Commissioning Approach Integrated Service Solutions

Integrated operation & maintenance - Dynamic simulation support - Process data reconciliation - etc. Engineering Side by Side optimising maintenance costs maximising plant productivity preserving asset integrity Conduct Plant operation Technical assistance for O&M Training Integrated operation & maintenance O&M Procurement Construction Plant Life Cycle Hands-on Classroom Training Training IOP Simplant® - Spare Parts - M.M. (Material Management) - I.P.O.S. (Integrated Procurement outsourcing services) - Turnover Management Methodology - Pre-commissioning - Commissioning / start-up - High Tech. Support - technical assistance Commissioning

Integrated operation & maintenance - Dynamic simulation support - Process data reconciliation - etc. Engineering optimising maintenance costs maximising plant productivity preserving asset integrity Integrated operation & maintenance O&M Procurement Construction Plant Life Cycle Hands-on Classroom Training Training IOP Simplant® - Spare Parts - I.P.O.S. (Integrated Procurement outsourcing services) - Turnover Management Methodology - Pre-commissioning - Commissioning / start-up - High Tech. Support - High tech. personnel Commissioning

Turnover Management Methodology Main Root Main Activities Certificates/Issues Turnover management system operating manual check and preparation Preparatory works (Home office activities) Tool for Mesurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc) Interim Handover Certificate verification (P/L outstanding) Mechanical Completion verification Field inspections, documentation inspection (outstanding Item verification) Inspections, Punch-list issueing, utilities comm, cleaning, flushing, blowing, chemical cleaning, non operating adjustment, motor run-in, catalyst, internal inspection, ... Ready for Commissioning Certificate Precommissioning Ready for Start-up Certificate Commissioning Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, …….. Ready for performance test Oil-In Start-Up Provisional Acceptance Certificate Performance Tests Conduct performance tests End

Turnover management system operating manual check and preparation Home Office Phase (Preparatory work) Turnover management system operating manual check and preparation Preparatory works (Home office activities) Tool for Measurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc) The Turnover Management System will allow to: Manage QA/QC certificates Manage Construction piping activities Manage Construction electrical activities Manage Construction instrument activities Manage Construction machinery activities Manage Construction punch lists Have Construction progress per area Have Construction overview progress Have day by day reports Manage the transaction between construction and commissioning activities Manage pre-commissioning activities based on construction progress Manage punch list outstanding items Manage pre-commissioning and commissioning punch list Manage Turnover progress and certificates Manage mechanical completion progress, certificates and activities Manage reinstatement progress, certificates and activities Manage ready for pre-commissioning turnover progress, certificates and activities Manage ready for commissioning turnover progress, certificates and activities Manage performance test turnover progress, certificates and activities Manage provisional acceptance turnover progress, certificates and activities Dossiers management

Turnover Management System System layout SYSTEM START-UP PASSWORD USER'S AREA PASSWORD ADMINISTRATOR'S AREA Construction Commissioning Piping Electrical Instrument Machninery Mechanical Completion Flushing Welding Type 1 Preinst. Type 1 Tighteness Test Piping Type 2 Installat. Type 2 Performance Test Hydrotest Type 3 Operation Type 3 Provisional Test Reports & Progress Reinstat. Type 4 Type 4 Acceptance Test Loop Check Dossier Filling Punch List Management Handover Management Outstanding Item management

Turnover Management System System detail pictures 2) Main Menu 3) Instrument management system 1) Main password 6) Punch List Out standing Item 4) Piping Menu 5) Punch List management system 9) Hydrotest Progress 7) Piping Construction management system 8) Equipment Management system

Pre-commissioning & Commissioning manuals preparation & check Pre-commissioning and Commissioning Manual Operating Manual Pre-commissioning and Commissioning Manual will be supplied as a collection of precommissioning procedures; these procedures are operating instructions for the activities to be carried out during the performing of precommissioning. The list of the procedures of the pre-commissioning manual is the following:     Mechanical Preparation ·                    Chemical Cleaning Instructions ·                    Physical Cleaning Instructions ·                    Mechanical Restoration ·                    Machinery Run in ·                    Tightness test ·                    Electrical testing/functional tests/energising ·                    Instruments calibration and functional test ·                    Loading of chemicals ·                    Loading of catalyst ·                    Heaters drying ·                    Chemicals boil out of steam generation facilities ·                    Verification of Mechanical Completion ·                    Performance Test Operating Manual with the following contents: Introduction General Basis of design Duty of plant Environmental conditions Feedstocks and products specifications Battery limit conditions Specifications and consumption of utilities, chemicals catalysts Process Description Description of flow Process Variables Process Theory Preparation for Initial Start-up Plant Inspection Cleaning of Piping and equipment Specific pre-start-up operations Start-up procedure Normal Operation Normal Shutdown Procedure Emergency Shutdown Analytical requirements Attachments (P&ID’s, Class Specifications and other Project documents)

In order to optimize time and costs we will: Interim Handover Certificate verification (P/L outstanding) Mechanical Completion verification Field inspections, documentation inspection (outstanding Item verification) In order to optimize time and costs we will: Verify the mechanical completion Punch list outstanding items via field inspections and certificates control and registration; Plan the pre-commissioning and commissioning activities based on the real situation

utilities commissioning cleaning flushing blowing chemical cleaning Inspections, Punch-list issueing, utilities comm, cleaning, flushing, blowing, chemical cleaning, non operating adjustment, motor run-in, catalyst, internal inspection, ... Ready for Commissioning Certificate Precommissioning inspection punch-listing utilities commissioning cleaning flushing blowing chemical cleaning non operating adjustment motor run in vessel loading internals catalyst desiccant resins packing drying machinery alignment instrument calibration loopchecking orifice plates installation safety valves bench test tightness test

Check all spring hangers Ready for Start-up certificate Commissioning Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, …….. Check all spring hangers Start up cooling water system,which may include Chlorinator Run in pumps on water,where possible, and establish Circulation Start up compressors,where possible,on nitrogen and air Activate the inert gas system Light flare pilots, if used, and activate flare purges at the extremity of lines in the unit Turn on the fuel gas system to process burners Start up the fuel oil system to process burners Boil out the steam generator (if it has not been chemically cleaned during pre-commissioning) Commission water treating facilities Implement steam system andsteam trcing before insulation is checked Activate condensate systems Purge equipment, where required Perform operational pressure test Run required vcuum tests Dry out refractories and heaters and special lines Reactor system dry out Check waste-treatment area for operation Circulate chemical solutions where required Activate catalysts where required Prepare for and circulate test oil Recheck all trip circuits and their bypasses Practice normal and emergency shutdowns. If time allows, practice restarts

Introduce feed at low flow rate Start-up Oil-in Ready for Performance test Introduce feed at low flow rate Adjust temperatures, pressures, levels and flows Route off-specifications material to the designated areas When the product reaches the specifications route it to storage Increase slowly the feed rate to the Unit until the designed value. Provisional Acceptance Certificate Performance Tests Conduct performance tests Performance Tests Procedures preparation and validation Systems preparation for performance tests Conduct performance test in order to meet process guaranteed figures

Pre-commissioning & Commissioning typical organization chart Comerint Main Contractor

iop, sop....etc

iop, sop....etc

Simplant

Simplant

Comerint Organisation Chart

Comerint services during Plant Life Cycle EPC CONTRACTORS OWNERS OPERATIONS MAINTENANCE CONSULTANCY SERVICES TRAINING AND HRD (CTS) ENGINEERING AND TECHNICAL DEPT. SUPPORT SERVICES (SIMULATION) COMMISSIONING START-UP