up from barrels
externally. DG’s have their own start/ stop panel with monitoring instruments for the
system. The remote indications and controls of the DG system is routed to remote
station (Central Control Building- OWS) through fibre optic / microwave system

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connected from Solar panel PLC. Security Compound DG is used for Lighting Power
in the CPF area roads on failure of normal power and starts automatically.

 Pre-commissioning Checks on DG sets

1. Ensure that the DG supplied is installed as per the vendor Manual.

2. Ensure that all Control and communication cables are connected as per wiring
schematic through the specific communication panel for indication and control
of important parameters at Operator Work Stations (OWS) in the Central
Control Room.
3. Ensure that all the Power cables from DG are also connected to local
Distribution Boards or PMCC’s as may be the case.

4. Ensure that all preliminary checks (like Coolant, Engine Oil, Diesel Fuel, DG
Battery health etc.) as specified in the vendor manual are carried out and
completed before start of the engine.

With the satisfactory completion of the above checks, DG sets will be ready to
be started and use including conducting Site Acceptance Test (SAT).

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14.12 Pre-commissioning of EMERGENCY DG SET System No. SYS-

070-12

 Brief Description of Essential DG Set

Two nos. Diesel engine driven Generators (02-DG 6201 A/B) are installed in
the CPF facility for meeting the Essential power requirement of CPF when
Gas Turbine Generators are not operational. These Generators are rated for
1200 KVA each (Continuous Rating) for 415 Volt, Three phase power
generation. Each DG set is supplied by SAKR Power Generation in a self-
contained enclosure complete with its own operations controls and safety
features. The Diesel engine is Cummins make and the Generators are
Marathon Electric make with Control Panel from GE. The total set is supplied
in a sound proof enclosure with its own Fire and smoke detection and
protection system. The Breaker Panel supplied by the vendor along with total
electrical Protection is also separately installed near EDG
Refer the supplier document No. PO 2014-04-092(EDG)
These Generators can be started without any external power as it has its own
24 V DC battery (with its own battery charger from alternator after start of the
Engine) for cranking motor and starting the engine on no load initially.
Subsequently, the Generators (individually or in parallel operation) can be
switched ON to supply power through 400 Volt Distribution Board.
Important operating parameters of DG’s are made available to the Plant
operator on Operator Work Station (OWS) through Modbus connection RS
485.
Refer Operations Manual 2014-04-092-M03-0001-C1 supplied by SAKR
Power Generation.

 Pre-commissioning Checks

The complete system is supplied in assembled and prewired condition after

conducting Factory Acceptance Test (FAT) and installed at site as per the laid
down procedure. Following checks shall be performed before embarking on
starting the Engines:
1. Ensure that the fully enclosed unit is installed and grouted firmly on the
pedestal foundation as per the plan.
2. On opening the enclosure doors, check and ensure that all the
subassemblies and parts are firmly in position and not loose during
transportation.

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3. Switch ON the 24 V batteries and ensure that it is fully charged (GE control
panel indications will be ON)
4. Check and ensure that Engine oil, Coolant in the radiators and Diesel Fuel
Tank is having sufficient quantity of fluid as per the Operations manual.
5. Ensure that the power supply cable laid from the 415 Volt PCC is tested
for insulation and ready with for termination on the Generator terminal.
6. Ensure that Air intake line including the Air Filters and Exhaust pipes are
clear without any shipping covers or foreign objects.
7. Ensure the healthiness of all Smoke detection sensors, Fire detectors and
protection system components by simulation from the local Panel.
Follow the complete installation and start up manual given by the
suppliers, preferably in presence of supplier representative, before starting
the system.
8. After obtaining clearance from the supplier's representative, connect the
power cables to the Generator and communication cables to the system
communication port for indication in the Central Control Room.

The system is ready for start and supplying power when PCC is ready to
receive and distribute the power. Balance tests like Automatic Voltage
Regulation (AVR), Load tests and wave form of power etc. can then be
checked and confirmed as per approved Site Acceptance Test (SAT)
procedure by the supplier

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14.13 Pre-Commissioning AC UPS System No. SYS-070-13

 Brief Description of the AC UPS System

230 volts, 1 phase Un-interrupted Power Supply is required for all Instrumentation
and control Systems (ICSS, PLC’s, Unit Control Panels), F&G System, FAC System,
Telecom System and Emergency Management systems. Also, 230 V 1 phase UPS
power is also required for Electrical Panels Control Supply. Continuous output from
these UPS is always ensured to essential systems, by DC batteries coming in case
of AC power failure. These DC batteries and the UPS power is interrupted only in
case of extreme site wide Emergency, initiated through ESD-0 operation.

One UPS system 02-UPS-6302 A/B is installed at Central Control Building for ICSS,
F&G system, Telecom System, Fire Pump Master Control Panel, Rim Seal
Protection system, CP System, Admn. Bldg UPS DB, Flare System and PLC’s
installed in CCB. Other UPS system 02-UPS-6303 A/B is installed at Instrument
Local Equipment Room (LER) building for local PLC’s and Unit Control Panels for
other packages ( Gas Treatment Plant Train-1/ 2 panels, F&G system, Cooling
Tower Pkg, Demin Water and Potable Water Pkg, Instrument Air Compressor/ Dryer
Pkg and besides Operator Work Controls (OWS) installed in the LER building. UPS
Power distribution is through individual Distribution Boards or Panels.
Each UPS, supplied by CEG Electr Indust SpA, Italy, is having two 400 V, 3phase
feeders besides one UPS bypass feeder from Essential feeder PMCC-3, which is
backed up by Essential DG. The UPS panels are dual systems with two Chargers,
Inverters, Ni-Cd Battery Banks for individual or parallel operation and one Bypass
line with Voltage Stabiliser and Static Switch for automatic change over on Inverter
failure.
Refer the Single Line Diagram (SLD) vide Document No. C-051-0002-00-070-SLD-
0007.
UPS power distribution Board (02-UPS DB-6301) is also included in the above
document.

 Pre-commissioning checks:

1. Ensure that all system components supplied are installed and connected as
per system details of the vendor.
2. Ensure that all outgoing feeders are isolated positively and tagged.

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3. Clean the entire area around the UPS panels and barricade the area to avoid
unwanted entry.
4. Ensure that all cell connections on the Battery Bank are properly tightened
maintaining the polarity.
5. Insulation Resistance of the earth with respect to Input supply system and
output power terminal shall be measured and noted satisfactory above 1
Megaohm.
6. Ensure proper level of Electrolyte in the batteries.
7. Charge the batteries by putting the charger ON after ensuring input power
from Essential feeder PCC.
8. After the battery bank has reached a steady voltage at full charge, the Inverter
shall be put ON. Observe the electrical parameters at the output terminal
without feeding to any load.
9. Once all the parameters specified are met, a load test may be performed by
using temporary water resistance load as per the approved Test Procedure.
Discharge the batteries once and recharge it again by putting on the UPS
Charger.
10. All the parameters specified (Load stability, waveform distortion, Auto
Changeover of inverters etc.) to be checked at the time of Performance
Acceptance Test or SAT shall be verified now as per the vendor approved
document. The load for this testing also can be temporary water resistance as
the downstream actual load may not be available yet. Refer Document No.
C-051-VP-070-UPS-AC-PRO-011
11. Power supply cables to UPS Distribution Boards can be connected but kept
isolated till the downstream system is ready to be charged.

AC UPS System is then ready for use by all the downstream systems (electrical
panels).

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14.14 Pre-commissioning DC UPS System No. SYS-070-14

 Brief Description of DC UPS System

DC UPS system is supplied by CEG Elect Industries Spa, Italy and is located in UPS
room in Substation Building at CPF area. Single feeder of 400 V AC is taken from
Essential Feeder PCC and the distribution of 110 V DC is through a DC Distribution
Board located in Substation Building. The System consists of Chargers and Ni-Cd
Battery Bank for 110 V DC supply located inside the Panel.
DC power is supplied as control Power for 11 KV Switch gear (3 feeders for three
bus sections)), 3.3 KV Switchgear (2 feeders for two bus sections) and two feeders
each for PMCC-1, 2 & 3 besides 1 feeder for PMS Panel, all located within the
Substation Building.

Refer Single Line Diagram (SLD) under Document No. C-051-0002-00-070-SLD-

008.

 Pre-commissioning Checks

1.Ensure that all system components supplied are installed and connected as per
system details of the vendor.
2.Ensure that all outgoing feeders are isolated positively and tagged.
3.Clean the entire area around the UPS panels and barricade the area to avoid
unwanted entry.
4.Ensure that all cell connections on the Battery Bank are properly tightened
maintaining the polarity.
5. Charge the batteries by putting the charger ON.
6.Once all the parameters specified are met, a load test may be performed by using
temporary water resistance load as per the approved Test Procedure. Discharge the
batteries once and recharge it again by putting on the UPS Charger.
7. The parameters specified to be checked at the time of Performance Acceptance
Test or SAT shall be verified as per the vendor approved document.

DC UPS System is then ready for use by all the downstream systems (electrical
panels).

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14.15 Pre-commissioning of Solar Power System No. SYS-070-15

 Brief Description of Solar Power System

Solar Power Systems, supplied by Chemical Injection system vendor,

TRIMPIANTI Montaggi Industriali, Italy, are installed at remote locations for 24
V DC power. Each Solar Panel system consists of Photo Voltaic (PV)
modules, 24 V Batter Bank and Battery Charger (also fed from local DG 400
V AC Distribution Board). Wellhead S1, Wellhead S4 and Gathering Hub-1
are provided with the Solar Power System for providing 24 V DC power to
Diesel Generator Control Circuit, Hydraulic Power Units and local Control
Station PLC panels at each location besides operation of Corrosion Inhibitor &
Scale Inhibitor Injection Pkg units.
Refer the Single Line Diagram (SLD) document No C-051-0001-1B/1C/1D-
070-SLD-0001 for power distribution and Vendor Document C-051-VP-070-
SOL-DAT-0001 for system details.

 Pre-commissioning Checks of the Solar System

Complete Solar System is supplied assembled by the vendor after conducting

Factory Acceptance Test (FAT) for proper functioning. Refer the Document
No. C-051-VP-070-SOL-FAT-001 for the test results.
However following checks shall be performed at site after installation and
connection, before using the system:
1. Ensure that Solar Panel is oriented towards the predominant solar light
trajectory.
2. Use Solar Simulator “PASAN” supplied by the vendor to test PV cells
proper functioning.
3. Check that the battery terminals and cell links are properly tightened and
polarity is maintained. The electrolyte level in the battery may also require
checking.
4. Check the control shelter for proper functioning of Ventilation system and
indicating lights on the control panels. Check completion of inter- panel
wiring completion as per the scheme.
5. Ensure that all communications from Control Panel is established between
ICSS- fibre optic and Micro wave link for remote alarm indication and
operation of ESD etc.

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Once the batteries are charged fully from Solar Panel or through DG set, the
system is ready for operation.
14.16 Pre-commissioning of Power Management System (PMS)- No.
SYS-070-16

 Brief Description of PMS

Power Management System at CPF is highly integrated site-wide Power

management solution and requires a thorough study to understand its
complete functioning. The complete system has been designed and supplied
by M/s Eaton.
The PMS panels, located in Sub-Station Building, houses the central PLC
(Siemens PLC S7400 H) and 15” touch screen HMI for Monitoring. The PLC
installed inside the PMS panel is mainly to acquire data(measurement and
status) from other systems such as, 11 KV switchgear, 3.3 KV switchgear,
PMCC-01/02/03(through interposing relays), AC and DC UPS systems,
GTG A, B and C, Essential DG A and B, 0.4KV VFDs, 0.4KV Soft starters,
3.3KV Soft starters, Cathodic Protection System, Synchronizing Panel,
EHT System, Communication Network Status etc... which are installed in
different stations, display on PMS HMI (alarms, shutdowns, status…etc.) and
send these data through electrical control network to PMS servers. PLC also
collects signals and commands from PMS servers/ Operator Work Station
(OWS) through electrical control network and communicates to respective
equipment. PLC also communicates with ICSS via a redundant communication
network.
The SCADA system is a redundant stand-alone system. The SCADA stations
perform the following functions:
 Data Acquisition from PMS system servers
 Display of the Mimic graphics and Status information for all system
components
 Allow authorized users to control equipment through PMS
 Display and record events and alarms as they are occurring
 Display and record Process Values from the system

The SCADA is performing the following operations:

 GTG control (Start/ Stop) as per operation Scenario selected
 control of GTG incomers
 Control of Switchgear 02-SP-6101 Buscoupler and feeders
 Perform load shedding operation and inhibits as per load shedding scheme

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 control of EDG
 Control 0f 3.3 KV switchgear 02-SP-6102 incomers, Bus coupler and
feeders
 Control PMCC-01 02-SP-6103 incomers and Bus coupler
 Control PMCC-01 02-SP-6104 incomers and Bus coupler
 Control PMCC-01 02-SP-6201 incomers and Bus coupler

Refer the Documents C-051-VP-070-PMS-ARCH-0001 for the System

Architecture and C-051-VP-070-PMS-MAN-001 for the Operating Manual.

 Pre-commissioning Checks on PMS

Complete PMS system components have been supplied pre-assembled,

tested and ready to install status, and no other check is required for
commissioning the system components. Refer the FAT document C-051-VP-
070-PMS-FAT-0001. The sequence of commissioning of PMS will be towards
the last end of the project, only after completion of Electrical Power system
and Tele-communication systems. However, following checks are required, in
presence of System supplier, for ensuring the desired functioning of PMS:
1. Ensure that all the communication cables have been laid and terminated
as per the layout diagram
2. Ensure that all the Input/ output cables have been terminated on the
Remote Terminal Units (RTU’s) as per the scheme
3. Ensure that all the system interface software programmes are installed
and operational.
4. Ensure that any changes, subsequent to FAT and despatch of the system,
are incorporated in the PMS and SCADA consoles through necessary
configuration changes
5. Ensure that all the indications from different systems from the field are
reflected on HMI and SCADA in the respective graphics.
6. Perform all checks one by one for system commands from the SCADA
consoles and its effects offline on the end element.

A detailed Site Acceptance Test along with system supplier will ensure the
sustained operation of the system on commissioning.

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 Electric Heat Tracing System

14.17 Electric Heat Tracing System(EHT) No. SYS-072-01

 Brief Description of EHT System

Electrical Heat Tracing has been adopted for avoiding condensation in FG

lines (2” and 4” pipe size) in the CPF. Manufactured and engineered by M/s
Chromalox, the system consists of laying Self Regulating Heat Tracers along
the specified pipelines as per Isometric Drawing No. C-051-VP-070-ISO-001
to maintain a pipe temperature of 85 Deg C (in all weather conditions) through
230 V, 1 phase power distributed in 8 Circuits based on the requirement. The
EHT system components also include RTD for temperature monitoring,
Clamps, Fibre tapes, splicing tools, Junction Boxes and End Connectors. The

EHT tapes after laying, bonding and termination are covered with 50 mm
insulation and a weather protection shield (cladding) all through the traced
portion. The EHT system is also equipped with its own power distribution (DB)
and system monitoring panel with Indication lamps. EHT covers all associated
small bore drains, vents and instrument tappings on the Heat Traced lines for
efficient result.

 Pre- commissioning Check on EHT

1. Ensure that all EHT job has been completed as per the drawing and
specification.
2. Ensure that all the binding clamps, tapes and supports of the Marshalling
boxes, Junction boxes are properly fixed and all the tapes are firmly in
contact with pipeline segments all throughout.
3. All electrical points are properly terminated and End Connectors where
specified have been provided. All RTD’s should have been properly
installed and fastened.
4. Get the area of EHT application completely cleaned of loose materials and
institute a system of trespassing in the area by unauthorised personnel
and causing damage to the tracers (not yet insulated and jacketed).
5. Obtain clearance to charge the EHT circuits one-by-one and compare the
current drawn current Vs design values. Repeat the process of all 8
circuits. All the circuit healthy operation shall be checked from the panel.
6. After all the circuits are satisfactorily tested, clearance may be given to
start the pipe insulation and cladding work as per the standard procedure.

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Ensure that the insulation & cladding is intact on pipe bends, elbows and
floor/ wall crossings, leaving no open spot for rain water entry.

After the EHT lines are tested for its functioning, the power supply can be
charged whenever the process conditions demand. Physical damage to EHT
has to be avoided at all times by proper vigilance.

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 CATHODIC PROTECTION SYSTEM

14.18 Pre-commissioning of Cathodic Protection System SYS-071-01

AND 02

 Brief Description of Cathodic Protection

Corrosion Technology Services Europe Limited (CTSEL) has engineered and

supplied the system to provide the Cathodic Protection against corrosion for
various tanks and vessels within CPF area.

CTSEL scope of CP work for the EPF includes:

(i) ICCP for External surface of the LPG Tank (bullet), 02-T-1801.
(ii) SACP system for Internal surface of Tanks and vessels
(iii) ICCP for buried piping comprising of CD and OD pipes inside CPF
(iv) SACP for hydrants and monitor riser pipes within the CPF (FW network is
non-metallic). In certain cases where the hydrants and monitor riser pipes are
close to CD or OD piping, ICCP has been considered.

Each type of Cathodic Protection based on service is described below:

I. An Impressed Current Cathodic Protection (ICCP) system for buried

LPG Bullet with 1 nos of 30V/10A safe area Variac Control Transformer
Rectifier Unit (TRU) and 200 m of Ti/MMO sock anode in three loops
have been used around the external surface of bullet. Locations are
marked in the CP layout drawings. Each Rectifier circuit is assumed to
have an associated 1 no of Anode Junction Box (AJB), 1 No. of
Negative Junction Box and 1no of Test Box. Each test post will have a
permanent reference electrode, Cu/CuSO4 with a DC coupon. Bonding
of the bullet with Cathode is achieved by pin brazing of the wires. The
complete LPG Bullet is having a protective outer coating as per the
specification.
All earthing is connected into an earthing JB (Ex-e Box) and
connections to earth made via Solid State Decoupler (SSD)- 3.5KA DC
for isolating the vessel earthing from the main earth.
Refer the drawing and design basis document CP pertaining to LPG
bullet Doc No. C-051-VP-070-CP-SCM-0002.

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Minimum Structure-to-soil (polarised) potential is expected to be -

850mV limited to a max of -1500mV

II. The internal SACP system for tanks and vessels containing a
separated corrosive water phase is based upon use of aluminium alloy
sacrificial anodes designed for 15 years life.
The internal surface of tanks and vessels in contact with water and
corrosive water is to be coated as per project coating specifications.

Qty of
Tank/ Tank
Qty anodes per Anode distribution Reference drawing
Vessel ID Product
tank/vessel
16 nos on tank floor
and 24 nos on wall,
Raw 40, Al-In- also included 2 nos C-051-VP-070-CP-SCM-0001
02-T-3101 Water 1 Zn permanent SSE Sheet 1 & 2 of 13
18 nos on tank floor
and 12 nos on wall,
Potable 30, also included 2 nos C-051-VP-070-CP-SCM-0001
02-T-3301 Water 1 Magnesium permanent SSE Sheet 3 & 4 of 13
16nos on tank floor
and 54 nos on wall,
02-T-5001A Fire 70, also included 2 nos C-051-VP-070-CP-SCM-0001
/B Water 2 Magnesium permanent SSE Sheet 5 & 6 of 13
On-
Spec 30, Al-In- C-051-VP-070-CP-SCM-0001
02-T-1802 Cond. 1 Zn 30 nos on tank floor Sheet 7 & 8 of 13
Off
Spec 12, Al-In- C-051-VP-070-CP-SCM-0001
02-T-1803 Cond. 1 Zn 12 nos on tank floor Sheet 9 & 10 of 13
LP
Flare
KO 2 anodes on vessel C-051-VP-070-CP-SCM-0001
02-V-2202 Drum 1 2, Al-In-Zn bottom Sheet 11 of 13
Closed 3, 3 anodes on vessel C-051-VP-070-CP-SCM-0001
02-V-2301 Drain 1 Magnesium bottom Sheet 12 of 13
HP
Flare
KO 4 anodes on vessel C-051-VP-070-CP-SCM-0001
02-V-2201 Drum 1 4, Al-In-Zn bottom Sheet 13 of 13

In case of carbon steel equipment which is immersed in water or corrosive

water phase and protected using sacrificial anodes, the cathodic protection

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criteria is (-) 800 mV polarised potential with respect to Silver/ Silver Chloride
(SSE) reference electrode. The maximum polarised potential is limited
to(-)1200mV to avoid overprotection.
In the case of water tanks, the potential is measured using a portable coupon
and a portable SSE electrode dropped from the tank roof with coupon
connected to tank and polarised to tank polarisation levels and switched using
a reed switch to determine the OFF potentials.

III. ICCP (Impressed Current Cathodic Protection) system for underground

piping (Closed Drain & Open Drain Piping) and 68 Nos. of hydrants and
monitor risers using MMO Ti tubular canister anodes distributed along
the pipeline route, designed for 25 years life.
Canister anodes are 25.4mm diameter x 1000 mm long tubular anodes
packed in 1500mm long x 150 dia GI canister and backfilled using
Calcined petroleum coke breeze. The anodes are provided with factory
assembled 10 mm2 HMWPE tail cables.
IV. SACP (Sacrificial Anode Cathodic Protection) for the balanced (62
Nos) hydrants and monitors using zinc anodes designed for 25 years
life.
Due to the location and the proximity of some of the hydrants from the
CD/OD piping area, 62 Nos. of the total amount of hydrants are bonded
to the ICCP system and the remaining quantity (62Nos) are protected
by SACP, designed for 25 years life.
A total of 75 anodes are installed based on an average 20-25 m
separation. A total of 3 nos. variac control Transformer Rectifier Units
(TRU’s) each 50V/ 60 Amp are provided in order to ensure adequate
protection. Wrapping Coating is provided for Closed Drain/ Open Drain
pipes. Each Rectifier circuit is having an associated Positive
Distribution Box (PDB), Negative Distribution Box (NDB), 4 nos Anode
Junction Boxes (AJB) and 3 nos Negative Bond Boxes (NBBs) installed
in safe areas. A total of 15 Test Stations have been provided based
upon 5 nos per TRU circuit. Each test post will have a permanent
reference electrode, Cu/CuSO4 with a DC coupon. Bonding of Cathode
wire with the pipe and anode cable to anode tail is achieved by Pin
brazing.

Refer the schematic Drawing Doc No. C-051-VP-070-CP-SCM-002 and the

Design Basis Document No. C-051-VP-070-CP-CAL-0002.

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 Pre-commissioning Checks

1. Ensure that the total work of cathodic protection has been completed
as per the installation drawing of the vendor before back filling.
2. Similarly, Cathodic Protection for Tank Internals shall be ensured for
completion after completion of hydrotesting/ calibration of tanks. No
other work inside the tank may be undertaken after the Cathodic
Protection work is undertaken.
3. Ensure that no physical damage to any of the system components has
been caused by other agencies working in the area. Check the
continuity of anode cables and cathode pins upto the Test Boxes
individually.
4. Back filling of soil to cover the buried pipes shall be carried out under
full supervision to prevent damage to the cables and boxes during this
operation.
5. TRU’s have been supplied after full testing (FAT) and hence no further
check should be necessary except proper fixing of the units and power
cable termination.
6. After complete backfilling and consolidation, where necessary, another
check shall be performed to see and correct any physical damage.
7. Note the common indications and alarms from the TRU to be shown on
Aux. Consoles in the Control Room Building through Communication
system cables as each TRU is supplied with Remote Monitoring
feature.
After ensuring that all work has been completed on the pipelines, TRU’s may
be energised one by one and Polarised potential should be measured at each
Test Box and readings noted. The measured values should be between -850
mV to -950 mV or as specified in the design documents. The power supply to
these TRU’s shall be kept ON for protection of the lines from corrosion from
the first day itself, long before these lines and tanks are charged and put to
use.

CP system stays commissioned for protection of the pipeline as long as the

power is available thru TRU’s.

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 HVAC System

14.19 Pre-commissioning of Heating, Ventilation, and Air

Conditioning (HVAC) System SYS-043-01

 Brief Description of HVAC System

HVAC system has been engineered and supplied by M/s Argonaut, Cairo as
per data sheet document No. C-051-VP-040-HVAC-DAT-0004 for installation
at Central Control Building (CCB), Local Equipment Room (LER) and
Substation Building at CPF area.
Central Control Building- HVAC system consisting of 2 Nos Air Handling
Unit (AHU) of 11500 CFM each and one AHU of 6000 CFM, along with Fresh
Air intake, Supply Air ducts, Return Air Ducts, Motorised Fire Dampers and
volume dampers, roof mounted Condensing units of 2 x 33 TR each and 1
x15 TR capacity with Electrical Duct Heater for temperature and Humidity
control, and HVAC control panel for local indication and remote indication
interface has been provided at the location. Refer the layout Drg. Document
No. C-051-VP-040-HVAC-LAD-0003 for the conditioned air distribution duct
and the supply and return air grills location.
Local Equipment Room- HVAC system consisting of 3 Nos Air Handling Unit
(AHU) of 10000 CFM each, along with Fresh Air intake, Supply Air ducts,
Return Air Ducts, Motorised Fire Dampers and volume dampers, roof
mounted Condensing units of 3 x 15 TR each capacity with Electrical Duct
Heater for temperature and Humidity control, and HVAC control panel for local
indication and remote indication interface has been provided at the location.
Refer the layout Drg. Document No. C-051-VP-040-HVAC-LAD-0002 for the
conditioned air distribution duct and the supply and return air grills location.
Substation Building- HVAC system consisting of 3 Nos Air Handling Unit
(AHU) of 12500 CFM each, along with Fresh Air intake, Supply Air ducts,
Return Air Ducts, Motorised Fire Dampers and volume dampers, roof
mounted Condensing units of 3 x 30 TR each capacity with Electrical Duct
Heater for temperature and Humidity control, and HVAC control panel for local
indication and remote indication interface has been provided at the location.
Refer the layout Drg. Document No. C-051-VP-040-HVAC-LAD-0001 for the
conditioned air distribution duct and the supply and return air grills location.
HVAC system panels are interfaced with FACP (Fire Alarm Control Panels)
and Clean Agent Gas Release Panels (GRP) for closing of appropriate
dampers in case of confirmed Fire and Smoke, Confirmed HC or Toxic Gas
presence or Confirmed H2 alarm in respective Battery room. The detailed

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actions are described in the Cause and Effect document of F& G system,
FACP system covered separately in this manual. The HVAC panels are also
interfaced for remote indication and alarm in the Central control room Auxiliary
Consoles at (ICSS).

 Pre-commissioning Checks

1. Obtain Mechanical Completion certificate from the construction group

including the complete ducting and wiring work. Fan & motor alignment,
foundation soundness should also be ensured
2. Ensure that power supply to respective HVAC panel is available for
operation check of Fan Motors, Motorised Dampers, Condensing units’
compressors and fans, Duct Heaters, and all control indications.
3. Ensure good Housekeeping in the HVAC-AHU room, Air Conditioned area,
and roof top for removing any fabrication leftover materials after
completion of the job.
4. Ensure that Refrigerant (R134A) as specified by the supplier is charged in
the condensing units, replacing the inert Nitrogen filled during
transportation.
5. Check the free operation of each damper (mechanical and automated),
supply and return Grills adjustment and leave them open before trial run of
AHU. Ensure that all air distribution ducts are properly supported after
insulation cladding and roof supported equipment are rigidly mounted.
6. Ensure presence of Vendor’s representative before trial operation. Start
the AHU fan and ensure circulation of air to the air conditioned area, return
air distribution, fresh air intake filtration system smooth operation without
any undue vibration/ abnormal sound. Check the local/panel indications of
the dampers position by moving dampers and corresponding indication on
the Auxiliary Console of Control room operator.
7. After satisfactory operation of AHU for few hours and filter cleaning, where
necessary, Condensing units may be started one by one. Note the
temperature of circulating air coming down towards the desired values.
8. Check the humidity in the controlled area and switch on the duct heaters
for checking the humidity levels by hand operated Humidity measuring
instrument. Ensure that all the doors and access areas are closed for
ascertaining the humidity levels.

After test runs of all the AHU and Condensing units, the system can be kept in
operation for the comfort and safety of persons occupying the building. If the other
incomplete jobs in the buildings do not permit operation of the HVAC, same can be
stopped for use subsequently. Supplier may be allowed to conduct Performance
test of HVAC at an appropriate time for meeting the contractual requirement.

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 LIFE SAFETY SYSTEMS

 Operating Philosophy for Fire Alarm and Fire Protection System

Fire Alarm system at CPF is designed for early warning system in case of fire
being notified at any location through installed sensors or by Manual Call
Point operation. The Fire Protection system protects the assets and personnel
of the company against fire by automatic operation of installed Fire Protection
equipment backed up by turnout of Fire Crew with Fire / Foam Tender for
containing and extinguishing the fire at an early stage.
Fire Alarm System Architecture is defined in the document C-051-VP-081-
TEL-ARC-0121 and will be covered subsequently in this chapter.
Automatic Fire Protection System consisting of sub systems like – Clean
Agent System for critical Buildings, Deluge spray and Deluge Foam system
for Hydrocarbon storage tanks and Plant areas handling Hydrocarbon, Deluge
Sprinkler Systems for some other equipment, Gas based Rim Seal Fire
Protection for Floating Roof Tank are dealt separately in various sub sections
of this chapter. The broad specifications of these automatic systems as well
as portable safety equipment, fire water ring main with Hydrants and Monitors
are described in the document C-051-000-SPC-0004.
Another sub set of Emergency Management is early detection of the presence
of Hydrocarbon (HC) and presence of Toxic Gas (H 2S) in open areas or Air
suction systems besides presence of Smoke (as an early indication of Fire) in
some areas. All these systems are covered in document C-051-080-CAE-002
—dealing with Cause and Effect matrix under Fire & Gas (F&G) System and
is addressed in the forthcoming chapters.

14.20 Pre-commissioning of Fire Alarm System SYS-000-01

 Brief description of Fire alarm system

Honeywell Middle East has supplied the Fire Alarm System. The
system consists of 7 Nos Fire Alarm Control Panel (FACP) model XLS-
3000 located 1 each in Fire Stn and Ambulance Bldg., Admn. Bldg.,
Warehouse, Central Control Building, Substation Bldg., Instrument
LER, and Workshop with Repeater Panels near the entry gates at
Substation, Instrument LER, Admn. Bldg. and Central Control Room.
GTG LER has been provided with a Synchro2 Loop Panel by GTG
vendor and Accommodation Camp FACP is provided by others. All
these FACP’s are interconnected to each other through a Fibre Optic
cable (ring network). Each controller is connected to High Sensitivity

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Smoke Detectors (HSSD) or Aspirating Smoke Detectors, Heat

Detectors (Rate Of Rise) and Manual call points as per Loop schematic
with Horn in each circuit.
Refer the Documents C-051-VP-081-TEL-ARC-0121 for the schematic
architecture and C-051-0002-00-080-BLD-0001-1 for Block Diagram.
The Fire Alarm Panels are powered by Primary and Redundant 230 V
AC supply from Essential PMCC and have got its own 24 V battery
back-up with built in charging circuit.
All the Seven FACP’s are interfaced to DCS through Redundant
Modbus Gateway on TCP/IP network. FACP’s are hard wired and
interfaced with F&G System, HVAC interface and Gas release panel
interface, etc) besides other package vendor’s F&G package (GTG,
Containerised cabins at metering stations etc)
All the output contacts from FACP system is connected through F& G
panel for final action.

 Pre-commissioning Checks
1. Ensure that all the system components are installed and wired as
per the schematic diagram
2. Ensure that all the Manual Call Points are in the normal position and
all smoke detection and heat detection sensors are in healthy state.
3. 230 V AC power to the FACP is switched on and all indications on
the panel is verified to be normal
4. Test each Manual call point for indication on the panel by inhibiting
the output. Restore to normal position after checking
5. Similarly, test the functioning of Smoke detectors by using Incense
stick (after necessary work permit) and heat detectors by using Hair
Dryer. Reset the sensors indication after checking.

After each FACP is tested one by one, the system is kept in

operation for monitoring and removing the inhibit action points.

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14.21 Pre-commissioning of FIRE & GAS DETECTION SYSTEM (FGS)

SYS-000-02

 Brief Description of the system

Honeywell Middle East (HME) has supplied complete F&G system. The
system is designed to alert the site personnel of release of
Hydrocarbon(HC) or Toxic Gas (H2S) in air intake of HVAC system,
Instrument Air Compressor etc. and plant areas during normal
operation. The complete details of system components, system
features and installation and interconnection details are provided by
HME in the document AEP 000193-122 and Project Document
C-051-VP-081-TEL-SPC-0122.
The marshalling cabinet and F&G card controllers (redundant system)
are located in Instrument Equipment Room of LER. The marshalling
cabinets receive inputs from all field F&G sensors including inside the
buildings and are connected to Safety Network of ICSS for operator
indication and control.
Refer the Control System Block Diagram Document C-051-0000-00-
080-BLD-0001
Following type of hazards are detected by the system:
a) The presence of smoke from smouldering or incipient fires by
using High Sensitivity Smoke Detectors (HSSD) or Aspirating
Smoke Detectors (ASD) in the buildings
b) The presence of a hazardous release or accumulation of
flammable gases due to loss of containment (H 2 from batteries in
the battery rooms, Hydro Carbon and H2S in the process areas)
c) The presence of a hazardous release or accumulation of a toxic
or asphyxiating gas (including those with a narcotic effect) due
to loss of containment (like Hydro Carbon and H 2S near Air
intake ducts of HVAC, Instrument Air Compressors, GTG Air
Intake duct etc.)
The system initiates following actions:
a) To alert or warn off using audible and visual means;
b) Isolate and minimize the inventory of hazardous materials
(which may contribute to escalation) in the affected area;
c) Minimize potential ignition sources by electrical isolation
of non-essential equipment or equipment not suitable for
use in the present hazard;

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d) Initiate active fire protection systems (HVAC, Rim Seal

Fire Protection, Sprinklers, Deluge Valves etc.), where
applicable, within the response time required;
e) Initiate release of emergency gates, access control doors
in affected area for safe evacuation.

Operation of two smoke detectors in the same Fire Zone is declared as

“Confirmed Fire” and necessary action is initiated accordingly.
Refer the Cause & Effect Diagram for F&G system document No. C-
051-080-CAE-0002

 Pre-commissioning check

1. Ensure that all the system components are installed and wired
as per the schematic diagram. Ensure to have presence of
system supplier HME for system checking and commissioning.
2. Ensure that all the HC and Toxicity sensors are provided with
Zero Caps for Zero indication at the system panel. Provide
proper tags to the components.
3. Check for installation of the Detectors at proper height and
proper location as per layout
4. Calibrate the H2, HC sensors and Toxic detectors by using the
calibration gas (portable gas bottles) depending on the range of
available sample gases and after removing Zero caps. Monitor
the system alarms based on limits set. The communication of
test results to operator console will be ensured when the ICSS
system is operational.
5. Test each F&G point for indication on the local panel by
inhibiting the output. Restore to normal position after checking
and install Zero caps on HC and Toxic sensors till the area being
monitored becomes operational.
6. Similarly, test the functioning of Smoke detectors by using
Incense stick (after necessary work permit) and heat detectors
by using Hair Dryer. Reset the sensors indication after checking.

After each F&G area panel is tested one by one, the system can be
kept in operation for monitoring after removing the inhibit action points
at an appropriate time.

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14.22 Pre-commissioning of NOVEC GAS BASED CLEAN AGENT

SYSTEM SYS-000-03

 Brief Description of the Clean Agent System

Fire extinguishing system of automatic flooding the Electrical and Instrumentation

Equipment area in case of confirmed Fire by a Gas based Clean Agent system is installed
at Central Control Building (CCB), Instrument Local Equipment Room (LER) and Electrical
Substation Building of CPF. These buildings house the most critical equipment and
personnel for operation of the facility in a HVAC environment and hence is most critical for
protection against any damage due to smoke or fire. The Clean Agent Systems, supplied by
M/s Silvani and Kidde, UK, are installed in a separate room of the buildings under
protection and Clean Gaseous Agent Novec 1230 is routed from storage cylinders through
rigid piping to the Cavity Area (equipment and personnel area), above the False ceiling and
below the False flooring area of these buildings. The Clean Agent is stored in cylinders of
243 ltrs or 142 ltrs at a pressure of 25.8 bar and equipped for release of total amount of fir
suppressing gas in 7 to 9 seconds reaching a desired concentration of 4.73 % as per
norms. The Audio-Visual indication of activation is provided near the protected spaces by
combined Beacon and Sounder for safe evacuation of personnel in the area besides the
status panel in each area.

Refer the Data Sheet document number C-051-VP-000-FSPS-DAT-001 for the flooding
System details.
In Central Control Building (CCB), there are five independent cylinder banks and piping of
Clean Agent to Instrument Equipment Room (IER), Telecom Equipment Room (TER), UPS
Room, Battery area and Central Control Room (CCR) with individual Gas Release Panels
(GRP). These Gas Release Panels are powered by 230 V AC (essential supply source) and
cylinders operate on 24 V DC (internally generated in the panel) solenoid operated Control
Heads on the cylinders.
Refer the P& ID document C-051-VP-000-FSPS-PID-0002 for the system schematic and
interconnection with Fire Alarm System.
In Instrument Local Equipment Room (LER), there are three independent cylinder banks
for Equipment room, UPS and battery area with individual GRP’s. The GRP’s are having
Low Cylinder Pressure warning and Pre discharge warning system besides Discharge
indicating system.
Refer the P& ID document C-051-VP-000-FSPS-PID-0003 for the system schematic and
interconnection with fire alarm system.
In Substation Building, the large area under protection is divided into two Zones- Zone A
and Zone B physically separated by a walled partition with emergency access door. There
are two independent cylinder banks and piping of Clean Agent to each Zone with its own
GRP.

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Refer the P&ID document C-051-VP-000-FSPS-PID-0001 for the system schematic and
interconnection with fire alarm system.
Refer the following installation diagrams of piping and nozzles of Clean Agent- C-051-VP-
000-FSPS-GAD-0026/ 0013/ 0015

 Pre-commissioning Check

The system components are supplied loose for installation at site with complete pre-testing
of Gas Release Panels. After installation of all the system components, following checks
may be performed before commissioning of the system:
1.Obtain Mechanical Completion certificate from construction contractor.
2.Carry out leak test of Clean Agent distribution piping at operating pressure, rectifying
the defects noticed and completing flushing of the lines by high pressure air.
3.All other agencies still working in the area should be prevented to enter so as not to
disturb the piping inadvertently.
4.The release of Clean Agent from the cylinders should be inhibited by mechanical
system provided, before carrying out the checking of the system.
5.On switching of incoming power, all parameters of alarm, indication and local/remote
operation may be checked by simulation without actually releasing the gas as per the
system description.

At an appropriate time after satisfactory completion of the check, the mechanical inhibit of
cylinders should be reverted back to normal, taking due care that Clean Agent gas is not
released inadvertently during this operation. Regular Hose connections may then be
restored and system declared as “Ready for Operation”.

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14.23 Pre-commissioning of CF3I GAS BASED RIM SEAL FIRE

PROTECTION SYSTEM No. SYS-000-04

 Brief Description of the system

CF3 I gas has been used as extinguishing media by automatic flooding in case of
Rim seal fire on the floating roof tank 02-T-1802, On-Spec Condensate tank. 25 ltr.
capacity each, CF3I bottles (substitute for halon system) are positioned on top of
the floating roof tank connected through rigid piping to spray nozzles cum detectors
fitted with glass bulb for activation on fire/ heat. The pressure in the supply line
segment is monitored through a pressure switch and connected to alarm system
panel SK-3000 located outside the dyke wall for access during fire on the tank. The
Fire protection system is supplied by M/s SAVAL and the specification for total
supply is included in document C-051-000-SPC-0003.
The SK-3000 system is connected thru flexible cable to central Fire Alarm system
for remote indication at Fire Station and Control Room operator.

 Pre-commissioning of the system

1. Obtain the mechanical completion certificate for installation of all system

components as per the schematic drawing.
2. Ensure that all other jobs on the tank roof has been completed by others and no
physical damage is likely to occur on any installed system components.
3. Isolate the gas bottles from the neck valves and remove few spray nozzles cum
detector for offline testing with controlled flame for bursting.
4. Check the system alarm of low pressure appearing on the local panel by
simulation.
5. Gas bottles valves can be re- opened after all the nozzles are refitted and no leaks
from the fittings are existing.
Please ensure that all the bottle valves are opened and signed off before taking
hydrocarbon in the tank. The complete protection system can stay operational with
proper care of not damaging any of the supply line equipment including Spray
nozzles.

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14.24 Pre-commissioning of WATER SPRINKLER SYSTEM No. SYS-

000-05

 Brief Description of the Water Sprinklers

Water sprinklers operated manually or operated from glass bulbs, have
been provided in the Admin Bldg., Warehouse and Chemical Storage
shed for cooling the affected area for safe evacuation of personnel
from buildings in case of fire. The sprinklers are normally filled with
water from the Fire water pipelines in the area, if individual segments of
sprinklers are kept energised.

 Pre-commissioning of Water Sprinklers

1. Ensure that the piping and installation of spray nozzles have been
completed as per the schematic.
2. The water line has been hydro-tested for any leaks, drained and
cleaned internally.
3. Check few of the sprinkler nozzles off-line for operation on fire/heat.
4. All the segments of Sprinkler water can be kept connected to water
supply lines after installation of all nozzles at the locations.
The system stays commissioned with the above check.

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14.25 Pre-commissioning of DELUGE SPRAY SYSTEM No. SYS-000-06

 Brief Description of Deluge Spray system

Deluge Spray system have been installed for supply of fire water where
water requirement is huge and fire, once started, can continue for
longer duration- predominantly equipment handling Hydrocarbon liquid
or Transformer Oil large storage points.
The system consists of Deluge valves, supplied by M/s Tyco and
operated through 24 V DC solenoids (normally de-energised) or
through manual lever on the valves, located at a distance from the area
under protection. Operation of these valves are indicated at central Fire
Alarm Panel (besides water operated local bell) besides remote
operation in case of confirmed fire.

Refer the P&ID for the details of Deluge system:

i. C-051-VP-000-FPTS-PID-0001 skid of 6 Nos Deluge Valves for

On- spec/ off-spec condensate tank area and Export pumps/
rerun Pumps
ii. C-051-VP-000-FPTS-PID-0002 skid of three Nos Deluge Valves
for Deluge Foam on On-spec/ Off-spec tanks
iii. C-051-VP-000-FPTS-PID-0003 one deluge valve for LPG Bullet
and LPG Export pumps
iv. C-051-VP-000-FPTS-PID-0004 one deluge valve for Slug
Catchers area
v. C-051-VP-000-FPTS-PID-0005 skid of 3 Nos Deluge valves for
Train 1/ Train 2 area
The above listed Deluge spray system is Medium Velocity (MV).
Besides above, two High Velocity (HV) Deluge valves have been
provided on largest Transformers 02-TR-6103 A/B. The Deluge valves
are supplied on skids installed away from protection area.

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 Pre-commissioning of Deluge Spray System

All the Deluge valves have been supplied as a skid after testing at
works. The same after installation requires little check of its functioning.
However, following general check points may be verified:
1. Ensure that the Deluge skid installed for each location is free of any
damaged part.
2. Ensure that Fire Water Header to each Deluge system is flushed
and leak tested.
3. Ensure that Fire water ring main header is under pressure. Test the
operation of the Deluge valve by draining the water line from the
control valve. During this check, isolate the operation of the
sprinklers to avoid messing up the area, by draining the water
locally. The operation of water operated bell is also checked now.

After checking the operation of the Deluge, the system is ready for
use when solenoid valve is put back and water is charged in the
header.

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14.26 FOAM MAKING AND SPRAY SYSTEM No. SYS-000-07

 Brief Description of Foam Package

Foam generating package is supplied by M/s Angus Fire Engineering,

with all components mounted on a skid. The skid consists of a storage
tank for AFFF (chemical for foam formation), capacity 1200 Ltrs, with
its own electrical pumps and operational control systems duly wired to
skid mounted local panel. The power supply to this local panel is
provided separately at site. The motorised valves operate on local
power with no separate electrical power or Instrument Air. The AFFF
storage tank and Piping upto the pumps are pre-insulated to prevent
clogging in low temperature ambient. No other blanketing is provided in
the AFFF tank.
Refer the P&ID document C-051-VP-040-FMPKG-PID-0001 and the
GAD document C-051-VP-040-FMPKG-GAD-0001
The proportioning element for mixing AFFF in a proportion of 3% with
Fire water is supplied loose and mounted in the fire water supply
system.
This skid is installed near On-spec condensate tank and Off-spec
Condensate tank, in Train1 plot, for generating foam and pouring
through installed foam pourers, in case of fire.

 Pre-commissioning Check
Since the system is supplied duly mounted on a skid, there is no
requirement of preparing for start up. However, following checks should
be performed before hand.
1. Ensure that all flange and hose connections are proper and not
loose.
2. Fill the Foam Generating material (AFFF) in the tank by hand pump
upto the required level.
3. Start the pump one by one, keeping the circulation on and
discharge valve closed for trial.
4. Foam Generation can be checked at site by draining Foam for
some time in the open drain channel.
The system is ready for use in case of any Fire emergency.

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 INSTRUMENTATION SYSTEM

14.27 Well Head Control System for S1 & S4 wells (WHCS) System SYS-
080-01

 Brief Description of the System

Well Head Control System comprises a Local PLC panel mounted in the Solar Panel,
connecting all field Instruments on one side and Operator display system in Central
Control Room on the other side through Fibre Optic cables and backed up by Micro
Wave Communication System for Well Head S1 and S4 individually.
Complete WHCS and Micro wave communication system is powered by individual
Solar Power System with a local PLC panel. The Solar Power system also powers
Corrosion Inhibitor Pkg. and Scale Inhibitor Package. A Diesel Generator (DG) is
provided for each Well Head for manual starting, to power Methanol Injection system
and to charge the batteries of Solar Power System. The Solar Power System, Diesel
Generator and Chemical Injection Packages are supplied after testing at factory
(FAT) and installed directly. Pre-commissioning checks for these packages are
covered elsewhere in this document.
Refer P&ID Nos C-051-0001-1B-020-PID-0101 and C-051-0001-1C-020-PID-0102
for all instruments and controls of WHCS.
Following Control System instruments are provided in the system for wellhead S1
and S4:
I. 01-PI-0102 /01-PI-0402 Diaphr. Seal Press. Gauges
II. 01-PT-0103 /01-PT-0403 Diaphr. Seal Press Transmitters
III. 01-PZT-0105 A/B and 01-PZT-0405 A/B Diaphr. Seal Press Transmitters for
one out of two logic in local PLC
IV. 01-TT-0107 and 01-TT-0407 Temp. Transmitters with Clamp on type RTD
elements
V. Hand operated Choke Valves (01-HV-0112 and 01-HV-0412)
VI. Fusible Plugs 01-PSL-0154 & 01-PSL-0155 and 01-PSL-0456 & 01-PSL-0457
for emergency operation of SSV-0101 and SSV-0401
VII. Local PLC (SIL-2 compliant) mounted on Solar Panels alongwith Hydraulic
supply system for Surface operated Sub Surface Valves. This panel also
houses all the operations and indications from Chemical Injection packages
for transmission to CCR at CPF for indication and remote operation interface.

VIII. Surface operated Sub Surface Safety Valve 01-SSSV-0101(with Hydraulic

actuator) and Surface Safety Valve 01-SSV-0401(with Nitrogen actuator)

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 Pre-commissioning checks

After completion of site installation of all the system components (connection of

Hydraulic lines, piping from Nitrogen Cylinder Package, wiring from WHCS cabinet to
field instruments as per Network connection, Solar Power system), following checks
must be performed before ensuring smooth operation of the system:
• Ensure that all inline instruments are mounted after the line flushing and
drying operation is complete.
• Check and confirm the calibration range of all instruments as per the latest
data sheet for correct indication on the PLC panel.
• Perform loop checking of each transmitter by hand held Hart Calibrator
with matching indication on PLC panel. The corresponding alarm settings
on Pressure transmitters should also be verified on local PLC display.
• Ensure that Solar Power battery is charged and 24 Volt DC supply is
available. Alternately, the Diesel Generator Package is started for
supplying 24 Volt DC to Hydraulic system and PLC power.
• Ensure that Hydraulic Fluid is available in the Hydraulic Oil Tank. Verify
that the pressure available from the hydraulic panel complies with the
pressure value indicated on the actuator nameplate. Also, ensure that
Nitrogen pressure from cylinders is as indicated on the valve actuator.
• Verify by visual inspection that there is no leakage from the
hydraulic/Nitrogen cylinder or from the hydraulic/ Nitrogen connections
after starting hydraulic pump and connecting Nitrogen Cylinders.
• The operation of the SSV’s must also be checked from local panel with
corresponding lamp indication of valve open and close. Operation of ESD
(Emergency Shut Down) from local PB and Reset PB operation should
also be checked.
• Power to the Chemical Injection Packages is also verified now for proper
functioning without actual injection at this point. This includes checking of
start and stop PB operation locally.
• Telecom System (Microwave system package), F&G system components
installed at Wellhead, and communication to ICSS at CPF will be prepared
for start up along with respective system description and checking covered
elsewhere in this document.

This system is then certified ready for commissioning and for start up with the
production fluid.
Commissioning of this system should be done as per the guidelines given in Start up
and Commissioning Manual following Safety procedures.

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14.28 Pre-commissioning of HUB CONTROL SYSTEM (HCS)) System No.

SYS-080-02

 Brief Description of the System

The Hub-1 or the Gas manifold from Well Head S1 and S4 is also located near the
shore, away from Central Processing Facility (CPF) with its own local PLC panel.
This PLC panel is housed and powered from Solar Power system with battery back-
up charging from Diesel Generator, locally installed.
Complete HCS and Micro wave communication system is powered by Solar Power
System. Communication from ICSS is via Fibre Optic cable from the local PLC. A
Diesel Generator (DG) is provided for HCS with manual starting for charging Solar
Power batteries. The Solar Power System (with Hydraulic panel and PLC panel) and
Diesel Generator Packages are supplied after testing at factory (FAT) and installed
directly. Pre-commissioning checks for these packages are covered elsewhere in this
document.

Refer P&ID Nos C-051-0001-1D-020-PID-0601, C-051-0001-1D-020-PID-0602 and

C-051-0002-2A-020-PID-1001 for all instruments and controls of HCS including Pig
Launcher/ Pig Receiver.

Following Control System instruments are provided in the system for Hub:
I. Hydraulic- operated Shut Down valves (06-SDV-0101 and 06- SDV-0104) on
wellhead S1 & S4
II. Pressure Gauges 06-PG-0103 and 06-PG-0106
III. Pressure Transmitters 06-PT-0102 and 06-PT-0105
IV. Multi Phase Flow Meter(MPFM) 06-FT-0127 (separately covered)
V. Production Header Instrument 06-TT-0112 (Temperature Transmitter) and 06-
PZT-0113 (Pressure Transmitter)
VI. Pig Launcher Bypass valve 06-SDV-0120
VII. Pig Receiver Bypass valve 10-SDV-0106 and 10-PT-0107 (located at CPF on
Trunkline receiving line

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 Pre-commissioning Activities

After completion of site installation of all the system components (connection of

Hydraulic lines, wiring from HCS cabinet to field instruments as per Network
connection), following checks must be performed for ensuring smooth operation of
the system:

• Ensure that all inline instruments are mounted after the line flushing and
drying operation is complete.
• Check and confirm the calibration range of all instruments as per the latest
data sheet for correct indication on the PLC panel.
• Perform loop checking of each transmitter by hand held Hart Calibrator
with matching indication on PLC panel. The corresponding alarm settings
on Pressure transmitters should also be verified on local PLC display.
 Ensure that Hydraulic Fluid is available in the Hydraulic Oil Tank
 Ensure that Solar Power battery is charged and available as indicated on
the local panel. Alternately, the local DG is started and 24 V DC supply to
Solenoid Valve and PLC panel is made available.
 Verify that the pressure available from the hydraulic supply line complies
with the pressure value indicated on the actuator nameplate.
 Verify by visual inspection that there is no leakage from the hydraulic
cylinder or from the hydraulic connections.

The loop checking for Temperature Transmitters and Pressure transmitters must be done
by using Hart Calibrator from the local PLC panel after completion of connection. The
operation of the Emergency Shutdown Valves with position indication must also be checked
from local panel and Central Control Room operator console (after completion of Telecom
network), after proper clearance and work permit. The position indication of Block and
Bleed Valve to the Test Header shall also be verified on the local panel.
The system is then certified ready for commissioning with the production fluid.

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14.29 HIPPS (High Integrity Pressure Protection System) No. SYS-080-

03

 Brief Description of the System

Gas from Wellhead Manifold HUB-1 proceeds further to Slug Catchers located at
CPF area. This gas line is protected against overpressure by an Instrumented
system of Safety Integrity Level-3 (SIL-3) design. The HIPPS System is procured
from a Package vendor – VALVITALIA, Italy. The system consists of following main
sub-assemblies:

a. Two Nos. 12’’ size Quarter turn ball valves 10-XV-0109 and 10-XV-
0110 with pneumatic actuators (designed to slam shut in Emergency
situations) along with 2 nos. Solenoid Valves (24 V operation) on each
actuator
b. One number prewired HIMA Control Cabinet (Logic Solver) with
mounted hardware installed at Instrument Equipment Room of LER
Building and Local Push Button Station (Shutdown and Reset) for
installation near the valves in the field. The panel is powered by 230
Volt AC UPS source.
c. Three Nos Yokogawa make Electronic Pressure Transmitters installed
near the valves in the field and connected to HIPPS Control Cabinet
d. Two Nos. Air receiver vessels
e. Complete fire proofing boxes in semi knocked down condition for fire
proofing covers on the two valves and two air receiver vessels
Please refer the Operating & Maintenance Manual of the Vendor under Project
Document No. C-051-VP-080-HIPPS- MAN- 0001 to 0006.

 Pre-commissioning Checks

Pre-commissioning checks for the Gas pipeline is covered elsewhere. The HIPPS
package itself (completely assembled) has been inspected at factory for operation as
per design criteria and specification. After completion of site installation of all the
system components (connection of air lines, wiring from HIPPS cabinet to field
instruments as per Network connection), following checks must be performed for
ensuring smooth operation of the system:
• Verify that the pressure available from the air supply line to receiver complies with
the pressure value indicated on the actuator nameplate.
• Verify by visual inspection that there is no leakage from the pneumatic cylinder or
from the pneumatic connections.

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• Verify that power is available to the HIPPS cabinet and all normal Indication Lamps
are glowing.
• Verify that the communication link from HIPPS panel to ICSS is established for
proper indication and operation from Operator Work Station of DCS.
Operate the actuator by carrying out the various types of operations available
(LOCAL/REMOTE/EMERGENCY operations) and verify its correct functioning.

 Partial Stroke Test

1. Press the “Valve Test” (black) push button for more than 3 seconds (but less than
10 seconds).
2. Observe that the green light starts flashing when the valve starts moving.
3. Observe that the valve moves no more than the configured PST travel limit (15-
20%) and on reaching the travel limit, the corresponding valve position is indicated
on HIPPS panel and OWS.
4. Observe that the valve returns to the normal operating position and the green light
comes on solid.

 Manually Aborted Partial Stroke Test

1. Press the “Valve Test” (black) push button for more than 3 seconds (but less than 10
seconds).
2. Observe that the green light starts flashing when the valve starts moving.

3. Before the valve reaches the travel limit of the configured partial stroke test, press the
“Valve Test” push button, or the push button next to the green light.
4. Observe that the valve immediately returns to the normal operating position and the
green light comes on solid.

 Loop Checking of Pressure Transmitters (10-PZT- 0108 A/B/C)

Perform the loop check by connecting the Portable Calibrator at the transmitters
junction box individually and verify the corresponding indications on the HIPPS Control
Cabinet and ICSS- Operator Work Station (OWS). Also, check the alarm signals from
Pressure Transmitter HH alarm operation at the OWS. Since the logic configuration is 2
out of 3 voting logic, it needs to be simulated accordingly for alarm warning at ICSS
Operator Console. These transmitters’ first isolation valves are also mechanically
interlocked to prevent operator isolating more than one transmitter at any time during
operation.

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After the above checks are completed, the clearance for putting the Fire Proof covers on
Air Receivers and Ball Valves can be given.

With this, the complete HIPPS is kept ready for introduction of Hydrocarbon, when other
systems are ready to be started.

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14.30 Pre-commissioning of MULTI PHASE FLOWMETER (MPFM)No.

SYS-080-04

 Brief Description of the System

A Multi-Phase Flowmeter (MPFM)- 4” size,Tag No. 06-FT-0127 has been

supplied by M/s Pietro Fiorentini, Italy and installed in the test header (6” Size)
of Production Fluid at production HUB. The system is skid mounted and pre-
assembled and pre-tested.
Refer the P&ID document C-051-VP-080-MPFM-PID-0001
This meter is configured to analyse and quantify the production output in
terms of Condensate quantity, Gas quantity, water quantity, Total HC with
pressure and temperature correction for mass flow calculations. The basic
elements of MPFM consists of Gamma Densiometer module, Venturi module,
Velocity modules (8 probes) and 3I sensor modules connected to skid
mounted Flow Computer 06-FIC-0301 for interconnection to ICSS via Modbus
protocol. Refer Interconnection diagram C-051-VP-080-MPFM-GAD-0003.
Complete system has been tested at vendor’s works vide FAT document C-
051-VP-080-MPFM-PRO-007.

 Pre-commissioning of MPFM

The system is ready for use when installed as per the documents supplied.
However, it may be advisable to have the vendor’s representative initially to
familiarise the operation & maintenance staff and perform site calibration.
Following general checks may be carried out before commissioning the meter:

1. Be careful to read the supplier’s manual carefully as this instrument alone

consists of radio-active source Cs-137 of 50 mCi strength supplied loose
for mounting at site. Inform the regulatory authorities for owning and
handling the radio-active source. Keep the source switched off and locked
till it is finally ready to use.
2. Connect all the systems as per the interconnection diagram.
3. Check the calibration of Venturi module by using Hart communicator as
per the system catalogue.
4. Check some of the parameters on local control panel as per the system
detailed catalogue.
Meter is ready for measurement of Production fluid with constituents after
switching on the Gamma Ray source.

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14.31 CUSTODY TRANSFER FLOW METERING SYSTEM No. SYS-080-05

 Brief Description of the custody Transfer Metering Systems

Each product out of CPF is exported back via pipelines to customers thru
Custody Transfer meters supplied by M/s Krohne Oil & Gas (KOG). Dry Gas
Metering Skid 03-Z-1801, LPG metering Skid 03-Z-1802 and Condensate
Metering skid 03-Z-1803 details are provided in KEIL document No. 2014-02-
059-C03-0001/ 0002,0006/0003,0007 respectively.
These meters are specified for exact measurement (in volume and weight
basis) for proper accounting purposes as these are destined for export. These
meters accuracy is of very high order and calibration proved periodically
through Master Meters or Meter Provers (proven and certified off-line
periodically).
Two Containerised cabins (one each for Dry Gas/LPG and other for
Condensate) having redundant metering with piping, meter provers,
redundant PLC systems, supervisory SCADA system complete with Fire
Suppression equipment, 230 V UPS and HVAC for the cabins have been
supplied. Analyser shelters with sampling systems and Gas Chromtography
Analysers have also been provided for Dry Gas and Condensate system
complete with Carrier Gas Cylinders and Callibration Gas cylinders while LPG
has been provided with Manual Liquid sampling system for measuring quality
parameters of the fluid being exported. Dry gas flow measurement is by two
redundant Ultra Sonic flowmeters while Coriolis type redundant meters have
been used for LPG and Condensate flow measurement.

 Pre-commissioning check of Custody Transfer Metering systems

The complete system at each location is supplied pre-assembled in

containerised cabins and pre-tested at FAT, ready for installation at site. After
installation at site, the system is required to be hooked up to the piping
systems after pre-commissioning activities on the respective piping system is
completed. All the analysers have been duly calibrated and data base for
chromatogram populated with test results. However, following check should
be performed before commissioning the system:
1. Check the internals inside the containers for proper positioning and
healthiness during transportation and installation. Any loose fasteners
shall be retightened.
2. Check that the Carrier Gas/ sample Gas cylinders are installed and tubing
completely intact.

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3. Connect the external 230 V AC power supply and test the internal
auxiliaries (like lighting, ventilation, fire detection system etc.) for its ready
state.
4. Ensure that internal UPS supply is switched ON and sustained power back
up is available.
5. Connect all the communication cables from CPF area for communication
with ICSS.
6. Simulate the calibration of Flowmeters by using handheld Hart
Communicator and monitoring the results on Local Panel. Actual fluid
calibration of flowmeters is not possible at site and should not be
attempted.
Complete system is ready for commissioning in presence of vendor after the
product pumping starts.

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14.32 Integrated Control and Safety System (ICSS) System No. SYS-
080-06

 Brief description of ICSS

An Integrated Control and Safety System (ICSS) has been used to
provide a fully integrated monitoring, control, protection and safety for
the entire well pads, production manifold hubs, Pipeline, CPF and
associated processing, utilities, storage facilities and export metering
stations etc.
The Central Control Building (CCB) has a Central Control Room
(CCR) wherein all the Operator consoles / workstations, Hardwired
Auxiliary consoles, CCTV Monitors, Graphic Monitors, Flare Monitor
etc. required for operator interfaces are located. Engineering
workstations of ICSS and other control systems are located in the
Engineering Room which is also part of the Central Control Building.
Other independent control systems such as Well Head Control System,
Hub Control System, Custody Metering control system, Package Unit
control panels etc. are used at remote locations such as at wells, hubs,
metering and for packages respectively for local controls. However,
these are interfaced with the ICSS and allow remote monitoring,
operation and shutdown of the facilities from the CCR.
All Instrument system / marshalling panels of ICSS system comprising
of Distributed Control System (DCS), Emergency Shutdown System
(ESD) and Fire & Gas System (F&G), etc. are located in the CPF
Instrument Equipment Room (IER) which is in a separate Instrument
Local Equipment Room (LER) building located away from the CCB.
Package Unit Control Panels (UCP’s) are installed either in the field or
in LER decided by distance and operational requirements.
Separate Containerised Control Cabins have been considered at
remote locations such as Custody Metering Stations, wherein local
control equipment are installed and interfaced with the CPF CCR.
ICSS has got two dual redundant Communication Bus – one is Control
Network for DCS controllers and the other as Safety Network for ESD
and F&G system Controllers. A redundant communication network is
provided between CPF CCR & IER as well as between various facilities
such as wells, hubs, CPF, metering stations etc. to integrate all the
distributed controls and make them available to the Operators in CCR.
Communication network redundancy within CPF shall be achieved by
using redundant Fiber Optic cables whereas redundancy of
communication between CPF & Remote Custody Transfer Metering
Stations etc. is achieved by using Fiber Optic as primary and
Microwave Link as secondary / backup communication.
Communication redundancy between CPF & Hubs/Wells shall be
achieved using redundant fibres of a single Fiber Optic cable.

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Refer the Block Diagram document No. C-051-000-00-080-BLD-0001

and System Architecture Drawing document No. C-051-VP-000-MAC-
ARC-0101
All ESD I/O’s are connected to ESD Marshalling racks and DCS I/O’s
are connected to DCS Marshalling racks kept in the LER building. An
internal High speed communication bus, Dual Redundant, runs through
all the Marshalling cabinets and brought to Operator Room for
indication and control on Operator Work Stations (OWS) thru HMI while
all the Unit Control Panels, F&G Rack, Analyser Racks are connected
to the same bus for operator indication and control. Aux Consoles and
Large Screen Display consoles are also provided in the CCR of Central

Control Building as also the Telecom Equipment Room (TER),

Operator Training Room (OTR) and Instrument Engineering Room
(IER). Different vendor supplied control Package PLC are connected to
respective marshalling racks for all indications and control from
operator console- the list of packages is as given below:

Package Name Pkg. ICSS Type of Mode of

Location Location Communi Communic
cation ation
Well Head Control Panel SW-1 IER 0 Modbus Fibre Optic
S1 PLC TCP/IP cable
Well Head Control Panel SW-4 IER 0 Modbus Fibre Optic
S4 PLC TCP/IP cable
Hub1 Hydraulic Control HUB-1 IER 0 Modbus Fibre Optic
PLC TCP/IP cable
HIPPS Panel IER 1 IER 1 Modbus Copper
RS 485 cable
Cooling Tower PLC CPF- IER 0 Modbus Fibre Optic
Field TCP/IP cable
Oily Water Treat Pkg. CPF- IER 0 Modbus Fibre Optic
PLC Field TCP/IP cable
Raw Fuel Gas Heater CPF- Substatio Modbus Copper
PLC Train 1/2 Field n RS 485 cable
Biocide Raw Water CPF- IER 0 Modbus Fibre Optic
Chem. Inj. Pkg. PLC Field TCP/IP cable
Potable Water CPF- IER 0 Modbus Fibre Optic
Treatment Pkg. PLC Field TCP/IP cable
Demin Water Gen. Pkg. CPF- IER 0 Modbus Fibre Optic

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PLC Field TCP/IP cable

Inst. Air Package PLC- CPF- IER 0 Modbus Fibre Optic
A/B/C Field TCP/IP cable
Inst. Air Dryer & Filter CPF- IER 0 Modbus Fibre Optic
A/B Package PLC Field TCP/IP cable
Novec Clean Agent Gas LER IER 1 Modbus Copper
Release Panel s/s RS 485 cable
Novec Clean Agent Gas CCB IER-1 Modbus Copper
Release Panel CCB RS 485 cable
Diesel/Electr. & Jockey CCR IER 1 Modbus Copper
Fire Pumps Panel RS 485 cable
GTG Pkg. Panel A/B/C GTG IER 0 Modbus Fibre Optic
LER TCP/IP cable
GTG Pkg. FACP GTG IER 0 Modbus Copper
LER RS 485 cable
Gas Treat. Pkg. UCP- CPF- IER 0 Modbus Fibre Optic
1161/1162/2161/2162 Field TCP/IP cable
Train1/2
Gas Treat GC CPF- IER 0 Modbus Copper
1101/1102/1103/2101/21 Field RS 485 cable
02/2103 Train1/2
Condensate Metering Condens IER 0 Modbus Copper
Skid PLC (Krohne) ate RS 485 cable
Container Cabin Metering
Stn.
Dry Gas and LPG Dry IER 0 Modbus Fibre Optic
Metering Skid PLC Gas/LP TCP/IP cable
(Krohne) Container G
Cabin Metering
Stn.
PMS Substati IER 0 Modbus Fibre Optic
on TCP/IP cable
Diesel Filter Coalescer CPF- IER 1
Pkg. Field
Foam Package Substati IER 1
on

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Central Control Room is equipped with Primary operator control point

but in case of any emergency when Central Control Building is
incapacitated or unapproachable, full operation and control can be
done from the operator room of LER building, which is designed as
Blast Proof.
Emergency Shutdown (ESD) command given by the operators by Push
Button Operation or by Confirmed Fire condition is four types: ESD 0,
ESD 1, ESD 2, ESD 3 while local plant level ESD actions by
Instruments are classified as ESD 4. The effect on actuation of ESD
command is described in the Cause & Effect Charts vide document No.
C-051-0800-CAE-0001.

All the panels, consoles, Printers, servers complete with software are
tested at vendor’s works, as FAT prior to despatch in an integrated
manner has been carried out. This FAT document should be referred at
site.
 Pre-commissioning checks for DCS & ESD system SYS-080-06-01

1. Complete system is installed at site under close supervision

of vendor (Main Automation Contractor- MAC). Ensure that
area housekeeping is well maintained when these
equipments are under installation.
2. Ensure continuous operation of HVAC if possible. All other
work in the building (like Clean Agent System, FACP,
Flooring and ceiling work, Lighting etc.) should have been
completed and place vacated by other agencies to maintain
the integrity of the system.
3. After getting clearance from MAC for completion of inter
panel wiring and termination, UPS power should be switched
ON in sequence to all the marshalling racks, OWS, Aux
Consoles and Printers etc. Check for any abnormal situation
or incomplete work and rectify the same before proceeding
further.
4. After complete system powering up and initial booting is
satisfactory, the communication bus connection shall be
established and its proper functioning ensured.
Communication from UCP’s or third party system panels by
package vendors has been tested, in principle, at FAT.
However, proper communication between two different
systems shall be assured by DCS vendor (HME) along with
package vendor. All panel displays should be verified by
panel operators as per the system specification.

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5. After getting the clearance from control room equipment

vendor, field instrument checking as given below should be
carried out.

 Pre-commissioning checks for field Instruments SYS-080-06-02

1. All the in-line instruments should be mounted after the piping

system/ equipment flushing and leak test is satisfactorily
completed. These include installation of all the Orifice plates and
flow meters, temperature elements in the thermo-well, level
instruments on the equipment/vessels, control valves, Motorised

valves and Block and bleed valves etc. as per the specified
service.
2. All the instruments on pipe manifold like Pressure Transmitters,
Pressure Switches, Pressure gauges, DP Transmitters etc. are
also mounted now after shop calibration and verification of their
measurement range as per the Instrument Index. All the First
isolation valves (root valves) for these instruments should be
kept isolated till commissioning with the process fluid stage is
reached
3. Check the termination of instruments in the field and its
connection upto the Marshalling rack by carrying out loop
checking. Check installation of all limit switches.
4. Provide proper tags/labels, nameplates to all field instruments
including MOV/DBB/CV valves for identification and traceability.
Check the installation as per PLC logic diagram, P& ID and
wiring diagram.
5. Check Junction boxes installation and proper cable entries and
closing of all unused entries and putting all the bolts back on the
box/panel covers before powering up.
6. Check the control valves’ stroking from control room console
ensuring matching opening and closing action and fail safe
action. This action will require availability of quality Instrument
air from the Instrument Air network commissioned separately.
7. Verify all the ESD actions by simulation of conditions and noting
the effects as per the Cause and Effect chart.
8. Carry out the installation of Radar Tank Gauges (RTG)
following the vendor Installation procedure as outlined in the
vendor document vide Project Document C-051-VP-080-HWFT-
CMT-0001.

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9. Carry out the field calibration using portable Hart Communicator

for 4-20 mA loop after switching On the power supply to RTG.
10. Calibration of RTG can also be verified with actual water filling
for preparing strapping chart of Product tank (On-spec
Condensate Tank) by taking actual tank Dip.

All these field instruments can be commissioned on receipt of

process fluid by opening the first isolation valves and manifold
valves as per standard procedure with venting and draining for
some time as necessary.

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 TELECOM

14.33 TELECOM SYSTEM No. SYS-081--01

 Brief Description of Telecom System

Telecom system installed at SIBA Field project is a total interconnection (for

operator indication & operational controls) system consisting of following sub
systems, integrated by a Telecom System Integrator (TSI) M/s Honewell
Middle East :
i. Microwave System
ii. PABX, Network Infrastructure & Structured Cabling Systems
iii. Public Address & General Announcement (PAGA) System
iv. Meteorological System
v. Video-teleconference System
vi. Audio Visual System
vii. Digital Signage System
viii. Master Clock System
ix. Wi-Fi Systems
x. Network Management Systems
xi. IT Systems
xii. Industrial Security- Access Control System
xiii. Industrial Security- CCTV System

Telecom System details are described in document No. C-051-VP-081-TEL-

ARC-100 and HME document AEP 000193-161. Overall Block Diagram is
documented in document No. C-051-0000-00-081-BLD-0001. Sub system
wise brief description and checks are given below:

 Pre-commissioning of MICROWAVE RADIO SYSTEM SYS-081-01-01

i. Microwave System consists of Microwave communication towers

at 5 locations, CPF Product Despatch station, Condensate Metering
Station, Dry Gas Metering Stn, SOC Gas Coordination Centre and
Intermediate/ repeater Stn. at Hamdan. This point to point
communication system is for process communication as well as for
administrative purposes. Primary communication between Metering

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Stn. and two CPF location is via Fibre Optic network and Microwave
serves as fall back in case of failure of Primary link. Each Micro
wave stn. has Network switches and Fibre Optic Patch Panel

(FOPP) for interconnection. Well Heads and HUB-1 locations are

connected to CPF thru redundant Fibre Optic cables only.
 Pre-commissioning Checks

a) Optical Fibre cable termination shall be checked for power loss (db
loss) by using Optical Time Domain Reflectometer (OTDR) and
Patch Cord for each core
b) Power supply stability to Network switch shall be ensured for its
power quality.
c) Adjustment of Parabolic dishes may require adjustment in the line of
sight for full signal transmission/reception.
After complete check of the installation, the system is ready for use.

 Pre-commissioning of EPABX and Network Infrastructure SYSTEM SYS-081-

01-02

- 19 Nos. CISCO VOIP handsets, 7 Nos. Executive VOIP handsets at Admn. Bldg.;
Handsets at Chemical Storage shed, GTG LER, Warehouse, Workshop, Accommodation
Camp, Fire Stn. & Ambulance Bldg. Vehicle Search Office, Inst. LER, Substation Bldg., and
IP handsets with weather hoods for outdoor Process safe area besides Explosion Proof IP
handsets in Hazardous areas are provided under this system. Hot line instruments are also
provided for voice communication at CCR, Instrument LER and Admn. Bldg. 1 No. Network
Management Server at Admn. Bldg. and 2 No. NMS redundant work station at TER of CCB
are provided under Network Management Infrastructure. Fibre Optic cables with various
Network Switches and Patch panels are installed as per the schematic for EPABX.

 Pre-commissioning Checks

All the components of the scheme shall be connected and as per the scheme and system
powered on for testing each handset for communication over the network. Effectiveness of
Hotline communication should also be tested for direct conversation.
No separate check list is essential for the system as the system is well established Plug and
Use type.

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 Pre-commissioning of PUBLIC ADDRESS SYSTEM (PAGA) SYSTEM SYS-081-

01-02

Public Address (PAGA) system consists of various Call Stations with keyboards at CCR
and Supervisor Room at CCB, Inst. LER Building and at Reception area of Admn. Bldg.
These call stations microphones are required to address targeted audience of selective
areas as Public address (mostly in Emergency) connected via speakers (ceiling, Wall/panel
mounted, spherical etc.) in buildings like Warehouse, Chemical Storage Shed, Primary
access Control Building, Gate Control facilities, Substation Bldg., Fire and Ambulance
Bldg., GTG LER Bldg., Workshop etc. besides in Plant areas (both ordinary type for safe
areas and Explosion Proof in Hazardous areas). The common system consists of two sets
of Power Amplifiers placed at Admn. Bldg. and CCR (TER) besides workstations with PC
loaded with call server Software.
Complete PAGA system is interfaced to F&G system and EPABX thru Network Control
units located in Admn. Bldg. and TER of CCB.
 Pre-commissioning Checks-

1) All cables laid shall be properly fastened and clamped as necessary.

Loose termination affecting the speech quality must be avoided.
2) After complete installation and connection of system components, quality
of speech at all locations should be checked. All amplifiers volume and
bass control should be adjusted at the nearest and farthest point of
communication.
After complete check of the installation for its operation, the system is ready
for use.

 Pre-commissioning of METEOROLOGICAL SYSTEM SYS-081-01-03

Meteorological System consists of an Integrated Sensor Suite (ISS) made up of Wind

Speed sensor, Wind Direction sensor, Rain collector, Temperature sensor and Relative
Humidity sensor in one unit mounted on the roof top of Admn. Bldg. The system is having
its own solar power and a small 3 Volt Li battery for transmitting the data to a Receiver Unit
and a work Console (Master Station with Environment Monitoring software) at Telecom
room in Admn. Bldg. The data is available to other Meteorological workstations at
Emergency Command Centre at Admn. Bldg thru LAN and to CCR at CCB via Optic Fibre
cable.
 Pre-commissioning Checks-

1. Ensure that the ISS has been installed properly with solar panel
facing the path of sunlight. Any shipping stops provided should be
removed before putting the system on roof.

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2. All the cable connections from receiver to workstation shall be

checked for correct termination and the switches including Fibre
Optic cable.
3. Verify the details displayed at Workstations for each parameter.
Recording and fetching the data from server for next few days
should also be checked.
The system is ready for use immediately after this.

 Pre-commissioning of VIDEO TELECONFERENCE SYSTEM SYS-081-01-04

Video Teleconferencing System has been provided at four locations- Safety & Training
Room (Admn. Bldg. ground floor, Conference Room & Librarary room (Admn. Bldg. first
floor), Emergency Command Centre (Admn. Bldg. first floor) and Conference Room
(Central Control Bldg.). Each system consists of wall mounted 42” LCD Monitor with a
precision High Definition camera and integrated Speaker, two nos. each table top omni-
directional mikes and a Touch controller for connecting the call. All the video cables are
special cables supplied by Video Conferencing vendor. All these systems are inter
connected to the network thru Cisco network switches. The system is powered from 230
Volt Power plug wall outlets in the rooms.

 Pre-commissioning Checks-
1. Ensure installation of all components of the system and laying of
cables has been completed as per the schematic.
2. Ensure that point to point Video Conferencing can be established
without any assistance from specialists.
3. The picture quality and sound quality can be initially adjusted for
proper reception and clarity at each end.
The system is ready for use after successful testing and can be switched off
for use when required.

 Pre-commissioning of VIDEO AUDIO/VISUAL SYSTEM SYS-081-01-05

Audio Visual System is stand-alone systems provided at four locations- Training Room at
CCB, Permit to work Room at CCB, Conference/ Library Room at Admn. Bldg. and Safety/
Training Room at Admn. Bldg. Each location has been provided with a wall mounted
Projector Screen (160 cm X 120 cm- 80” D) with HD colour Projector (6000 Lumens) and a
Home Theatre. The projector has provision to connect portable laptop via HDMI cable for
any projection and discussion. Also separately provided at each location is a wall mounted
White Board (77” D) which can be connected to any laptop thru HDMI cable for
downloading the written material on the boards. The system is powered from 230 V wall

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socket available in the room and not interconnected with any network outside the room. The
purpose of the system is only for group discussion and training of small group of people.
 Pre-commissioning Checks-

No special checking is required for the above system after installation of all
the systems at specified positions. The system is ready for use anytime
when required.

 Pre-commissioning of DIGITAL SIGNAGE SYSTEM SYS-081-01-06

Digital Signage System provided at two locations- Reception area of Admn. Bldg. and
Reception/ waiting Room of Central Control Building- is basically intended to display a
general message or catchy slogan for personnel entering these areas. The system consists
of one each a 42” Samsung LED display screen mounted at a vantage point on the wall
connected thru a network switch to PC desktop. The messages displayed can be altered
frequently from the PC including the number of lines, font size, scrolling or fixed, colour
combinations etc. as per the configuration chosen. The display units can be switched off or
on by a hand held remote control unit provided with each screen.

 Pre-commissioning Checks-

The system is quite simple and menu driven configuration type not requiring any
preparation for using the system after installation as per the scheme.

 Pre-commissioning of MASTER CLOCK SYSTEMSYS-081-01-07

Master Clock System consists of a GPS antenna installed at the roof top of Central
Control Building and connected to a Master Clock System Controller provided in the TER
room of CCB. This controller in turn is connected to all Telecom system network for
synchronising all the clocks of various systems including third party PLC’s. The connection
is also extended to two Metering Station (Condensate and Dry Gas/LPG metering) panels
thru CAT-6 cable. All the system clocks are required to be synchronised for analysis of
logged data from different systems with its own digital clock stamping. ICSS clock is not
connected with this system as it is separately provided with its own similar GPS system.

 Pre-commissioning Checks

1. Ensure that the antenna is properly installed and aligned to a

particular satellite and received signal strength is above the
threshold value.

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2. Ensure that the clock timing of different system clocks are

synchronised in milliseconds not leading to any time stamping
difference of more than a few milliseconds in a year.
Once started, the system remains online and functional without any
further check or intervention.

 Pre-commissioning of WIFI SYSTEM SYS-081-01-08

Wi-Fi System consists of Wireless LAN controller to access the Internet or Local Area
Network thru Wi-Fi in two buildings- Admn. Bldg. office rooms and Central Control Building
office rooms thru small table top mounted wireless access antenna units in each room.
Fibre Optic cable between the two buildings thru Cisco switches provide the interconnection
thru passive Patch Panels. The system is used for data and video communication thru Wi-
Fi means. Any threat of intrusion or malware spreading from outside the local system is
prevented by use of a firewall, configurable for known viruses and websites.

 Pre-commissioning Checks

1. Check the wireless LAN controller for downloading and

uploading rate of data including video streaming. The speed of
the communication should be as specified for fast connectivity.
2. Check the denial of access to prohibited web sites as per the
configuration of firewall in line with IT policy.
After checking, the system is ready for use at any of the specified points.

 Pre-commissioning of NETWORK MANAGEMENT SYSTEM SYS-081-01-09

Network Management System for the Telecom Network consists of a Network

Management Server located in IT room of Admn. Bldg. connected to a workstation at
Admn. Bldg. and the other one in TER of Central Control Building. The workstations are
connected thru Network switches via Cat 6 cable and via Fibre Optic cable to other sub
systems of Telecom Network including ICSS.
 Pre-commissioning Checks

1. Ensure that switches and work stations are installed and

connected as per the schematic.
2. Ensure that essential power supply is available from the UPS
and all system components are functioning normally.
3. Ensure that all the software for the workstations are loaded and
are operational with proper security.
System is ready for use after installation checks.

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 Pre-commissioning of IT SYSTEM SYS-081-01-10

IT System consists of IT Server Rack (includes Servers, Data Storage System, Tape
Library) and software for data management (storage, back up, archiving, retrieval, and
rearrangement) both operator initiated and automatic time scheduled. There are various
redundant servers in the Blade server rack for different applications with Firewall. System
configuration philosophy (which include access rights, user/ administrator registration etc.)
can be referred for details.
 Pre-commissioning Checks
1. System FAT has been performed for specified functionality and
local configuration setting alone has to be assigned. All other
functions would be tested and demonstrated by the vendor as per
the contract clauses.

System is operational after installation check is completed.

 Pre-commissioning of ACCESS CONTROL SYSTEM SYS-081-01-11

Access Control System defines the access to the office and plant areas by use of a
predefined system. The basic access control starts with Omni class Reader, Omni class
Long Range reader, TEMA line Voyager for Muster application and Emergency Pull
Stations besides Badge Printer. The controls are executed through Turnstile, Boom Barrier
at Entry/ Exit, Sliding Gate, Single/ Double door electromagnetic locks in all office rooms
and Plant buildings. Different RTU’s with Access Control Servers are provided at various
locations.
Refer the system Architecture Diagram Document No. C-051-VP-081-TEL-ARC-131.
Server Cabinet at TER room (Admn. Bldg.) consists of ACS server, CCTV+ ACS
workstation and a separate CCTV workstation at Emergency Command Centre of Admn.
Bldg. Server Cabinet consists of EIS server, Database Server and Camera Servers 1/2.
Fibre Optic cable network originates from FOP’s at Main Gate (Vehicle search Office),
Badging Office, Accommodation Camp, GTG LER and Inst. LER, all leading to IT room of
Admn. Bldg.
 Pre-commissioning Checks
1. After installation and completion of wiring, each function is checked
from individual locations for proper functioning.
2. Ensure proper reading of few cards and prepare the reader cards
for each regular staff visiting the premises.
3. Check the smooth functioning of all the hardware (Turnstile, Boom
Barriers, sliding gate, Electromagnetic locks on each door)
4. Check the traceability of movement of personnel through records of
various readers and doors with time stamp.

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After complete functioning of the system is demonstrated by the system vendor, the Access
Control System is available for regulating movement of personnel and vehicles within the
CPF campus.
 Pre-commissioning of CLOSED CIRCUIT TV SYSTEMSYS-081-01-12

Closed Circuit TV (CCTV) system consists of Dome type IP Cameras- Indoor in Buildings
(Admn. Bldg. Ground/ First floor area, vehicle search office, Badging Office, Instrument
LER, GTG LER, Fire stn./ Ambulance Bldg., Warehouse Entry, Substation Bldg. Workshop
entrance); 20 Nos. Fixed IP cameras- outdoor for perimeter monitoring; 8 Nos. PTZ
Day/Night IP Cameras-outdoor for Guard Towers/ Security Gate/ Muster area; 16 Nos Expl.
Proof PTZ day/night IP Camera for process areas and two remote metering stations; and 1
No. Thermal camera for Flare monitoring with its own network cable, connected to work
stations located in Emergency Command Centre & Reception (Admn. Bldg.) besides
workstation at CCR. Besides 21.5” monitors at work stations, a 55” monitor for Process
cameras including Flare and 42” monitor for CCTV are also provided (hung from the ceiling)
in Central Control Room. All these locations are connected to the Admn. Bldg. Fibre Optic
cable (FOC) network via Fibre optic Patch Panel and Fibre Optic cable is extended to
Central Control Room for display.
CCTV cameras installed in the process areas are pre-programmed to Pan, Tilt and Zoom to
nearest area of emergency as confirmed by the two fire alarm in the respective Fire Zone
from FACP.
Refer the Document No. C-051-VP-081-TEL-ARC-0141 for the system architecture.
 Pre-commissioning Checks

1. Ensure that all cameras are installed firmly on its brackets or supports
in various areas as per designated area. Also ensure that all camera
network cables and power cables, where necessary, are terminated
with proper connectors.
2. Ensure the connection of work stations with necessary configuration
already done with total camera assignment. Check the quality of
pictures both in day and night without any blur or rasting.
3. Ensure that all the interconnecting cables from rest of the Telecom
System components are connected share the common data and
functionality as described in specifications.
4. Check the storage and retrieval of pictures in the system database
including viewing it from any web enabled device through proper
authorisation. Duration of storage of data over a specified period
should also be verified.
5. Check proper PTZ operation individually of each camera and washer
operation, where provided.
After the system is tested for proper functioning, CCTV system can be
kept in continuous use for safety & security monitoring.

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