FPSO TOPSIDES COMMISSIONING PROCEDURE SYSTEM: 60 & 62

Revision Date:

14-12-2007 Rev No.:

A Document No.(per DENS Section 2.3):

K1-13P-FCA-AN-PRD-0000001 K1-13P-FCA-AN-PRD-0000001

Official Copy located in DMS, UNSTAMPED printed copies are UNCONTROLLED documents and MAY NOT BE CURRENT Page 1 of 65 Printed: 1/6/2014

Document Name:

FPSO TOPSIDES COMMISSIONING PROCEDURE SYSTEM: 60 & 62 - FCA Crude Oil & Diesel Fuels

Author:

Approved By: (Name)

Permanent: XX Temporary:

Temp. Expiration:

Document Owner: (Job Title)

FPSO Topsides Commissioning Superintendent Review Frequency: 1 Year

Last Review Date: 14/12/2007 Legacy Document Name:

N/A Legacy Document Number:

N/A Created On:

14/12/2007

NOTES:

1. This Document contains proprietary information belonging to and must not be wholly or partially reproduced nor disclosed without written permission from .

2. For any questions regarding population of the template, please contact the COPC Document Control Coordinator.

The record copy of this document is maintained by COPC Document Management System. If you receive notice of an approved revised version of this document you shall immediately destroy the previous version and implement the latest version. Any changes to this procedure shall be done in accordance with Document Control. Contact Document owner if there is doubt that this procedure is the most current.

REVISION HISTORY

Revision Number

Revised By

Approved By

Approval Date

Description

A 14/12/2007 Issued for Review

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TABLE OF CONTENTS

1.0 PURPOSE 2.0 SCOPE 3.0 RESPONSIBILITY 4.0 DEFINITIONS 5.0 SAFETY 6.0 SPECIAL RESOURCES / SERVICES 7.0 SYSTEM DESCRIPTION 8.0 CONTROL AND OPERATING DESCRIPTION 9.0 SYSTEM LIMITS 10.0 SYSTEM REQUIREMENTS 11.0 TEST FACILITIES

11.1 Temporary Facilities 11.2 Lubricants 11.3 Supplier assistance 11.4 Commissioning Spares

12.0 DEPRESERVATION /REPRESERVATION 13.0 SYSTEM PREPARATION

13.1 Mechanical Preparation 13.2 Electrical Preparation 13.3 Instrument Preparation

14.0 DYNAMIC TESTS 14.1 System Operating Tests

15.0 REFERENCES 15.1 General Procedures 15.2 Project Document List 15.3 Sellers Document List

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1.0 PURPOSE

The purpose of this procedure is to give clear instructions for the activities to be carried out to complete the dynamic commissioning of the described system, from preparatory activities onshore through to execution and verification of system operating tests. The signed off and completed version of this procedure will form part of the Commissioning Handover dossier which will be presented to Operations together with all supporting documentation including Completions Management certification for acceptance of the specific system. 2.0 SCOPE

This procedure shall be used by the Bohai Bay Topsides Commissioning group throughout onshore Preparation, Dynamic Commissioning and where applicable Offshore Commissioning and Start Up. The System Status Reports for Pre-Commissioning Completion for this procedure are contained in the System Commissioning Dossier, detailing all equipment items contained in the system and the associated Inspection Test Records (ITRs) to be completed. Upon acceptance of the system from the Construction Department, the Commissioning Group will prepare for and carry out pre-commissioning in accordance with the procedure as indicated in Section 13.0.

System Preparation and Dynamic Commissioning will be carried out in accordance with the procedure as detailed in Section 14.0.

System component items and the associated Inspection Test Records, including incomplete onshore work punchlists are listed in the System Status Report for Commissioning Completion contained in the System Commissioning Dossier. The scope of the operational test to be carried out is:

To verify mechanical completion of specified activities, including incomplete work, items removed for sea transportation and equipment de-preservation.

Review CMS status indices of pre commissioning Inspection Test records for the sub-systems described in section 11.0, to determine the extent of testing/retesting required for dynamic commissioning.

Complete Pre-commissioning Inspection Test Records

Prepare and complete tests as described in sections 13.0 and 14.0.

To outline and satisfy the Certification Authority (DNV) review requirements.

Handover system to the COPC Operations group. The System Responsible Engineer or his nominated deputy shall ensure that all necessary safety precautions are being taken as detailed in, Section 5.0 of this procedure and shall ensure that all work is carried out in accordance with the project Permit to Work procedure. 3.0 RESPONSIBILITY

The FPSO Topsides Commissioning Superintendent will be responsible for the implementation and execution of this procedure and its associated instructions.

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The Commissioning Group shall be responsible in all respects for the development and verification of the Mechanical Completion (MC) and Pre-Commissioning (PC) database within the Completions Management System (CMS) and for developing Commissioning Procedures (CP) for all Systems and sub-systems with built in quality control activities to verify the achieved quality standard throughout the Pre-commissioning/Commissioning phase.

The CMS Custodian will be responsible for ensuring the accuracy and integrity of the CMS database including physical records of MC and PC Inspection Test Records (ITRs), status indices and project certification used in the handover between the responsible parties in each phase

The Commissioning Superintendent will designate a System Responsible Engineer for each System or group of Systems who shall be responsible for the provision of suitable personnel, equipment and facilities to implement the requirements tests and checks set out in this approved Commissioning Procedure with.

All requirements of Safety Section 5.0 are strictly adhered to. All required ‘permits to work’ are in place.

Ensure Communication both written and verbal within all departments in the commissioning group, Construction group and operations department and conduct Tool Box talks prior to the start-up of any system or part System.

Ensure all tests and checks are carried out, witnessed and recorded in accordance with the step by step activities.

Ensure all sections of the procedure are signed and dated where required and that the signatories provide specimen signatures on the Specimen Signature Record in section 2.2 of this document.

All personnel involved in commissioning activities are to have read & be fully familiar with the Commissioning Manual (Document No. K1-13P-GAA-AN-PRD-0000001), which sets out and explains in full, the relevant and necessary details pertaining to the implementation of System Commissioning.

For details of overall Completions and Commissioning organizational responsibilities refer to; Commissioning Execution Plan K1-13P-GAA-AN-PLN-0000001.

4.0 DEFINITIONS

CA Certifying Authority CCR Central Control Room CER Central Equipment Room CE Commissioning Engineer CMS Completion Management System COPC ConocoPhillips China CP Commissioning Procedure DAC Discipline Acceptance Certificate DENS Document and Equipment Numbering System DNV Det Norske Veritas ESD Emergency Shutdown F&G Fire and Gas FAT Factory Acceptance Test

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FPSO Floating Production Storage & Offloading HC Hydrocarbons HMI Human/ Machine Interface HSE Health Safety & Environment HUC Hook Up & Commissioning ITR Inspection Test Record JSA Job Safety Analysis LER Local Equipment Room LO/TO Lock Out / Tag Out LQ Living Quarters MC Mechanical Completion MCC Motor Control Cubicle MF Mechanical Flow Diagram (P&ID) MSR Main Switchgear Room MSS Mooring Support Structure PA Public Address PAF Prepare to Abandon Facility PC Pre-commissioning PCCC Pre-commissioning Completion Certificate PCS Process Control System P&ID Piping and Instrument Diagram PFD Process Flow Diagram PMT Project Management Team PIMS Project Information Management System PN Process Narrative PSD Process Shutdown PSV Pressure Safety Valve PTW Permit to Work QA/QC Quality Assurance / Quality Control RUP Riser Utility Platform SAC System Acceptance Certificate SLD Single Line Diagram SMOE Sembawang Marine Offshore Engineering SOG System Operating Guide SRE System Responsible Engineer SSPL Sembawang Shipyard Pte. Ltd SSS Safety Shutdown System SWS Shanghai Waigaoqiao Shipyard SYMS Soft Yoke Mooring System UPS Un-interruptible Power Supply VFM Valve and Flange Management 5.0 SAFETY

Commissioning of a system surrounded by normal construction work has potential safety hazards involved, construction personnel accustomed to having relative freedom of working may not be fully aware of the hazards or procedures involved in system commissioning and careful planning and communications are required at all levels. A clear definition of what is handed over from construction has to be made e.g., with the marking-up of relevant P&IDs and or electrical single line drawings where relevant, segregation barriers with clear signs and labeling of equipment and pipework to be energized.

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System commissioning procedures will detail any specific safety requirements for the system or sub-system under test, and these shall be complied with at all times in addition to other project safety codes or standards. Commissioning activities shall at all times be carried out in accordance with the relevant specification, codes of practice and statutory regulations, as well as the relevant commissioning procedures. All personnel involved, including vendors and temporary workers, shall comply with the COPC Site Integration and Commissioning Health, Safety and Environment (HSE) Plan requirements and also with safety requirements contained in Site Manuals and procedures. Examples of HSE plan content that will be addressed include but are not limited to: specific HSE roles and responsibilities, energy isolation (LO/TO) procedures, risk management (JSAs) and environmental management. Requirements in both the SMOE and SSPL HSE Plans, as well as local regulatory requirements must be adhered to. Communication concerning HSE matters during integration and commissioning is critical. An element that is in place to coordinate this communication is the Daily Safety Coordination meeting. A representative(s) from the commissioning team will be required to attend these meetings during the integration / commissioning phase. If integration / commissioning activities take place in the existing construction areas (berth side) the meeting will be the Daily Construction Safety Coordination Meeting coordinated by SMOE. Once work commences on the vessel SSPL will conduct the Daily Vessel Safety Coordination Meeting. A separate Simultaneous Operations meeting may be required to establish a prioritization of activities. This will alleviate the potential hazards created when construction needs to perform work in the same area that a commissioning activity is taking place. Another key HSE communication tool is the Permit to Work (PTW) System. For onshore activities the SMOE PTW System shall be utilized. Once work commences on the vessel the SSPL PTW System will be followed. Both PTW Systems will be evaluated to ensure consistency with the COPC PTW System. Upon sail away of the FPSO the COPC PTW will take effect. The PTW System shall include procedures for the livening up of equipment and systems, and definition of ownership responsibilities during the Pre-commissioning and commissioning phase. COPC Operations shall be responsible on completion of offshore installation for the Offshore Permit to Work System for all FPSO equipment, systems and sub systems. The Permit to Work system shall define the limitations, isolations and specific requirements and precautions to be taken in the initial livening up of the system or sub system and during execution of the work to ensure the safety of both personnel and plant All systems, sub-systems or equipment items which are undergoing commissioning shall be labeled using an adhesive label on equipment items, or continuous tape on piping with the words 'system live' clearly printed. All subsequent work on this equipment shall require a valid Work Permit duly authorized by the nominated System Responsible Engineer. Access to areas undergoing commissioning shall be restricted to those persons directly involved in commissioning. Barriers shall be erected around the area to prevent access to non-authorized personnel, and signs specifying "Danger System Live - System being commissioned" shall be prominently displayed. At the time completed systems or sub-systems are handed over to operations offshore, the Nominated Operations and Commissioning Group personnel shall jointly remove the 'system live' labels and attach an "operational" label. All subsequent work on this equipment shall require a Work Permit duly authorized by the nominated Operations Responsible person.

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The Permit to Work procedure should be directly compatible with the COPC procedure utilized offshore, with specific regard to the sail-away isolations. All systems will be isolated prior to sail-away in a state ready for safe re-energization offshore. 6.0 SPECIALIST RESOURCES

Crude Treatment Package Westfalia Separator Mineral Oil Systems Werner-Habig-Str. 1 59302 Oelde F.R. Germany Tel: +49 2522 77-1022 Contact: Jan Hoppe, Project Manager 7.0 SYSTEM DESCRIPTION Crude Treatment Package The purpose of the crude oil washing system is to reduce the high temperature corrosion and ash fouling of hot section components in gas turbines or other combustion engines. Crude oil is a complex mixture of hydrocarbons and other components, which may occur in the mixture in different percentages and states. These components can be e.g. water emulsions, dissolved salts and ash forming trace metal impurities. Most of the crude oils contain also Sodium and Potassium ( Na & K ) in form of salts. The origin of both can be from different sources like produced water, sea water or from the refinery process. The crude oil washing process shall reduce the Sodium and Potassium content of the raw crude oil to a required value. The value is given by the manufacturer of the combustion engines. It is practically acceptable to assume that all Sodium and Potassium salts in the crude oil are dissolved in the entrained water phase. That means, any extraction of water from the oil will consequently lead to a reduction of the salt content. Generally, a suitable type of centrifuge and well adjusted is able to reduce the water content from a few percent in the crude oil feed to a content of 0,1 – 0,3% in the oil outlet. The separation efficiency can be improved by using chemical additives known as “demulsifiers ”. Demulsifiers are surface-active materials which promote the separation of water from oil, when applied to water-in-oil emulsions. Vanadium and other oil-soluble trace metals cannot be removed by crude oil washing and corrosion inhibition can only be achieved by using chemical additives, so called “ inhibitors ”. Diesel Fuel Distribution The topsides diesel fuel distribution system is a pressurized distribution ring main fed from the hull located diesel oil service pumps and incorporates a pressure controlled spill back return line which carries unused diesel back to the Hull diesel storage tanks. Individual diesel supply lines to the following equipment are taken from the distribution header via block valves; Pedestal Cranes 19CRN001, 19CRN002, 19CRN003, 19CRN004, 19CRN005 Power Generators 97LAN001A & 97LAN001B Crude Oil Washing Package 97FT010 Treated Crude Feed package 97FT011 Boiler Crude Fuel Skid 97FT002 The diesel supply to the cranes is via flow restriction orifices with the filling of the crane diesel day tanks being a manual operation through the use of hand bowsers.

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Diesel to the power generation packages is hard piped into the liquid fuel supply line for the generators via a 3-way valve, with the other valve connection being for the treated crude fuel supply. This allows for selection of running the generators on either fuel supply. Diesel supply to the crude oil washing and treated crude feed packages, along with the boiler crude fuel skid is for flushing purposes, to clean the lines of crude fuel for shut down or maintenance purposes. The diesel supply used in these packages is protected against seeing abnormal high pressure by self regulating control valves located down stream of the supply line block valve. 8.0 CONTROL & OPERATING DESCRIPTION Crude Treatment Package Crude oil with entrained salt laden water (in the following called as emulsion) is supplied by a pump (67PBE070A or 67PBE070B) to a heater (41HZZ066A or 41HZZ066B) and heat recovery package. If necessary, demulsifier is added into the emulsion to facilitate the coalescence of water drops. The cold emulsion flows at first through a heat exchanger (41HZZ066A or 41HZZ066B), where heat recovery from the treated hot crude oil takes place, coming from the crude oil washing package. Then the emulsion flows through a steam heater (41HZZ060A or 41HZZ060B), where it is heated to the required separation temperature and from there into a mixer (34MIX001A or 34MIX001B) upstream of the first stage centrifuge (35ZAK040A or 35ZAK040B). Before the emulsion enters into the first-stage mixer (34MIX001A or 34MIX001B), wash water separated from the oil in the second-stage centrifuge (35ZAK041A or 35ZAK041B) is added to the emulsion upstream of the first-stage mixer (34MIX001A or 34MIX001B). The separated wash water from the second-stage centrifuge (35ZAK041A or 35ZAK041B) is used as wash water upstream of the first-stage mixer (34MIX001A or 34MIX001B) because of the low content of salts and to reduce the consumption of fresh wash water. The emulsion is intensively but gently mixed with the wash water to avoid any creation of stable emulsion’s. The salt laden water phase in the row emulsion is diluted by the wash water from the second-stage centrifuge (35ZAK041A or 35ZAK041B). The emulsion flows then into the first-stage centrifuge (35ZAK040A or 35ZAK040B), where the free water of the emulsion is mostly extracted from the crude oil, together with the solids. The content of salts in the oil as well as the content of solids have been reduced considerably after the treatment in the first-stage centrifuge (35ZAK040A or 35ZAK040B). The treated oil from the first-stage centrifuge (35ZAK040A or 35ZAK040B) is pumped by a built-in centripetal pump into the second-stage mixer (34MIX002A or 34MIX-002B) upstream of the second stage centrifuge (35ZAK041A or 35ZAK041B). The separated free wash water of the first-stage centrifuge (35ZAK040A or 35ZAK040B) is discharged under pressure out of the package by means of a built-in centripetal pump. Wash water is added again into the emulsion, upstream of the second-stage mixer (34MIX002A or 34MIX002B). An intensive mixing takes place in the same way as done in the first-stage mixer (34MIX001A or 34MIX001B). However, the wash water added into the emulsion upstream of the second-stage mixer (34MIX002A or 34MIX002B) is fresh water supplied from a pump (67PBE071A or 67PBE071B) and will be heated up by a steam heater (41HZZ061A or 41HZZ061B). The temperature of the fresh wash water is equal to the temperature of the emulsion. The amount of fresh wash water depends on:

-The Sodium and Potassium content of the emulsion in the feed. -The water content of the emulsion in the feed. -The Sodium and Potassium content of the wash water. -The allowable water content in the treated emulsion. -The required Sodium and Potassium content in the treated emulsion.

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The emulsion flows then into the second-stage centrifuge (35ZAK041A or 35ZAK041B), where the free water of the emulsion is mostly extracted again from the crude oil, together with the solids. The Sodium and Potassium content as well as the water content in the emulsion should now be reduced to the required values. The discharge of the treated emulsion from the second-stage centrifuge (35ZAK041A or 35ZAK041B) flows via a heat exchanger (41HZZ062A or 41HZZ062B) and a cooler (41HZZ069A or 41HZZ069B) into a storage tank. If required, an analyzer can be fitted between the emulsion discharge of the second-stage centrifuge (35ZAK041A or 35ZAK041B) and the storage tank, to monitor continuously the Sodium und Potassium content of the emulsion. The emulsion is returned to the “raw crude oil” tank by a 3/2-way change over valve (43XY0149 or 43XY0100), if the specified limits are exceeded. There is a strict cooperation between the first-stage (35ZAK040A or 35ZAK040B) and the second stage centrifuge (35ZAK041A or 35ZAK041B) of each line, since the discharge of the first-stage centrifuge (35ZAk040A or 35ZAK040B) is directly fed into the second-stage centrifuge (35ZAK041A or 35ZAK041B), during separation. That means, that any interruption of the separation process at the first-stage centrifuge (35ZAK040A or 35ZAK040B) will also interrupt the separation process of the second-stage centrifuge 35ZAK041A or 35ZAK041B) and vice versa. An interruption of the separation process can be caused, e.g. by an alarm or the end of the separating time. An interruption of the separation process means, that the crude oil supply into the centrifuge is stopped and a de-sludging procedure is initiated. The centrifuge keeps running and the separation process can be started again under certain circumstances. Monitoring and control of the package is performed by a PLC system from Allen-Bradley Control Logix. The package is remotely controlled from a centralized control room, located in a classification area of Class 1, Division 2, Group C&D. The control room contains the PLC and UPS system, the motor starters included frequency converters and all monitoring and control instruments. The start and stop of each centrifuge is performed with the rated current of the drive motor, controlled by a frequency converter. The control room has a pressurizing system, a HVAC system and a fire and gas detection system. Manual fire extinguisher of CO2 type is also provided. The connections with the field instruments are done via local junction boxes. Motors and ESD switches, located on the package, are directly connected to the control room. Diesel Fuel Distribution The topsides diesel fuel distribution is pressure controlled by valve 43PV0809, which is set at 689 kPa (g) (100 psi). This valve spills diesel fuel from the topsides distribution header directly back to the Hull storage tanks. Diesel supply taken from the distribution header for the Crude Oil Washing Package 97FT010, Treated Crude Feed package 97FT011 and Boiler Crude Fuel Skid 97FT002 are protected against over pressure in the case of the distribution header seeing abnormally high pressures, by self regulating control valves 43PCV0786 and 43PCV787, which are set to the header normal operating pressure of 689 kPa(g). 9.0 SYSTEM LIMITS Marked up system limits can be found in the System Commissioning Dossier The Sub-Systems covered by this procedure are listed below; Sub-System Sub-System Description

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Crude Treatment Package 60-FCA-001 Raw Crude Oil To/From Hull C.O.F. Tanks 60-FCA-002 Raw Crude Oil Heating and Transfer 60-FCA-003 Wash Water Skid 60-FCA-004 Raw Crude Oil Washing Line 1 60-FCA-005 Raw Crude Oil Washing Line 2 60-FCA-006 Raw Crude Oil Demulsifier Injection 60-FCA-007 Treated Crude Fuel Oil Pumping and Forwarding Package 60-FCA-008 Treated Crude Fuel Oil Inhibitor Injection 60-FCA-009 Treated Crude Fuel Oil To/From Hull C.O.F. Tanks 60-FCA-010 Treated Crude Fuel Oil to Power Generators 60-FCA-011 Boiler Crude Fuel Skid 60-FCA-012 COTP Control Cabin Equipment Diesel Fuel Distribution 62-FCA-001 Diesel Distribution Header 62-FCA-002 Diesel Supply to Cranes 62-FCA-003 Diesel Supply to Power Generator 1A 62-FCA-004 Diesel Supply to Power Generator 1B 62-FCA-005 Diesel Supply to Module P5 62-FCA-006 Diesel Supply to Module S7 10.0 SYSTEM REQUIREMENTS

Prior to commencing commissioning activities for 60 & 62-FCA Crude Oil & Diesel Fuels, the following Systems (covered by other procedures) shall be operational. System System Description 40-FIA Cooling Medium 43-FRA Flare, Vent & Blowdown 44-BDA Produced water 53-IDA Demineralizer (Fresh Water) 55-FPA Steam Generation 56-FEA Drains Open Hazardous 57-FFA Closed Drains 63-FNA Instrument Air 64-FMA Nitrogen 70-HDA Fire & Gas Detection (Part) 79-HFA SSS Safety Shutdown System (ESD/PSD) (Part) 82-FUA LV Power Distribution (Part) 87-IKA Process Control Computer System (PCS) (Part) 11.0 TEST FACILITIES

11.1 Temporary Facilities The use of temporary filters, strainers, blind flanges, temporary wire links etc. is to be controlled by the relevant discipline engineer. A register by system and discipline to record the use and removal of the above must be kept.

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Prior to system handover if any temporaries are still in use these must be recorded in the Commissioning Punchlist for the relevant system. Temporary wire links etc. should be colour coded ‘Yellow’ and numbered for easy identification as per the Lock-out Tag-out Procedure R048-13P-GAA-G-PRD-000054

11.2 Lubricants Crude Treatment Package

Equipment Lubricant 67PBE070A/B, Untreated Crude Transfer p/p Hold 30PBEMT070A/B, Untreated Crude Transfer p/p motor Hold 67PBE071A/B, Wash Water p/p Hold 30PBEMT071A/B, Wash Water p/p motor Hold 35ZAK040A & 040B, Pri/Sec Crude Oil Washing Centrifuges Hold 30ZAKMT040A & 040B, Pri/Sec Cr/Oil Wash Centrifuge motor. Multifak EP 3 grease (pre-lubed) 67PBE140A & 140B, Line 1 & 2 Lube Oil p/p 1 Hold 30PBEMT140A & 140B, Line 1 & 2 Lube Oil p/p 1 motor Hold 67PBE142A & 142B, Line 1 & 2 Sludge Oil p/p 1 (Air Diaphragm) Hold 95MIX001A & 001B, Line 1 & 2 Mixer 1 Hold 30MIXMT001A & 001B, Line 1 & 2 Mixer 1 motor Hold 35ZAK041A & 041B, Pri/Sec Crude Oil Washing Centrifuges Hold 30ZAKMT041A & 041B, Pri/Sec Cr/Oil Wash Centrifuge motor. Multifak EP 3 grease (pre-lubed) 67PBE141A & 141B, Line 1 & 2 Lube Oil p/p 2 Hold 30PBEMT141A & 141B, Line 1 & 2 Lube Oil p/p 2 motor Hold 67PBE143A & 143B, Line 1 & 2 Sludge Oil p/p 2 (Air Diaphragm) Hold 95MIX002A & 002B, Line 1 & 2 Mixer 2 Hold 30MIXMT002A & 002B, Line 1 & 2 Mixer 2 motor Hold 67PBE076A/B, Demulsifier injection p/p Hold 30PBE0MT076A/B, Demulsifier injection p/p motors Hold 67PBE072A/B, Treated Crude Fuel Oil Forwarding p/p Hold 30PBE0MT072A/B, Treated Crude F/Oil Forwarding p/p motors Hold 35MAJ051A/B, Treated Crude Forwarding Filters Hold 35MAJMT051A/B, Treated Crude Forwarding Filters Motors Hold 67PBE073A/B, Inhibitor Injection p/p Hold 67PBEMT073A/B, Inhibitor Injection p/p motor Hold

11.3 Supplier Assistance Crude Treatment Package Westfalia Separator Mineral Oil Systems Werner-Habig-Str. 1 59302 Oelde F.R. Germany Tel: +49 2522 77-1022 Contact: Jan Hoppe, Project Manager

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11.4 Commissioning Spares Refer to the Suppliers Parts Interchangeability Record (SPIR) within the System Commissioning Dossier.

12.0 DEPRESERVATION/ REPRESERVATION

On acceptance of a System / Sub-system from construction ensure that the check sheets covering the required maintenance and preservation of the system during the storage and construction phases are included with the system handover certificate and inserted in the System Commissioning Dossier of this procedure. The maintenance and preservation of the system then becomes the responsibility of the Commissioning Group until handover to COPC Operations. Check all system's equipment including Maintenance Manuals and preservative listings prior to carrying out any operational tests. Ensure all transit locking devices are removed as per vendor instructions. On completion of dynamic testing the Commissioning group will operate and maintain the system and/or re-preserve in accordance with Vendor and Project maintenance, operating and preservation procedures until the system is accepted by COPC Operations group. 13.0 SYSTEM PREPARATION

This section covers the work required to prepare equipment items, sub-systems and systems for operating tests. The section is divided by discipline, such that each may extract their sub-section and complete the activities independent of other disciplines. As each item in the section is completed it shall be checked then signed and dated as accepted by the commissioning discipline engineer or nominated deputy. Commissioning engineer shall ensure that where project or seller documents are referenced to assist in any commissioning activity, the documentation shall be the latest revision. Any as built drawings produced at this stage should be actioned through the correct project procedure and a copy retained in the System Commissioning Dossier.

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13.1 Mechanical Preparation Checklist

13.1 MECHANICAL PREPARATION SIGNED DATE

1. Prior to commencement of Mechanical Commissioning confirm that all relevant Mechanical ITRs are complete as identified in the System Commissioning Dossier. Ensure all ‘A’ punchlist items have been actioned and signed off as completed. Ensure ‘B’ punchlist items are minimized.

2. On acceptance of a sub-system and upon receipt of the appropriate permit to work, prepare to commence pre-commissioning / commissioning activities complying with all relevant safety procedures as defined in section 5.

3. Confirm all Mechanical As-Built drawings associated with this System have been included in the System Commissioning Dossier.

4. Confirm all system PSVs have been tested and are certified.

5. Ensure all temporary devices used within the system (e.g. strainers, dust blinds, screen) are clearly marked and recorded in the appropriate register.

6. Ensure all preservation and shipping locking devices are removed from installed equipment and sprung piping supports.

7. Ensure all required safety guarding and personnel protection is securely installed.

8. Confirm with Piping Dept that all fuel lines have been thoroughly cleaned and inspected as part of mechanical completion.

9. Confirm all equipment lubrication requirements have been attended to with correct lubricant as per the Project Lubrication Inventory List.

Crude Treatment Package

10. Inspect and confirm the cleanliness of the two air receivers on the crude oil washing package 97FT010 and confirm all internal and external fixtures are correctly installed and undamaged. Ensure a new gasket is used upon final closure of the vessel inspection door.

11. Inspect and confirm the suction strainers for the crude oil transfer pumps 67PBE070 A/B are undamaged and clean.

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12. Confirm alignments have been checked and are within allowable tolerances for the following equipment;

i. Crude oil transfer pump 67PBE070 A ii. Crude oil transfer pump 67PBE070 B

13. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the crude oil transfer pump 67PBE070A. Confirm correct reinstatement of couplings and guards when the activities are complete.

14. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the crude oil transfer pump 67PBE070B. Confirm correct reinstatement of couplings and guards when the activities are complete.

15. To facilitate commissioning and running of the crude oil transfer pumps, line out the pump suction and discharge lines to recirculate fluid from the Hull COF tanks via control valve 43PV001. Ensure this valve is in manual mode and driven fully open.

16. Carry out a 4 hour commissioning run on the crude oil transfer pump 67PBE070A, ensuring all pump operating parameters are normal and as per design. Record the pump running parameters.

17. Carry out the 4 hour commissioning run on the crude oil transfer pump 67PBE070B, ensuring all pump operating parameters are normal and as per design. Record the pump running parameters.

18. Inspect and confirm the cleanliness of the wash water storage tank 95ABJ078 on the wash water skid. Confirm all internal and external fixtures are correctly installed and undamaged. Ensure a new gasket is used upon final closure of the vessel inspection door.

19. Inspect and confirm the suction strainers for the wash water pumps 67PBE071 A/B are undamaged and clean.


i. Wash water pump 67PBE071A ii. Wash water pump 67PBE071B

21. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the wash water pump 67PBE071A. Confirm correct reinstatement of couplings and guards when the activities are complete.

22. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the wash water pump 67PBE071B. Confirm correct reinstatement of couplings and guards when the activities are complete.

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23. Liaise with the instrument department and open filling valve 43XY0032. Proceed to fill the wash water storage tank 95ABJ078 through the installed filling line, with demineralized water supplied from the Hull until a working level of water is established.

24. To facilitate commissioning and running of the wash water pumps, line out the pump suction and discharge lines to recirculate water from and back to the wash water storage tank. Remove flow orifice 43FE0005 to facilitate this recirculation run and isolate the wash water heaters.

25. Carry out a 4 hour commissioning run on the wash water pump 67PBE071A, ensuring all pump operating parameters are normal and as per design. Record the pump running parameters.

26. Carry out the 4 hour commissioning run on the wash water pump 67PBE071B, ensuring all pump operating parameters are normal and as per design. Record the pump running parameters.

Crude Oil Washing Line 1

27. Inspect and confirm the cleanliness of the following tanks. Confirm all internal and external fixtures are correctly installed and undamaged. Ensure a new gasket is used upon final closure of the inspection door; i. Sludge tank 95ABJ048A ii. Sludge tank 95ABJ049A iii. Lube oil tank for 97ZZZ040A iv. Lube oil tank for 97ZZZ041A v. Mixing tank for 34MIX001A vi. Mixing tank for 34MIX002A

28. Fill the sludge tank 95ABJ048A with water until a working level is achieved. Line out the sludge pump 67PBE142A to pump the sludge tank contents to the Hull slops tank. With the attached air supply, run the sludge pump and prove it’s pumping function. NOTE: As this is a diaphragm pump, only a short run is required for commissioning purposes.

29. Fill the mixing tank 34MIX001A with water until a working level is achieved. Liaise with the electrical department and run the mixer to prove the direction of rotation is correct and to carry out a commissioning run for the mixer drive motor.

30. Carry out the following steps to commissioning the centrifuge lube oil unit 97ZZZ040A; i. Fill the lube oil tank with the correct grade of lube oil – capacity 16 Litres ii. Check the lube oil pump in line strainer is clean and the screen is undamaged

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iii. Liaise with the electrical dept, uncouple the pump drive motor and carry out a bump check to confirm the direction of rotation is correct iv. Recouple the motor and pump and reinstate all guards v. Liaise with the electrical department and start the lube oil pump, ensuring that an oil flow through the centrifuge is established and returns back to the lube oil tank. Proceed to carry out a commissioning run for the lube oil pump 67PBE140A

31. Liaise with the electrical department, uncouple the VFD from the centrifuge 35ZAK040A and carry out a bump check to confirm the direction of rotation is correct. Recouple the VFD and reinstate all guards.

32. Install the bowl assembly in to the centrifuge 35ZAK040A, making reference to the Westfalia “OIM Manual”, Doc No.

33. Fill the sludge tank 95ABJ049A with water until a working level is achieved. Line out the sludge pump 67PBE143A to pump the sludge tank contents to the Hull slops tank. With the attached air supply, run the sludge pump and prove it’s pumping function. NOTE: As this is a diaphragm pump, only a short run is required for commissioning purposes.

34. Fill the mixing tank 34MIX002A with water until a working level is achieved. Liaise with the electrical department and run the mixer to prove the direction of rotation is correct and to carry out a commissioning run for the mixer drive motor.

35. Carry out the following steps to commissioning the centrifuge lube oil unit 97ZZZ041A; i. Fill the lube oil tank with the correct grade of lube oil – capacity 16 Litres ii. Check the lube oil pump in line strainer is clean and the screen is undamaged iii. Liaise with the electrical dept, uncouple the pump drive motor and carry out a bump check to confirm the direction of rotation is correct iv. Recouple the motor and pump and reinstate all guards v. Liaise with the electrical department and start the lube oil pump, ensuring that an oil flow through the centrifuge is established and returns back to the lube oil tank. Proceed to carry out a commissioning run for the lube oil pump 67PBE141A

36. Liaise with the electrical department, uncouple the VFD from the centrifuge 35ZAK041A and carry out a bump check to confirm the direction of rotation is correct. Recouple the VFD and reinstate all guards.

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37. Install the bowl assembly in to the centrifuge 35ZAK041A, making reference to the Westfalia “OIM Manual”, Doc No.


38. Inspect and confirm the cleanliness of the following tanks. Confirm all internal and external fixtures are correctly installed and undamaged. Ensure a new gasket is used upon final closure of the inspection door; i. Sludge tank 95ABJ048B ii. Sludge tank 95ABJ049B iii. Lube oil tank for 97ZZZ040B iv. Lube oil tank for 97ZZZ041B v. Mixing tank for 34MIX001B vi. Mixing tank for 34MIX002B

39. Fill the sludge tank 95ABJ048B with water until a working level is achieved. Line out the sludge pump 67PBE142B to pump the sludge tank contents to the Hull slops tank. With the attached air supply, run the sludge pump and prove it’s pumping function. NOTE: As this is a diaphragm pump, only a short run is required for commissioning purposes.

40. Fill the mixing tank 34MIX001B with water until a working level is achieved. Liaise with the electrical department and run the mixer to prove the direction of rotation is correct and to carry out a commissioning run for the mixer drive motor.

41. Carry out the following steps to commissioning the centrifuge lube oil unit 97ZZZ040B; i. Fill the lube oil tank with the correct grade of lube oil – capacity 16 Litres ii. Check the lube oil pump in line strainer is clean and the screen is undamaged iii. Liaise with the electrical dept, uncouple the pump drive motor and carry out a bump check to confirm the direction of rotation is correct iv. Recouple the motor and pump and reinstate all guards v. Liaise with the electrical department and start the lube oil pump, ensuring that an oil flow through the centrifuge is established and returns back to the lube oil tank. Proceed to carry out a commissioning run for the lube oil pump 67PBE140B

42. Liaise with the electrical department, uncouple the VFD from the centrifuge 35ZAK040B and carry out a bump check to confirm the direction of rotation is correct. Recouple the VFD and reinstate all guards.

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43. Install the bowl assembly in to the centrifuge 35ZAK040B, making reference to the Westfalia “OIM Manual”, Doc No.

44. Fill the sludge tank 95ABJ049B with water until a working level is achieved. Line out the sludge pump 67PBE143B to pump the sludge tank contents to the Hull slops tank. With the attached air supply, run the sludge pump and prove it’s pumping function. NOTE: As this is a diaphragm pump, only a short run is required for commissioning purposes.

45. Fill the mixing tank 34MIX002B with water until a working level is achieved. Liaise with the electrical department and run the mixer to prove the direction of rotation is correct and to carry out a commissioning run for the mixer drive motor.

46. Carry out the following steps to commissioning the centrifuge lube oil unit 97ZZZ041B; i. Fill the lube oil tank with the correct grade of lube oil – capacity 16 Litres ii. Check the lube oil pump in line strainer is clean and the screen is undamaged iii. Liaise with the electrical dept, uncouple the pump drive motor and carry out a bump check to confirm the direction of rotation is correct iv. Recouple the motor and pump and reinstate all guards v. Liaise with the electrical department and start the lube oil pump, ensuring that an oil flow through the centrifuge is established and returns back to the lube oil tank. Proceed to carry out a commissioning run for the lube oil pump 67PBE141B

47. Liaise with the electrical department, uncouple the VFD from the centrifuge 35ZAK041B and carry out a bump check to confirm the direction of rotation is correct. Recouple the VFD and reinstate all guards.

48. Install the bowl assembly in to the centrifuge 35ZAK041B, making reference to the Westfalia “OIM Manual”, Doc No.

Raw Crude Demulsifier

49. Confirm the following for the raw crude demulsifier injection pumps 67PBE076 A/B; i. Alignments have been checked and are within allowable tolerances. ii. Lubricant grade and fill level is correct. iii. Packing torque is correct. iv. Suction strainer is undamaged and clean.

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50. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the raw crude demulsifier injection pump 67PBE076A.

51. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the raw crude demulsifier injection pump 67PBE076B.

52. Carry out visual inspections and confirm the following for the raw crude demulsifier tote tanks 95ABJ066 A/B; i. Confirm the cleanliness of tank internals ii. Verify all internal and external fixtures are correctly installed and undamaged iii. The tanks pressure & vacuum valves 93PVSVXXXX/XXXX are in good operable condition with vent paths clear iv. The vent path is clear and free from obstruction

53. Locate the flexible hoses supplied for the raw crude demulsifier injection tote tanks 95ABJ066 A/B, confirm they are fitted with correct sized fittings and are uniquely colour coded. i. EI/13P-0084 x 2 pieces ii. EI/13P-0086 x 2 pieces

54. Prepare raw crude demulsifier tote tank 95ABJ066 and raw crude demulsifier injection pumps 67PBE076 A/B for running; i. Remove the pump relief valves 93PSV0003 and 93PSV0004 and connect temporary tubing from this line back to tote tank 95ABJ066A ii. Line out the system valves to pump water from and recirculate to the tote tank 95ABJ066A iii. Attach the flexible hose from the outlet of the tote to the pump suction piping iv. Fill the tote with water so that a working level is seen in the level gauge 43LG0335. v. Confirm all pump lube requirements have been attended to

55. Liaise with the Electrical Dept and carry out the commissioning run on the raw crude demulsifier injection pump 67PBE076A, ensuring all required performance parameters are met.

i. Start pump at 90-95% max output. ii. When flow is established, adjust pump stroke to 100%. iii. Carry out the commissioning pump run and confirm all pump

running conditions and parameters are normal.

56. Liaise with the Electrical Dept and carry out the commissioning run on the raw crude demulsifier injection pump 67PBE076B, ensuring all required performance parameters are met.

i. Start pump at 90-95% max output. ii. When flow is established, adjust pump stroke to 100%. iii. Carry out the commissioning pump run and confirm all pump

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running conditions and parameters are normal

57. On completion of the pump runs reinstate the pumps PSV’s. Drain the water from the tote tank and leave it in a dry, clean condition ready to accept the first chemical fill.

58. Precharge the pulsation damper 43PG0003.

Treated Crude Feed Package

59. Inspect and confirm the cleanliness of the air receiver on the treated crude feed package 97FT011 and confirm all internal and external fixtures are correctly installed and undamaged. Ensure a new gasket is used upon final closure of the vessel inspection door.

60. Inspect and confirm the suction strainers for the treated crude forwarding pumps 67PBE072 A/B are undamaged and clean.

61. Confirm the gearboxes for the treated crude forwarding pumps 67PBE072 A/B are filled to the correct level with oil.


i. Treated crude forwarding pump 67PBE072A ii. Treated crude forwarding pump 67PBE072B

63. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the treated crude forwarding pump 67PBE072A. Confirm correct reinstatement of couplings and guards when the activities are complete.

64. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the treated crude forwarding pump 67PBE072B. Confirm correct reinstatement of couplings and guards when the activities are complete.

65. To facilitate commissioning and running of the treated crude forwarding pumps, line out the pump suction and discharge lines to recirculate fluid from the Hull COF tanks via control valve 43PV002. Ensure this valve is in manual mode and driven fully open.

66. Carry out a 4 hour commissioning run on the treated crude forwarding pump 67PBE072A, ensuring all pump operating parameters are normal and as per design. Record the pump running parameters.

67. Carry out the 4 hour commissioning run on the treated crude forwarding pump 67PBE072B, ensuring all pump operating parameters are normal and as per design. Record the pump

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running parameters.

68. Inspect and confirm the cleanliness of the forwarding filters 35MAJ051 A/B on the treated crude feed package 97FT011. Verify the filtration elements are free from damage and have sufficient clearance for rotation.

69. Liaise with the electrical department and check the rotation of the electric drive for the forwarding filters; 35MAJ051A 35MAJ051B

Treated Crude Inhibitor

70. Confirm the following for the treated crude inhibitor injection pumps 67PBE073 A/B; i. Alignments have been checked and are within allowable tolerances. ii. Lubricant grade and fill level is correct. iii. Packing torque is correct. iv. Suction strainer is undamaged and clean.

71. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the treated crude inhibitor injection pumps 67PBE073A.

72. Liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the treated crude inhibitor injection pumps 67PBE073B.

73. Carry out visual inspections and confirm the following for the treated crude inhibitor tote tanks 95ABJ079 A/B; i. Confirm the cleanliness of tank internals ii. Verify all internal and external fixtures are correctly installed and undamaged iii. The tanks pressure & vacuum valves 93PVSVXXXX/XXXX are in good operable condition with vent paths clear iv. The vent path is clear and free from obstruction

74. Locate the flexible hoses supplied for the treated crude inhibitor injection tote tanks 95ABJ079 A/B, confirm they are fitted with correct sized fittings and are uniquely colour coded. i. EI/13P-0079 x 2 pieces ii. EI/13P-0085 x 2 pieces

75. Prepare treated crude inhibitor tote tank 95ABJ079 and treated crude inhibitor injection pumps 67PBE073 A/B for running; i. Remove the pump relief valves 93PSV0042 and 93PSV0043 and connect temporary tubing from this line back to tote tank 95ABJ079A

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ii. Line out the system valves to pump water from and recirculate to the tote tank 95ABJ079A iii. Attach the flexible hose from the outlet of the tote to the pump suction piping iv. Fill the tote with water so that a working level is seen in the level gauge 43LG0333. v. Confirm all pump lube requirements have been attended to

76. Liaise with the Electrical Dept and carry out the commissioning run on the treated crude inhibitor injection pump 67PBE073A, ensuring all required performance parameters are met.

i. Start pump at 90-95% max output. ii. When flow is established, adjust pump stroke

to 100%. iii. Carry out the commissioning pump run and

confirm all pump running conditions and parameters are normal.

77. Liaise with the Electrical Dept and carry out the commissioning run on the treated crude inhibitor injection pump 67PBE073B, ensuring all required performance parameters are met.

i. Start pump at 90-95% max output. ii. When flow is established, adjust pump stroke

to 100%. iii. Carry out the commissioning pump run and

confirm all pump running conditions and parameters are normal.

78. On completion of the pump runs reinstate the pumps PSV’s. Drain the water from the tote tank and leave it in a dry, clean condition ready to accept the first chemical fill.

79. Precharge the pulsation damper 43PG0045.

Boiler Crude fuel Skid

80. Inspect and confirm the cleanliness of the crude fuel filters 35MAJ047 A/B ensuring the strainer elements are installed correctly and free from damage.


i. Boiler crude fuel pump 67PBE056A ii. Boiler crude fuel pump 67PBE056B

82. Remove the motor to pump coupling and liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the boiler crude fuel pump 67PBE056A. Confirm correct reinstatement of couplings and guards

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when the activities are complete.

83. Remove the motor to pump coupling and liaise with the Electrical Commissioning Dept to carry out rotation checks and commissioning of the drive motor of the boiler crude fuel pump 67PBE056B. Confirm correct reinstatement of couplings and guards when the activities are complete.

84. To facilitate commissioning and running of the boiler crude fuel pumps, diesel will be supplied through the flexible hose (flushing) arrangement on the raw crude from Hull COF tanks line. When the pumps are running, diesel will be recirculated down to and back from the boiler burner units as well as opening the by-pass valve to circulate diesel around control valve 43PCV0064.

85. Carry out a 4 hour commissioning run on the treated crude forwarding pump 67PBE072A, ensuring all pump operating parameters are normal and as per design. Record the pump running parameters.

86. Carry out the 4 hour commissioning run on the treated crude forwarding pump 67PBE072B, ensuring all pump operating parameters are normal and as per design. Record the pump running parameters.

87. Inspect and confirm the cleanliness of the forwarding filters 35MAJ051 A/B on the treated crude feed package 97FT011. Verify the filtration elements are free from damage and have sufficient clearance for rotation.

Diesel Fuel Distribution

88. Prepare the Topsides diesel distribution ring main for flushing with diesel fuel from the Hull diesel oil service pumps by isolating the end user supply lines from the distribution header. Confirm the block valves for the following equipment supply lines are in the closed position; i) Pedestal Crane 19CRN001 ii) Pedestal Crane 19CRN002 iii) Pedestal Crane 19CRN003 iv) Pedestal Crane 19CRN004 v) Pedestal Crane 19CRN005 vi) Power Generator 97LAN001A vii) Power Generator 97LAN001B viii) Crude Oil Washing Package 97FT010 ix) Treated Crude Feed package 97FT011 & Boiler Crude Fuel Skid 97FT002

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89. Install a temporary commissioning flushing screen in the return line back to the Hull diesel storage tank. This screen shall be checked periodically and cleaned as required.

90. Place control valve 43PV0809 in manual control and drive the valve fully closed. Close the control valve inlet and outlet block valves and open the bypass valve.

91. Introduce diesel from the Hull diesel oil service pumps into the Topsides diesel distribution and return ring main by opening the following block valves; i) Supply header valve A ii) Supply and return header isolation valve G iii) Return header valve F

92. Establish a flow of diesel and flush the supply and return headers of the topsides diesel ring main back to the hull diesel storage tank.

93. After the flushing of diesel has been established, manually drive open the control valve 43PV0809 to increase the flushing rate of the diesel ring main.

94. Sequentially introduce diesel into the Topsides end user supply lines from the distribution supply header by opening the block valves in the supply lines to the following; i) Pedestal Crane 19CRN001 ii) Pedestal Crane 19CRN002 iii) Pedestal Crane 19CRN003 iv) Pedestal Crane 19CRN004 v) Pedestal Crane 19CRN005 vi) Power Generator 97LAN001A vii) Power Generator 97LAN001B viii) Crude Oil Washing Package 97FT010 ix) Treated Crude Feed package 97FT011 & Boiler Crude Fuel Skid 97FT002

95. On the following crane diesel filling lines, flush the lines through with diesel and test bowser trigger nozzles function correctly when filling the crane diesel day tanks; i) Pedestal Crane 19CRN001 ii) Pedestal Crane 19CRN002 iii) Pedestal Crane 19CRN003 iv) Pedestal Crane 19CRN004 v) Pedestal Crane 19CRN005

96. Flush through the diesel supply line associated with the Crude Oil Washing Package 97FT010 up to the hose connection point.

97. Locate the flexible hose EI/13P-0122 associated with the Crude Oil Washing Package 97FT010, trial fit the hose and confirm all

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connections can be positively made.

98. Flush through the diesel supply line associated with the Treated Crude Feed Package 97FT011 up to the hose connection point.

99. Locate the flexible hose EI/13P-0017 associated with the Treated Crude Feed Package 97FT011, trial fit the hose and confirm all connections can be positively made.

100. Flush through the diesel supply line associated with the Boiler Crude Fuel Skid 97FT002 up to the hose connection point.

101. Locate the flexible hose EI/13P-0015 associated with the Boiler Crude Fuel Skid 97FT002, trial fit the hose and confirm all connections can be positively made.

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13.2 Electrical Preparation Checklist

13.2 ELECTRICAL PREPARATION SIGNED DATE

1. Prior to commencement of Electrical Pre-commissioning confirm that all relevant Electrical MC ITRs are complete as identified in the System Commissioning Dossier. Ensure all ‘A’ punchlist items have been actioned and signed off as completed. Ensure ‘B’ punchlist items are minimized.

2. Confirm all Electrical As-Built drawings associated with this System have been included in the System Commissioning Dossier.


4. Confirm that all auxiliary equipment is installed as per Manufacturers instructions and that all relevant safety equipment is available.

5. Confirm all control panels, motors, and equipment are correctly earthed per earthing detail drawings.

Sub-System 60-FCA-002

Raw Crude Oil Heating and Transfer

6. Check the correct routing/ segregation of all Raw Crude Oil Heating and Transfer Unit Control Panel FCA43LAG-358 earths ensuring that connections to the 3 Main Earthing Systems are correct.

7. Confirm with vendor that installation is complete and that all static checks have been completed prior to energization of Raw Crude Oil Heating and Transfer Unit Control Panel FCA43LAG-358

8. Confirm Control Panel FCA43LAG-358 Power Supply circuit – 28PPACDP2-50F4 input has been tested and is ready to be energized.

9. In conjunction with the Instrument Department energize Raw Crude Oil Heating and Transfer Unit Control Panel FCA43LAG358 as per vendor documentation if available, ensuring everything is healthy and ready to accept loops.

10. Confirm Raw Crude Oil Heating and Transfer Unit Control Panel FCA43LAG-358 remote alarms, controls, and indicators have been tested and are fully functional.

11. Function test the correct operation of the following starter cubicles from FUA28MCC026 associated with Raw Crude Heating and Transfer System.

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a) FUA28MCC026-03FG Untreated Crude Oil Transfer Pump A 30PBEMT070A

b) FUA28MCC026-03FI Untreated Crude Oil Transfer Pump B 30PBEMT070B

12. Confirm the correct operation of Local Control Stations for the following;

a) 30PBEMT070A-CS Untreated Crude Oil Transfer Pump A b) 30PBEMT070B-CS Untreated Crude Oil Transfer Pump B

13. In conjunction with the Mechanical / Instrument Commissioning Departments confirm that the following have completed a no load/ load run and are available to be put into service.

a) FUA28MCC026-03FG Untreated Crude Oil Transfer Pump A 30PBEMT070A

i. No Load/ Directional rotation ii. Load Run b) FUA28MCC026-03FI Untreated Crude Oil Transfer Pump B

30PBEMT070B i. No Load/ Directional rotation ii. Load Run


Wash Water Skid

14. Function test the correct operation of the following starter cubicles from FUA28MCC026 associated with Wash Water Skid.

a) FUA28MCC026-03FC Crude Oil System Wash Water Pump A 30PBEMT071A

b) FUA28MCC026-03FE Crude Oil System Wash Water Pump B 30PBEMT071B


a) 30PBEMT071A-CS Crude Oil System Wash Water Pump A b) 30PBEMT071B-CS Crude Oil System Wash Water Pump B


a) FUA28MCC026-03FC Crude Oil System Wash Water Pump A 30PBEMT071A

i. No Load/ Directional rotation ii. Load Run b) FUA28MCC026-03FE Crude Oil System Wash Water Pump

B 30PBEMT071B i. No Load/ Directional rotation

ii. Load Run

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Raw Crude Oil Washing Line 1

17. Check the correct routing/ segregation of all Line 1 Crude Oil Washing Unit Control Panel FCA43LAG-356 earths ensuring that connections to the 3 Main Earthing Systems are correct.

18. Confirm with vendor that installation is complete and that all static checks have been completed prior to energization of Line 1 Crude Oil Washing Unit Control Panel FCA43LAG-356

19. Confirm Control Panel FCA43LAG-356 Power Supply circuit – 28PPACDP2-50F2 input has been tested and is ready to be energized.

20. In conjunction with the Instrument Department energize Line 1 Crude Oil Washing Unit Control Panel FCA43LAG-356 as per vendor documentation if available, ensuring everything is healthy and ready to accept loops.

21. Confirm Line 1 Crude Oil Washing Unit Control Panel FCA43LAG-356 remote alarms, controls, and indicators have been tested and are fully functional.

22. Verify that the Control Rack on the VFD is correctly configured with drive motor parameters provided by the motor manufacturer for correct shutdown functions for the following 400V equipment.

a) FUA28VFD040A Crude Oil System Centrifuge 1 30ZAKMT040A

b) FUA28VFD041A Crude Oil System Centrifuge 2 30ZAKMT041A

23. Function test the correct operation of the following starter cubicles from FUA28MCC026 associated with Raw Crude Oil Washing.

a) FUA28MCC026-02FKL Crude Oil System Centrifuge 1 30ZAKMT040A

b) FUA28MCC026-02FC Crude Oil System Lube Oil Circ Pump 1, 30PBEMT140A

c) FUA28MCC026-01FA Line 1 Crude Oil Mixer 1 30MIXMT001A

d) FUA28MCC026-02FKR Crude Oil System Centrifuge 2 30ZAKMT041A

e) FUA28MCC026-02FE Crude Oil System Lube Oil Circ Pump 2, 30PBEMT141A

f) FUA28MCC026-02FA Line 1 Crude Oil Mixer 2 30MIXMT002A


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a) 30PBEMT140A-CS Crude Oil System Lube Oil Circ Pump b) 30PBEMT141A-CS Crude Oil System Lube Oil Circ Pump c) 30MIXMT001A-CS Line 1 Crude Oil System Mixer 1 d) 30MIXMT002A-CS Line 1 Crude Oil System Mixer 2


a) FUA28MCC026-02FKL Crude Oil System Centrifuge 1 30ZAKMT040A

i. No Load/ Directional rotation ii. Load Run b) FUA28MCC026-02FC Crude Oil System Lube Oil Circ Pump

1, 30PBEMT140A i. No Load/ Directional rotation ii. Load Run c) FUA28MCC026-01FA Line 1 Crude Oil Mixer 1

30MIXMT001A i. No Load/ Directional rotation ii. Load Run d) FUA28MCC026-02FKR Crude Oil System Centrifuge 2

30ZAKMT041A i. No Load/ Directional rotation ii. Load Run e) FUA28MCC026-02FE Crude Oil System Lube Oil Circ Pump

2, 30PBEMT141A i. No Load/ Directional rotation ii. Load Run f) FUA28MCC026-02FA Line 1 Crude Oil Mixer 2

30MIXMT002A i. No Load/ Directional rotation ii. Load Run


Raw Crude Oil Washing Line 2

26. Check the correct routing/ segregation of all Line 2 Crude Oil Washing Unit Control Panel FCA43LAG-357 earths ensuring that connections to the 3 Main Earthing Systems are correct.

27. Confirm with vendor that installation is complete and that all static checks have been completed prior to energization of Line 2 Crude Oil Washing Unit Control Panel FCA43LAG-357

28. Confirm Control Panel FCA43LAG-357 Power Supply circuit – FUA-28PPACDP2-50F3 input has been tested and is ready to be energized.

29. In conjunction with the Instrument Department energize Line 2 Crude Oil Washing Unit Control Panel FCA43LAG-357 as per

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vendor documentation if available, ensuring everything is healthy and ready to accept loops.

30. Confirm Line 2 Crude Oil Washing Unit Control Panel FCA43LAG-357 remote alarms, controls, and indicators have been tested and are fully functional.

31. Verify that the Control Rack on the VFD is correctly configured with drive motor parameters provided by the motor manufacturer for correct shutdown functions for the following 400V equipment.

a) FUA28VFD040B Crude Oil System Centrifuge 1 30ZAKMT040B

b) FUA28VFD041B Crude Oil System Centrifuge 2 30ZAKMT041B

32. Function test the correct operation of the following starter cubicles from 28MCC026 associated with Raw Crude Oil Washing.

a) 28MCC026-03FKL Crude Oil System Centrifuge 1 30ZAKMT040B

b) 28MCC026-05FK Crude Oil System Lube Oil Circ Pump 1 30PBEMT140B c) 28MCC026-02FG Line 2 Crude Oil Mixer 1 95MIXMT001B d) 28MCC026-03FKR Crude Oil System Centrifuge 2

30ZAKMT041B e) 28MCC026-03FA Crude Oil System Lube Oil Circ Pump 2 30PBEMT141B f) 28MCC026-02FI Line 2 Crude Oil Mixer 2 95MIXMT002B


a) 28MCC026-03FKL - FUA28VFD040B Crude Oil System Centrifuge 1, 30ZAKMT040B

i. No Load/ Directional rotation ii. Load Run b) 28MCC026-05FK - Crude Oil System Lube Oil Circ Pump 1 30PBEMT140B i. No Load/ Directional rotation ii. Load Run c) 28MCC026-02FG Line 2 Crude Oil Mixer 1 95MIXMT001B i. No Load/ Directional rotation ii. Load Run d) 28MCC026-03FKR - FUA28VFD041B Crude Oil System

Centrifuge 2, 30ZAKMT041B i. No Load/ Directional rotation ii. Load Run e) 28MCC026-03FA Crude Oil System Lube Oil Circ Pump 2 30PBEMT141B i. No Load/ Directional rotation ii. Load Run

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f) 28MCC026-02FI Line 2 Crude Oil Mixer 2 95MIXMT002B i. No Load/ Directional rotation ii. Load Run


Raw Crude Oil Demulsifier Injection

34. Function test the correct operation of the following starter cubicles from 28MCC026 associated with Raw Crude Oil Demulsifier Injection.

a) 28MCC026-05FC Crude Oil System Demulsifier Injection Pump1 30PBEMT076A

b) 28MCC026-05FE Crude Oil System Demulsifier Injection Pump 2 30PBEMT076B


a) 30PBEMT076A -CS Crude Oil System Demulsifier Injection Pump1

b) 30PBEMT076B -CS Crude Oil System Demulsifier Injection Pump2


a) 28MCC026-05FC Crude Oil System Demulsifier Injection Pump1 30PBEMT076A

i. No Load/ Directional rotation ii. Load Run b) 28MCC026-05FE Crude Oil System Demulsifier Injection

Pump 2 30PBEMT076B i. No Load/ Directional rotation ii. Load Run


Treated Crude Fuel Oil Pumping and Forwarding Package

37. Function test the correct operation of the following starter cubicles from 28MCC026 associated with Treated Crude Fuel Oil and Forwarding Package.

a) 28MCC026-05FG Crude Oil System Forwarding Pump A 30PBEMT072A b) 28MCC026-05FI Crude Oil System Forwarding Pump B 30PBEMT072B c) 28MCC026-04FG Treated Crude Oil Forwarding Filter A 35MAJMT051A d) 28MCC026-04FI Treated Crude Oil Forwarding Filter B 35MAJMT051B

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a) 28MCC026-05FG Crude Oil System Forwarding Pump A 30PBEMT072A i. No Load/ Directional rotation ii. Load Run b) 28MCC026-05FI Crude Oil System Forwarding Pump B 30PBEMT072B i. No Load/ Directional rotation ii. Load Run c) 28MCC026-04FG Treated Crude Oil Forwarding Filter A 35MAJMT051A i. No Load/ Directional rotation ii. Load Run d) 28MCC026-04FI Treated Crude Oil Forwarding Filter B 35MAJMT051B i. No Load/ Directional rotation ii. Load Run


Treated Crude Fuel Oil Inhibitor Injection

39. Verify that the Control Rack on the VFD (Controller) is correctly configured with drive motor parameters provided by the motor manufacturer for correct shutdown functions for the following 400V equipment.

a) FUA28FC5-53U1 Crude Oil System Inhibitor Injection Pump1 30PBEMT073A

b) FUA28FC5-54U1 Crude Oil System Inhibitor Injection Pump2 30PBEMT073B

40. Function test the correct operation of the following starter cubicles from 28MCC026 associated with Treated Crude Fuel Oil Inhibitor Injection.

a) 28MCC026-04FE-CB1 Crude Oil System Inhibitor Injection Pump1 30PBEMT073A

b) 28MCC026-04FE-CB2 Crude Oil System Inhibitor Injection Pump 2 30PBEMT073B


a) 28MCC026-04FE-CB1 Crude Oil System Inhibitor Injection Pump1 30PBEMT073A

i. No Load/ Directional rotation ii. Load Run b) 28MCC026-04FE-CB2 Crude Oil System Inhibitor Injection

Pump 2 30PBEMT073B

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i. No Load/ Directional rotation ii. Load Run


Boiler Crude Fuel Skid

42. Confirm availability of K1-11PHEA28PPAC0211-1J UPS supply for K1-13P-FPA43LAG258 Aft LER Boiler PLC Master Cabinet. Energize and record correct voltage and phasing @ incoming terminals.

a) Voltage b) Phasing

43. In conjunction with Instrument Commissioning Department power up Boiler PLC Master Cabinet as per manufacturers manual if available confirming all internal components are healthy.

44. Function test the correct operation of the following starter cubicles from 28MCC010 associated with Boiler Crude Fuel Skid.

a) 28MCC010-04F Crude Fuel Pump A 30PBEMT056A b) 28MCC010-04G Crude Fuel Pump B 30PBEMT056B

45. In conjunction with Instrument Commissioning Department confirm the correct Modbus / Devicenet signals for a Type 4 Motor Scheme for the following;

a) 28MCC010-04F Crude Fuel Pump A 30PBEMT056A b) 28MCC010-04G Crude Fuel Pump B 30PBEMT056B


a) 28MCC010-04F Crude Fuel Pump A 30PBEMT056A i. No Load/ Directional rotation ii. Load Run b) 28MCC010-04G Crude Fuel Pump B 30PBEMT056B i. No Load/ Directional rotation ii. Load Run


COTP Control Cabin Equipment

47. Confirm all Panel Board 28PPACDP0 out-going circuits are isolated.

48. Confirm that Distribution Box 28PPACDP0 incoming supply circuit FUA28MCC011-04G is available and ready to be energized.

49. Energize Panel Board 28PPACDP0 from FUA28MCC011-04G and verify correct phase rotation and voltage at FUA28PPACDP0-25Q1.

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50. Confirm transformer 40T3 is ready to be energized and breaker 40Q3 is open.

51. Energize transformer supply breaker 28PPACDP0-25F2 and verify correct phase rotation and voltage on the line side of transformer panel 40T3 breaker 40Q3.

52. Confirm with vendor that installation is complete and that all static checks have been completed prior to energization of Pressurization Control Panel IFA43LAG-PCP

53. Confirm Pressurization Control Panel 43LAG-PCP Power Supply circuit FUA28PPACDP0-25F3 input has been tested and is ready to be energized.

54. In conjunction with the Instrument Department energize Pressurization Control Panel IFA43LAG-PCP as per vendor documentation if available, ensuring everything is healthy and ready to accept loops.

55. Confirm Pressurization Control Panel IFA43LAG-PCP remote alarms, controls, and indicators have been tested and are fully functional.

56. Confirm with vendor that installation is complete and that all static checks have been completed prior to energization of Battery Room Ventilation Control Panel IFA43LAG-CPBRV

57. Confirm Battery Room Ventilation Control Panel IFA43LAG-CPBRV Power Supply circuit FUA28PPACDP0-25F4 input has been tested and is ready to be energized.

58. In conjunction with the Instrument Department energize Battery Room Ventilation Control Panel IFA43LAG-CPBRV as per vendor documentation if available, ensuring everything is healthy and ready to accept loops.

59. Confirm Battery Room Ventilation Control Panel IFA43LAG-CPBRV remote alarms, controls, and indicators have been tested and are fully functional.

60. Confirm all Panel Board FUA28PPACDP1 out-going circuits are isolated.

61. Confirm that FUA28PPACDP1 incoming supply circuit from panel 40T3 breaker 40Q3 is available and ready to be energized.

62. Energize Panel Board FUA28PPACDP1 and verify correct phase rotation and voltage.

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63. Confirm Battery Room Heater FCA27HEE-BRHTR is ready to be energized.

64. Energize Battery Room Heater FCA27HEE-BRHTR circuit FUA28PPACDP1-60F2 and verify correct heater operation.

65. Confirm Battery Room Lighting is ready to be energized.

66. Energize FUA28PPACDP1-60F3 and verify correct Battery Room lighting operation.

67. Confirm Control Cabin Lighting is ready to be energized.

68. Energize FUA28PPACDP1-60F5 and verify correct Control Cabin lighting operation.

69. Confirm Control Cabin Exit Lighting is ready to be energized.

70. Energize FUA28PPACDP1-60F6 and verify correct Control Cabin Exit lighting operation.

71. Energize FUA28PPACDP1-60F7 and verify supply to Gas Detection Panel

72. Verify transformer FUA31TRFMTPFDP2 is ready to be energized.

73. Confirm all Panel Board FUA28PPACDP2 out-going circuits are isolated.

74. Energize Panel Board FUA28PPACDP2 and verify correct phase rotation and voltage.

75. Confirm control cabin socket outlets are ready to be energized.

76. Energize FUA28PPACDP2-50F1 and verify correct control cabin socket outlets operation.

77. Confirm battery room socket outlets are ready to be energized.

78. Energize FUA28PPACDP2-50F5 and verify correct battery room socket outlets operation.

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13.3 Instrument Preparation Checklist

13.3 INSTRUMENT PREPARATION SIGNED DATE

1. Prior to commencement of Instrument Pre-commissioning confirm that all relevant Instrument MC ITRs are complete as identified in the System Commissioning Dossier. Ensure all ‘A’ punchlist items have been actioned and signed off as completed. Ensure ‘B’ punchlist items are minimized.

2. Confirm all Instrument As-Built drawings associated with this System have been included in the System Commissioning Dossier.


4. Confirm that the relevant sections of the PCS Procedure, application tests and associated logic function blocks are complete.

5. Confirm that the relevant sections of the PSD Procedure, application tests and associated logic function blocks are complete.

6. Confirm that the relevant sections of the ESD/ F&G Procedure, application tests and associated logic function blocks are complete.


7. Function test the correct operation of 43PC-0809 Diesel Return to the Hull Diesel Storage Tank pressure controller, including the pressure input from 43PT-0809, correct action of the controller (direct) and operation of 43PV-0809 pressure control valve.

8. Function test the correct operation of 43PC-0810 Diesel Supply to the GT Generator 1A pressure controller, including the pressure input from 43PT-0810, correct action of the controller (direct) and operation of 43PV-0810 pressure control valve.

9. Check the PCS logic to ensure that the liquid fuel for GT Generator 1A shall not exceed a peak to peak range of 69 kPa (10 psi) in 10 seconds at startup and 55 kPa (8 psi) in each minute after ignition.

10. Function test 43FT-0497 Diesel Supply to the GT Generator 1A flow transmitter to the UCP/PCS.

11. Function test the correct operation of 43FV-0530 Liquid Fuel Supply to the GT Generator 1A 3-way valve from the UCP/PCS, including 43FSZC0530 Crude selected indication and 4343FZSO-0530 Diesel selected indication.

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12. Function test the correct operation of 43XV-0785 Diesel Fuel Supply valve to the GT Generator 1A from the UCP/PCS, including the open and closed indications.

13. Function test the correct operation of 43PC-2810 Diesel Supply to the GT Generator 1B pressure controller, including the pressure input from 43PT-2810, correct action of the controller (reverse) and operation of 43PV-2810 pressure control valve.

14. Check the PCS logic to ensure that the liquid fuel for GT Generator 1B shall not exceed a peak to peak range of 69 kPa (10 psi) in 10 seconds at startup and 55 kPa (8 psi) in each minute after ignition.

15. Function test 43FT-2497 Diesel Supply to the GT Generator 1B flow transmitter to the UCP/PCS.

16. Confirm the correct setting of 43PCV-0787 diesel supply to module P5 end users, this is to be set at 689.0 kPa (g)

17. Function test the correct operation of 43FV-2530 Liquid Fuel Supply to the GT Generator 1B 3-way valve from the UCP/PCS, including 43FSZC2530 Crude selected indication and 4343FZSO-2530 Diesel selected indication.

18. Function test the correct operation of 43XV-2785 Diesel Fuel Supply valve to the GT Generator 1B from the UCP/PCS, including the open and closed indications.

60-FCA-001 Raw Crude Oil To/From Hull C.O.F. Tanks

19. Function test 43PT-0608 Raw Crude to 67PBE070A-B pressure transmitter to the PSD/PCS. This is to include the HH and LL trip set points and H alarm.

20. Function test 43TT-0428 Raw Crude to Hull COF Tanks temperature transmitter to the PSD/PCS. This is to include the HH and LL trip set points and H alarm.

Crude Oil Transfer Pumps

21. In conjunction with the Electrical Department confirm all associated power supplies are available for the Raw Crude Oil Heating and Transfer Unit Control Panel FCA-43LAG-358. Energize the panel as per Nuovo Pignone documentation if available, ensuring everything is healthy and ready to accept loops.

22. Connect the Modbus link between the UCP FCA-43LAG-358 and the PCS and ensure it is communicating correctly.

23. Complete all Instrumentation/ Logic checks between Raw Crude Oil Heating and Transfer Skid and the Control Panel 43LAG-358 as per the Commissioning Function Test Register and Nuovo Pignone Commissioning Procedure N. SOK-6615133/4.

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24. Function test the following hardwired signals between the Control Panel 43LAG-358 and PCS.

a) 43UA-0039 Common Trouble to PCS b) 43XI-0334 Run Status to PCS

25. Function test the following hardwired signals between the Control Panel 43LAG-358, ESD and PSD.

a) 43XY-0585 Treated Crude Feed Shutdown from PSD b) 43XY-0594 COW Package Shutdown from PSD c) 43XY-0694 Emergency Stop from ESD d) 43XS-0586 Treated Crude Feed Pkg Tripped to PSD e) 43XS-0595 COW Package PLC 1 WDT Tripped to PSD f) 43XS-0596 Treated Crude Package Tripped to PSD g) 43XS-0597 COW Package PLC 2 WDT Tripped to PSD h) 43XS-0599 COW Package PLC 3 WDT Tripped to PSD

26. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-070A Untreated Crude Oil Transfer Pump ‘A’ , to include all, Start / Stop / Running / Tripped / Available signals.

27. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-070B Untreated Crude Oil Transfer Pump ‘B’ , to include all, Start / Stop / Running / Tripped / Available signals.

28. Function test the Duty/ Standby logic of the Untreated Crude Oil Transfer Pumps from Control Panel 43LAG-358, a pressure drop of the pump in service should lead automatically to the start of the standby pump as per 4.2.2 of the NP Start-Up Procedures

29. Function test the following instrumentation associated with the Untreated Crude Oil Transfer Pumps A/B to UCP/HMI. Confirm HH/LL trip set-points and H/L alarm set-points.

a) 43PDT-0001 Untreated Crude Transfer Pump A DP b) 43PDT-0002 Untreated Crude Transfer Pump B DP c) 43PT-0001 Untreated Crude Transfer Pump A Disch. d) 43PT-0002 Untreated Crude Transfer Pump B Dich. e) 43PT-0051 Untreated Crude Header Pressure

30. Function test the correct operation of 43PC-0051 Raw Crude Oil Pressure Controller including input from 43PT-0051 and ensuring the correct operation Pressure Control Valve 43PV-0051. To include the open/ closed limit indications.

31. Confirm the correct setting of the following self regulating PCV’s located on the Crude Oil Heating and Transfer System.

a) 43PCV-0013 Inst Air to Skid Valves (550kPa) b) 43PCV-0014 Inst Air to Skid Valves (550kPa) c) 43PCV-0025 Inst Air to Skid Valves (550kPa) d) 43PCV-0026 Inst Air to Skid Valves (550kPa)

Crude Oil Heat Recovery & Heating Package

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32. Function test the correct operation of 43TC-0007 Cooling Medium Supply to Crude Washing Cooler 41HZZ-069A Controller including input from 43TT-0007 and ensuring the correct operation Temperature Control Valve 43TV-0004. To include the open/ closed limit indications.

33. Function test the correct operation of 43TC-0013 Cooling Medium Supply to Crude Washing Cooler 41HZZ-069B Controller including input from 43TT-0013 and ensuring the correct operation Temperature Control Valve 43TV-0003. To include the open/ closed limit indications.

34. Function test the correct operation of the following XV’s to/from the UCP/ PCS, to include the open/ closed limit indications.

a) 91XV-0101 Cooling Medium Supply to 41HZZ-069A b) 91XV-0102 Cooling Medium Supply to 41HZZ-069B c) 91XV-0103 Steam Supply to 41HZZ-060A d) 91XV-0104 Cond. Disch. Valve from 41HZZ-060A e) 91XV-0105 Steam Supply to 41HZZ-060B f) 91XV-0106 Cond. Disch. Valve from 41HZZ-060B g) 91XV-0090 Treated Crude to Hull COF Tanks

35. Function test the correct operation of 43LC-0001 Condensate Discharge Level Controller on Crude Heater 41HZZ-060A including inputs from 43LT-0001 and 43TT-0006. Ensure the correct operation Level Control Valve 43LV-0005, to include the open/ closed limit indications.

36. Function test the correct operation of 43LC-0002 Condensate Discharge Level Controller on Crude Heater 41HZZ-060B including inputs from 43LT-0002 and 43TT-0014. Ensure the correct operation Level Control Valve 43LV-0006, to include the open/ closed limit indications.

37. Function test the following instrumentation associated with the Untreated/Treated Crude Oil Recovery and Heating to UCP/HMI. Confirm HH/LL trip set-points and H/L alarm set-points.

a) 43PT-0050 Steam Supply Pressure b) 43PT-0005 Raw Crude Oil Heater Inlet Pressure c) 43TT-0046 Crude Heater 41HZZ-060B Outlet Temp d) 43TT-0045 Crude Heater 41HZZ-060A Outlet Temp

Wash Water Skid

38. In conjunction with the mechanical dept’s filling of the vessel, function test all the level instrumentation to PCS/PSD associated with 95ABJ-078 Wash Water Storage Tank. This includes 43LAHH-0013, 43LSH-0014 and 43LSL-0016, and all associated alarm/ trip points.

39. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-071A Water Wash Pump ‘A’ , to include all,

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Start / Stop / Running / Tripped / Available signals.

40. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-071B Water Wash Pump ‘B’ , to include all, Start / Stop / Running / Tripped / Available signals.

41. Function test the Duty/ Standby logic of the Water Wash Pump from Control Panel 43LAG-358, in case of any failure during operation, the duty pump the standby pump should start as per 6.0 of the NP Start-Up Procedures


a) 91XV-0107 Demin Water Supply Valve b) 91XV-0108 Steam Supply Valve to 41HZZ-061A c) 91XV-0109 Condensate Discharge from 41HZZ-061A d) 91XV-0110 Steam Supply Valve to 41HZZ-061B e) 91XV-0111 Condensate Discharge from 41HZZ-061B

43. Function test the correct operation of 43LC-0003 Condensate Discharge Level Controller on Wash Water Heater 41HZZ-061A including inputs from 43LT-0003 and 43TT-0017. Ensure the correct operation Level Control Valve 43LV-0007, to include the open/ closed limit indications.

44. Function test the correct operation of 43LC-0004 Condensate Discharge Level Controller on Wash Water Heater 41HZZ-061B including inputs from 43LT-0004 and 43TT-0016. Ensure the correct operation Level Control Valve 43LV-0008, to include the open/ closed limit indications.

45. Function test the following instrumentation associated with the Wash Water Skid to UCP/HMI. Confirm HH/LL trip set-points and H/L alarm set-points.

a) 43PT-0004 Wash Water Pump A Disc. Pressure b) 43PT-0006 Steam Supply Header Pressure c) 43PT-0007 Wash Water Pump B Disc. Pressure d) 43TT-0015 Condensate Discharge on Steam A e) 43TT-0018 Condensate Discharge on Steam B

Crude Oil Washing Line 1 Centrifuge 1

46. In conjunction with the Electrical Department confirm all associated power supplies are available for the Line 1 Crude Oil Washing Unit Control Panel FCA-43LAG-356. Energize the panel as per Nuovo Pignone documentation if available, ensuring everything is healthy and ready to accept loops.


48. Complete all Instrumentation/ Logic checks between Crude Oil Washing Line 1 Centrifuge 1 Unit and the Control Panel 43LAG-356

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as per the Commissioning Function Test Register and Nuovo Pignone Commissioning Procedure N. SOK-6615133/4.

49. In conjunction with Electrical Commissioning Department connect the serial link between the UCP FCA-43LAG-356 and the Variable Frequency Drive for 34ZAK-040A Line 1 Oil Washing Centrifuge 1. Ensure it is communicating correctly and check all signals utilized via this link.

50. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 34ZAK-040A Line 1 Oil Washing Centrifuge 1. This is a variable frequency drive and is to include the following signals,

a) 43SI-0004 Centrifuge 1 Speed Indication b) 43IA-0004 Current Measuring Centrifuge 1 c) 43TI-0004 Motor Temp. Centrifuge 1 d) 43XSH-0004 Vibration Centrifuge 1 e) 43TI-0062 Centrifuge 1 Temperature f) 4-20mA Control of the drive.

.

51. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-140A Line 1 Lube Oil Pump 1, to include all, Start / Stop / Running / Tripped / Available signals.

52. Function test 43FS-0001 Low Flow Lube Oil Pump Discharge Line 1 LO Unit 1 to the UCP/ PCS. This is to include the LL trip set point.

53. Function test 43LS-0001 Low Level in Lube Oil Tank Line 1 LO Unit 1 to the UCP/ PCS. This is to include the LL trip set point.

54. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-142A Line 1 Sludge Pump 1, to include all, Start / Stop / Running / Tripped / Available signals.

55. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 34MIX-001A Line 1 Mixer 1, to include all, Start / Stop / Running / Tripped / Available signals.

56. In conjunction with the mechanical dept’s filling of the vessel, function test all the level instrumentation to PCS/PSD associated with 95ABJ-048A Line 1 Crude Oil Washing Sludge Tank 1. This includes 43LAHH-0003, 43LSH-0002 and 43LSL-0001, and all associated alarm/ trip points.


a) 91XV-0011 Wash Water Supply Header b) 91XV-0012 Wash Water to Mixer 1 c) 91XV-0013 Operating Water to Centrifuge 1 d) 91XV-0014 Operating Water to Centrifuge 1

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e) 91XV-0015 Operating Water to Centrifuge 1 f) 91XV-0052 Wash Water Return from Centrifuge 2 g) 91XV-0091 Nitrogen Supply Header h) 91XV-0093 Raw Crude Supply to Centrifuge 1 i) 91XV-0112 Raw Crude Supply to Mixer 1 j) 91XV-0113 Sealing Water to Centrifuge 1 k) 91XV-0114 Nitrogen to Crude Tank 1 l) 91XV-0115 Nitrogen to Centrifuge 1 m) 91XV-0116 Waste Water Discharge fm Centrifuge 1 n) 91XV-0117 Nitrogen Outlet to Vent Centrifuge 1 o) 91XV-0118 Nitrogen Outlet to Vent Tank 1 p) 91XV-0119 Crude Oil to Centrifuge 2

58. Function test the following instrumentation associated with the Crude Oil Washing Line 1 Centrifuge 1 to UCP/HMI. Confirm HH/LL trip set-points and H/L alarm set-points.

a) 43PDT-0004 Nitrogen Outlet to Vent Centrifuge 1 b) 43FT-0002 Raw Crude Supply c) 43FT-0003 Wash Water Supply d) 43FT-0009 Wash Water to Mixer 2 e) 43FT-0015 Sealing Water Supply Flow f) 43PT-0010 Operating Water Supply g) 43PT-0011 Wash Water Supply Header h) 43PT-0012 Raw Crude Supply i) 43PT-0013 Sealing Water from Line 1 Centrifuge 1 j) 43PT-0014 Nitrogen Supply k) 43PT-0015 Line 1 Sludge Tank 1 Oil Pressure l) 43PT-0016 Produced Water from Line 1 Centrifuge 1 m) 43PT-0017 Crude Oil to Centrifuge 2 n) 43PT-0018 Nitrogen Outlet to Vent o) 43TT-0021 Wash Water Supply Temperature p) 43TT-0024 Raw Crude to Centrifuge 1 Temperature


a) 43PCV-0015 Inst Air to Line 1 Sludge Pump 1 (600kPa) b) 43PCV-0016 Operating Water to Centrifuge 2 (400kPa) c) 43PCV-0017 Wash Water to Mixer 2 (400kPa) d) 43PCV-0018 Nitrogen Supply to Centrifuge 1 (400kPa) e) 43PCV-0019 Nitrogen Supply to Centrifuge 1 (25kPa) f) 43PCV-0020 Nitrogen Supply to Vent (35kPa) g) 43PCV-0021 Sealing Water to Mixer 1 (300kPa)


60. Complete all Instrumentation/ Logic checks between Crude Oil Washing Line 1 Centrifuge 2 Unit and the Control Panel 43LAG-356 as per the Commissioning Function Test Register and Nuovo Pignone Commissioning Procedure N. SOK-6615133/4.

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61. In conjunction with Electrical Commissioning Department connect the serial link between the UCP FCA-43LAG-356 and the Variable Frequency Drive for 34ZAK-041A Line 1 Oil Washing Centrifuge 2. Ensure it is communicating correctly and check all signals utilized via this link.

62. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 34ZAK-041A Line 1 Oil Washing Centrifuge 2. This is a variable frequency drive and is to include the following signals,


63. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-141A Line 1 Lube Oil Pump 2, to include all, Start / Stop / Running / Tripped / Available signals.



66. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-143A Line 1 Sludge Pump 2, to include all, Start / Stop / Running / Tripped / Available signals.

67. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 34MIX-002A Line 1 Mixer 2, to include all, Start / Stop / Running / Tripped / Available signals.

68. In conjunction with the mechanical dept’s filling of the vessel, function test all the level instrumentation to PCS/PSD associated with 95ABJ-049A Line 1 Crude Oil Washing Sludge Tank 2. This includes 43LAHH-0004, 43LSH-0005 and 43LSL-0006, and all associated alarm/ trip points.


a) 91XV-0016 Operating Water to Centrifuge 2 b) 91XV-0017 Operating Water to Centrifuge 2 c) 91XV-0018 Operating Water to Centrifuge 2 d) 91XV-0094 Raw Crude Supply to Centrifuge 2 e) 91XV-0121 Sealing Water to Centrifuge 2 f) 91XV-0147 Nitrogen to Crude Tank 2

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g) 91XV-0122 Nitrogen to Centrifuge 2 h) 91XV-0120 Waste Water Discharge fm Centrifuge 2 i) 91XV-0123 Nitrogen Outlet to Vent Centrifuge 2 j) 91XV-0125 Nitrogen Outlet to Vent Tank 2 k) 91XV-0124 Treated Crude to Heat Recovery l) 91XV-0149 Treated Crude to Heat Recovery


a) 43PDT-0005 Nitrogen Outlet to Vent Centrifuge 2 b) 43FT-0005 Sealing Water Supply Flow c) 43PT-0052 Sealing Water from Line 1 Centrifuge 2 d) 43PT-0023 Line 1 Sludge Tank 2 Oil Pressure e) 43PT-0020 Produced Water from Line 1 Centrifuge 2 f) 43PT-0021 Treated Crude Line 1 Centrifuge 2 Disch. g) 43PT-0022 Nitrogen Outlet to Vent h) 43TT-0025 Raw Crude to Centrifuge 2 Temperature


a) 43PCV-0011 Nitrogen Supply to Vent (35kPa) b) 43PCV-0022 Inst Air to Line 1 Sludge Pump 1 (600kPa) c) 43PCV-0023 Sealing Water to Mixer 1 (300kPa)


72. In conjunction with the Electrical Department confirm all associated power supplies are available for the Line 2 Crude Oil Washing Unit Control Panel FCA-43LAG-357. Energize the panel as per Nuovo Pignone documentation if available, ensuring everything is healthy and ready to accept loops.



75. In conjunction with Electrical Commissioning Department connect the serial link between the UCP FCA-43LAG-357 and the Variable Frequency Drive for 34ZAK-040B Line 2 Oil Washing Centrifuge 1. Ensure it is communicating correctly and check all signals utilized via this link.

76. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 34ZAK-040B Line 2 Oil Washing Centrifuge 1. This is a variable frequency drive and is to include the following signals,

Revision Date:

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.

77. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-140B Line 2 Lube Oil Pump 1, to include all, Start / Stop / Running / Tripped / Available signals.



80. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-142B Line 2 Sludge Pump 1, to include all, Start / Stop / Running / Tripped / Available signals.

81. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 34MIX-001B Line 2 Mixer 1, to include all, Start / Stop / Running / Tripped / Available signals.

82. In conjunction with the mechanical dept’s filling of the vessel, function test all the level instrumentation to PCS/PSD associated with 95ABJ-048B Line 2 Crude Oil Washing Sludge Tank 1. This includes 43LAHH-0007, 43LSH-0008 and 43LSL-0009, and all associated alarm/ trip points.


a) 91XV-0024 Wash Water Supply Header b) 91XV-0025 Wash Water to Mixer 1 c) 91XV-0019 Operating Water to Centrifuge 1 d) 91XV-0020 Operating Water to Centrifuge 1 e) 91XV-0026 Operating Water to Centrifuge 1 f) 91XV-0097 Wash Water Return from Centrifuge 2 g) 91XV-0096 Nitrogen Supply Header h) 91XV-0098 Raw Crude Supply to Centrifuge 1 i) 91XV-0126 Raw Crude Supply to Mixer 1 j) 91XV-0127 Sealing Water to Centrifuge 1 k) 91XV-0128 Nitrogen to Crude Tank 1 l) 91XV-0133 Nitrogen to Centrifuge 1 m) 91XV-0129 Waste Water Discharge fm Centrifuge 1 n) 91XV-0131 Nitrogen Outlet to Vent Centrifuge 1 o) 91XV-0130 Nitrogen Outlet to Vent Tank 1 p) 91XV-0132 Crude Oil to Centrifuge 2

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a) 43PDT-0006 Nitrogen Outlet to Vent Centrifuge 1 b) 43FT-0007 Raw Crude Supply c) 43FT-0008 Wash Water Supply d) 43FT-0010 Wash Water to Mixer 2 e) 43FT-0001 Sealing Water Supply Flow f) 43PT-0026 Operating Water Supply g) 43PT-0027 Wash Water Supply Header h) 43PT-0028 Raw Crude Supply i) 43PT-0034 Sealing Water from Line 2 Centrifuge 1 j) 43PT-0029 Nitrogen Supply k) 43PT-0030 Line 2 Sludge Tank 1 Oil Pressure l) 43PT-0031 Produced Water from Line 2 Centrifuge 1 m) 43PT-0032 Crude Oil to Centrifuge 2 n) 43PT-0033 Nitrogen Outlet to Vent o) 43TT-0027 Wash Water Supply Temperature p) 43TT-0028 Raw Crude to Centrifuge 1 Temperature


a) 43PCV-0027 Inst Air to Line 2 Sludge Pump 1 (600kPa) b) 43PCV-0028 Operating Water to Centrifuge 2 (400kPa) c) 43PCV-0029 Wash Water to Mixer 2 (400kPa) d) 43PCV-0030 Nitrogen Supply to Centrifuge 1 (400kPa) e) 43PCV-0031 Nitrogen Supply to Centrifuge 1 (25kPa) f) 43PCV-0032 Nitrogen Supply to Vent (35kPa) g) 43PCV-0033 Sealing Water to Mixer 1 (300kPa)



87. In conjunction with Electrical Commissioning Department connect the serial link between the UCP FCA-43LAG-357 and the Variable Frequency Drive for 34ZAK-041B Line 2 Oil Washing Centrifuge 2. Ensure it is communicating correctly and check all signals utilized via this link.

88. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 34ZAK-041B Line 2 Oil Washing Centrifuge 2. This is a variable frequency drive and is to include the following signals,

a) 43SI-0002 Centrifuge 2 Speed Indication b) 43IA-0002 Current Measuring Centrifuge 2 c) 43TI-0002 Motor Temp. Centrifuge 2 d) 43XSH-0002 Vibration Centrifuge 2

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e) 43TI-0065 Centrifuge 2 Temperature f) 4-20mA Control of the drive.

89. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-141B Line 2 Lube Oil Pump 2, to include all, Start / Stop / Running / Tripped / Available signals.



92. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-143B Line 2 Sludge Pump 2, to include all, Start / Stop / Running / Tripped / Available signals.

93. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 34MIX-002B Line 2 Mixer 2, to include all, Start / Stop / Running / Tripped / Available signals.

94. In conjunction with the mechanical dept’s filling of the vessel, function test all the level instrumentation to PCS/PSD associated with 95ABJ-049B Line 2 Crude Oil Washing Sludge Tank 2. This includes 43LAHH-0010, 43LSH-0011 and 43LSL-0012, and all associated alarm/ trip points.


a) 91XV-0021 Operating Water to Centrifuge 2 b) 91XV-0022 Operating Water to Centrifuge 2 c) 91XV-0023 Operating Water to Centrifuge 2 d) 91XV-0099 Raw Crude Supply to Centrifuge 2 e) 91XV-0135 Sealing Water to Centrifuge 2 f) 91XV-0148 Nitrogen to Crude Tank 2 g) 91XV-0136 Nitrogen to Centrifuge 2 h) 91XV-0134 Waste Water Discharge fm Centrifuge 2 i) 91XV-0137 Nitrogen Outlet to Vent Centrifuge 2 j) 91XV-0139 Nitrogen Outlet to Vent Tank 2 k) 91XV-0100 Treated Crude to Heat Recovery l) 91XV-0138 Treated Crude to Heat Recovery


a) 43PDT-0003 Nitrogen Outlet to Vent Centrifuge 2 b) 43FT-0016 Sealing Water Supply Flow c) 43PT-0035 Sealing Water from Line 2 Centrifuge 2 d) 43PT-0039 Line 2 Sludge Tank 2 Oil Pressure e) 43PT-0036 Produced Water from Line 2 Centrifuge 2 f) 43PT-0037 Treated Crude Line 2 Centrifuge 2 Disch. g) 43PT-0038 Nitrogen Outlet to Vent h) 43TT-0031 Raw Crude to Centrifuge 2 Temperature

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a) 43PCV-0034 Nitrogen Supply to Vent (35kPa) b) 43PCV-0035 Inst Air to Line 1 Sludge Pump 1 (600kPa) c) 43PCV-0024 Sealing Water to Mixer 1 (300kPa)

Raw Crude Demulsifier / Coolers

98. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-076A Demulsifier Injection Pump A, to include all, Start / Stop / Running / Tripped / Available signals.

99. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-076B Demulsifier Injection Pump B, to include all, Start / Stop / Running / Tripped / Available signals.

100. Function test the Duty/ Standby logic of the Demulsifier Injection Pumps from Control Panel, as per 7.10 of the NP Start-Up Procedures

101. Function test 43LT-0036 Demulsifier Tote Tank Level to UCP/HMI, to include the low alarm point.

102. Function test 43FT-0001 Demulsifier to Raw Crude flow transmitter to the UCP/HMI. This is to include the HH and LL trip set points.

103. Function test 43TT-0414 Treated Crude to Hull Crude Tanks temperature transmitter to the PCS/HMI. This is to include the H/L alarm set points.

104. Function test 43PT-0989 Treated Crude from Hull Crude Tanks pressure transmitter to the PSD/ PCS. This is to include the HH/LL trip set points.


105. Complete all Instrumentation/ Logic checks between Treated Crude Oil Forwarding Skid and the Control Panel 43LAG-358 as per the Commissioning Function Test Register and Nuovo Pignone Commissioning Procedure N. SOK-6615133/4.

106. Function test 43PT-043/044 instrument air supply pressure transmitters to UCP/ HMI, to include the HH/LL trip set-points.


a) 43PCV-0001 Inst Air to Skid Valves (550kPa) b) 43PCV-0002 Inst Air to Skid Valves (550kPa)

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108. Function test 43PDT-003/004 Suction Strainers differential pressure transmitters to UCP/ HMI, to include the high alarm.

109. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-072A Treated Crude Forwarding Pump A, to include all, Start / Stop / Running / Tripped / Available signals.

110. Function test 43PT-0040 Pump A Discharge pressure transmitter to UCP/ HMI, to include the HH/LL trip set-points.

111. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-072B Treated Crude Forwarding Pump B, to include all, Start / Stop / Running / Tripped / Available signals.

112. Function test 43PT-0041 Pump B Discharge pressure transmitter to UCP/ HMI, to include the HH/LL trip set-points.

113. Function test the correct operation of 43PC-0039 Treated Crude Return to Treated Crude COF Tanks pressure controller including input from 43PT-0042 and ensuring the correct operation of Control Valve 43PV-00042. To include the open/close limit indications back to UCP/ HMI

114. Function test the correct operation of 43LC-0039 Forwarding Filter A Drain to Condensate System level controller including inputs from 43LT-0005/43TT-0039 and ensuring the correct operation of Control Valve 43LV-0009. To include the open/close limit indications back to UCP/ HMI

115. Function test the correct operation of 43LC-0038 Forwarding Filter B Drain to Condensate System level controller including inputs from 43LT-0006/43TT-0038 and ensuring the correct operation of Control Valve 43LV-0010. To include the open/close limit indications back to UCP/ HMI


a) 91XV-0040 Steam Supply Valve to Forwarding Filter A b) 91XV-0042 Steam Supply Valve to Forwarding Filter B c) 91XV-0044 Oily Sludge Discharge from Filter A d) 91XV-0045 Oily Sludge Discharge from Filter B e) 91XV-0041 Cond Outlet from Forwarding Fliter A f) 91XV-0043 Cond Outlet from Forwarding Fliter A g) 91XV-0046 Treated Crude oil return


a) 43PDS-0001 Treated Crude Suction Filter A DP b) 43PDS-0002 Treated Crude Suction Filter B DP c) 43FT-0061 Treated Crude Suction Flow d) 43PT-0045 Steam Supply to Filters e) 43PT-0046 Treated Crude Suct to Forwarding Filters f) 43TT-0040 Treated Crude Suction to Power Gen g) 43TT-0041 Cond Discharge from Forwarding Filter A

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h) 43TT-0042 Cond Discharge from Forwarding Filter A

Treated Crude Demulsifier

118. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-073A Inhibitor Injection Pump A, to include all, Start / Stop / Running / Tripped / Available signals.

119. In conjunction with Electrical Commissioning Department complete interface checks between the UCP, PCS and MCC for 67PBE-073B Inhibitor Injection Pump B, to include all, Start / Stop / Running / Tripped / Available signals.

120. Function test 43LT-0334 Inhibitor Tote Tank Level to UCP/HMI, to include the low alarm point.

121. Function test 43FT-0080 Inhibitor to Treated Crude Static Mixer flow transmitter to the UCP/HMI. This is to include the H and L alarm set points.

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14.0 DYNAMIC TESTS This section covers the start-up and operational testing for the Dynamic Commissioning of the System 60 & 62-FCA Crude Oil & Diesel Fuels. As each item in this procedure is satisfactorily completed it shall be signed and dated as accepted by the appropriate commissioning engineer.

Operating Tests Operating tests in Bold Text are deemed Safety Critical and require both witness and signature by the Certifying Authority (DNV). Advanced notice of the tests should be given to the relevant parties involved to avoid having to repeat the tests at a later date. Prior to commencing any operating tests confirm that all safety precautions have been taken and that relevant Permit to work has been issued. Overall Start Procedure Ensure prior to commencing operating tests the personnel involved in the tests familiarize themselves fully with the system description section 9.0 and understand the complete system operation. As-Builts Any as builts drawings produced at this stage should be actioned through the correct Project Procedure and a copy retained in the System Commissioning Dossier.

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14.1 System Operating Tests

14.1 SYSTEM OPERATING TESTS SIGNED DATE

Crude Treatment Package

1. All the following actions associated with running equipment associated with the treated crude forwarding skid are to be controlled automatically by the PLC.

2. Confirm that instrument air pressure on the package is regulated to 550 kPa(g) as seen by i. Line 1: 43PT0009 by reducing valve 43PRV0013 or 43PRV0014 ii. Line 2: 43PT0025 by reducing valve 43PRV0025 or 43PRV0026

3. Line out the untreated crude transfer pumps 67PBE070 A/B to take suction from the Hull COF tank and then establish a closed loop from the pump(s) discharge, through the heat recovery and heating package, by-passing the crude oil wash line centrifuges at the 3-way valves listed below and returning back to the suction side of the transfer pumps. i. Crude oil washing line 1 – 3-way valve 91XV0093 ii. Crude oil washing line 2 – 3-way valve 91XV0096

4. Confirm that steam of a minimum pressure of 931 kPa(g) is available at the inlet of the crude auxiliary heaters 41HZZ060 A/B. Keep the manual isolation valves for steam supply and condensate closed at this point.

5. Confirm that cooling medium of a pressure range 900 to 1200 kPa(g) is available at the inlet of the crude wash coolers 41HZZ069 A/B.

6. Select at the PLC and line out the following equipment to operate as Line 1; i. Crude oil Transfer pump 67PBE070A ii. Crude washing cooler 41HZZ069A iii. Untreated/treated crude cross exchanger 41HZZ062A iv. Crude auxiliary heater 41HZZ060A v. Crude oil washing line 1

7. Start crude oil transfer pump 67PBE070A from the control panel. Use the manual throttle valve in the common pump discharge line to provide a back pressure on the pump as seen at 43PT0051 and a suction pressure slightly higher than atmospheric as seen on 43PG0001.

8. Adjust control valve 43PV0001 to a pressure level that induces a flow rate of 30 m3/hr, as seen at flow transmitter 43FT0002

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upstream of the Line 1 mixer 1 34MIX001A.

9. Confirm that once the minimum flow requirements are achieved that steam supply valve 91XV0103 opens. Slowly open the manual steam supply valve and drain any condensate from the supply line. Slowly open the manual condensate valve and drain any condensate from the heater.

10. Confirm that condensate valve 91XV0104 opens once a condensate level of 50% ‘High Level’ in the heater is achieved.

11. Confirm that automatic temperature control starts simultaneously with valve 91XV0104 opening and control valve 43LV0005 maintains the oil discharge temperature at 98 0C.

12. Select at the PLC and line out the following equipment to operate as Line 2; i. Crude oil Transfer pump 67PBE070B ii. Crude washing cooler 41HZZ069B iii. Untreated/treated crude cross exchanger 41HZZ062B iv. Crude auxiliary heater 41HZZ060B v. Crude oil washing line 2

13. Start crude oil transfer pump 67PBE070B from the control panel. Use the manual throttle valve in the common pump discharge line to provide a back pressure on the pump as seen at 43PT0051 and a suction pressure slightly higher than atmospheric as seen on 43PG0002.

14. Adjust control valve 43PV0001 to a pressure level that induces a flow rate of 30 m3/hr, as seen at flow transmitter 43FT0007 upstream of the Line 2 mixer 1 34MIX001B.




Wash Water Package

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18. Confirm that demineralized water supply for make-up water to the storage tank 95ABJ078 is available and that the level in the tank is above the LSH (1010mm) as seen at 43LSH014.

19. Confirm that instrument air pressure is available on the package at 550 kPa(g) as seen at 43PG0010.

20. Confirm that steam of a minimum pressure of 931 kPa(g) is available at the inlet of the wash water heaters 41HZZ061 A/B. Keep the manual isolation valves for steam supply and condensate closed at this point.

21. Select wash water pump 67PBE071A to start and wash water heater 41HZZ061A to be in service.

22. Throttle in the manual valve in the pump discharge return line to the storage tank until a discharge pressure of approximately 500 kPa(g) is seen at 43PT0004. record the pressure; Pump discharge pressure __________kPa(g)

23. Confirm the steam supply valve 91XV0108 has opened by activation from the PLC. Slowly open the manual steam supply valve and drain any condensate from the supply line. Slowly open the manual condensate valve and drain any condensate from the heater.



26. Select wash water pump 67PBE071B to start and wash water heater 41HZZ061B to be in service.

27. Throttle in the manual valve in the pump discharge return line to the storage tank until a discharge pressure of approximately 500 kPa(g) is seen at 43PT0007. record the pressure; Pump discharge pressure __________kPa(g)

28. Confirm the steam supply valve 91XV0110 has opened by activation from the PLC. Slowly open the manual steam supply valve and drain any condensate from the supply line. Slowly open the manual condensate valve and drain any condensate from the heater.


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31. Confirm the auto-start function of the selected standby pump by the PLC when a failure of the selected running duty pump is initiated. Confirm for the following configurations; i. Duty pump: 67PBE071A Standby pump:67PBE071B ii. Duty pump: 67PBE071B Standby pump:67PBE071A

32. During the operation of the wash water system, observe the level of water in the storage tank and confirm the correct functioning of the following; i. Falling water level seen at 43LSL0015, filling valve 91XV0107 opens ii. Rising water level seen at 43LSH0014, filling valve 91XV0107 closes


33. Prepare the centrifuges 35ZAK040A & 35ZAK041A of washing line1 for running; i. Confirm instrument air pressure at transmitter 43PT0009 is 550 kPa(g). ii. Confirm sludge water tanks 95ABJ048A & 95ABJ049A are blanketed with nitrogen at a pressure of 25 kPa(g) at transmitter 43PT0014 for line 1. iii. Check correct level of lube oil in the lube oil tanks and start the lube oil pumps 67PBE140A & 67PBE141A confirming the flow. iv. Confirm a supply of seal water through the sealing water supply panel and verify 43PT0013/0052 and 43FS0015/0005 supplying centrifuges 35ZAK040A and 35ZAK041A display an operating pressure of 250 kPa(g) and a flow of 300 ltrs/hr.

34. Establish a flow of wash water from the wash water skid to mixing tanks 34MIX001A & 34MIX002A.

35. Start centrifuge motor 35ZAKMT040A, confirm at centrifuge start speed of approximately 1000 rpm that the lube oil unit is started and flow switch 43FS0001 correctly monitors a 1 ltr/hr supply to the centrifuge and the returning oil has an unobstructed flow back to the lube oil unit tank.

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36. Confirm the correct flow and pressure of the sealing water supply at 43PT0013 and 43FT0015 located on the supply panel and readjust if necessary. Pressure: High – 400 kPa(g) Low – 100 kPa(g) Operation – 250 kPa(g)

Flow: High – Hold Low – 200 ltr/hr Operation – 300 ltr/hr

37. As soon as the centrifuge has reached its full speed, the hydraulic system of the bowl opening and closing mechanism must be filled as follows:

i. The operating water supply valve for the opening of the bowl in open for approximately 15 seconds.

ii. After that, the operating water supply valve for the bowl closing is open for approximately 10 seconds.

iii. The centrifuge is now ready for separation after a speed recovery time of approximately 20 seconds.

iv. The closing water valve is open every 10 minutes to compensate any loss of closing water in the hydraulic system of the bowl.

v. Confirm the correct bowl speed – 4750 rpm.

38. The 35ZAKMT040A centrifuge is now ready for separation.

39. Start centrifuge motor 35ZAKMT041A, confirm at centrifuge start speed of approximately 1000 rpm that the lube oil unit is started and flow switch 43FS0002 correctly monitors a 1 ltr/hr supply to the centrifuge and the returning oil has an unobstructed flow back to the lube oil unit tank.

40. Confirm the correct flow and pressure of the sealing water supply at 43PT0052 and 43FS0005 located on the supply panel and readjust if necessary. Pressure: High – 400 kPa(g) Low – 100 kPa(g) Operation – 250 kPa(g)


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42. The 35ZAKMT041A centrifuge is now ready for separation.


43. Prepare the centrifuges 35ZAK040B & 35ZAK041B of washing line

2 for running; i. Confirm instrument air pressure at transmitter 43PT0025 is 550

kPa(g) ii. Confirm sludge water tanks 95ABJ048B & 95ABJ049B are

blanketed with nitrogen at a pressure of 25 kPa(g) 43PT0029 for line 2.

iii. Check correct level of lube oil in the lube oil tanks and start the lube oil pumps 67PBE140B & 67PBE141B confirming the flow

iv. Confirm a supply of seal water through the sealing water supply panel and verify 43PT0034/0035 and 43FS0001/0016 supplying centrifuges 35ZAK040B and 35ZAK041B display an operating pressure of 250 kPa(g) and a flow of 300 ltrs/hr.

44. Establish a flow of wash water from the wash water skid to mixing tanks 34MIX001B & 34MIX002B.

45. Start centrifuge motor 35ZAKMT040B, confirm at centrifuge start speed of approximately 1000 rpm that the lube oil unit is started and flow switch 43FS0003 correctly monitors a 1 ltr/hr supply to the centrifuge and the returning oil has an unobstructed flow back to the lube oil unit tank.

46. Confirm the correct flow and pressure of the sealing water supply at 43PT0034 and 43FT0001 located on the supply panel and readjust if necessary. Pressure:

High – 400 kPag Low – 100 kPag

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Operation – 250 kPag








48. The 35ZAKMT040B centrifuge is now ready for separation.

49. Start centrifuge motor 35ZAKMT041B, confirm at centrifuge start speed of approximately 1000 rpm that the lube oil unit is started and flow switch 43FS0004 correctly monitors a 1 ltr/hr supply to the centrifuge and the returning oil has an unobstructed flow back to the lube oil unit tank.

50. Confirm the correct flow and pressure of the sealing water supply at 43PT0035 and 43FT0016 located on the supply panel and readjust if necessary. Pressure:

High – 400 kPag Low – 100 kPag Operation – 250 kPag




ii. After that, the operating water supply valve for the bowl closing

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is open for approximately 10 seconds. iii. The centrifuge is now ready for separation after a speed

recovery time of approximately 20 seconds. iv. The closing water valve is open every 10 minutes to

compensate any loss of closing water in the hydraulic system of the bowl.


52. The 35ZAKMT041B centrifuge is now ready for separation.

Demulsifier Injection Pumps A/B

53. Line out the demulsifier injection system from pump 67PBE076A to the untreated crude transfer pump discharge line. Start the pump with the stroke at 95% and then increase to 100%. Using the calibration pot, record the pump discharge flow rate at the following adjusted stroke settings; 100% Stroke, Flow recorded: (Lt/s) (gpm) 75% Stroke, Flow recorded: (Lt/s) (gpm) 50% Stroke, Flow recorded: (Lt/s) (gpm) 25% Stroke, Flow recorded: (Lt/s) (gpm) 10% Stroke, Flow recorded: (Lt/s) (gpm)

54. Line out the demulsifier injection system from pump 67PBE076B to the untreated crude transfer pump discharge line. Start the pump with the stroke at 95% and then increase to 100%. Using the calibration pot, record the pump discharge flow rate at the following adjusted stroke settings; 100% Stroke, Flow recorded: (Lt/s) (gpm) 75% Stroke, Flow recorded: (Lt/s) (gpm) 50% Stroke, Flow recorded: (Lt/s) (gpm) 25% Stroke, Flow recorded: (Lt/s) (gpm) 10% Stroke, Flow recorded: (Lt/s) (gpm)

55. Confirm that the demulsifier injection pumps 67PBE073 A/B will only operate in automatic mode as controlled by the PLC when; i. The 3/2-way valve 43XY0093 of centrifuge 1 – line 1 leads oil into the centrifuge 35ZAK040A with a flow seen at 43FT002 ii The 3/2-way valve 43XY0098 of centrifuge 1 – line 2 leads oil into the centrifuge 35ZAK040B with a flow seen at 43FT007


56. All the following actions associated with running equipment associated with the treated crude forwarding skid are to be controlled automatically by the PLC.

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57. Confirm that instrument air pressure on the package as seen at 43PT0043 is regulated to 550 kPa (g) by reducing valve 43PRV0001 or 43PRV0002.

58. Line out the treated crude forwarding package to take suction from the Hull COF tank and routing the discharged fluid back to the Hull COF tank via the treated crude oil return line and by-passing the crude oil supply to the power generation.

59. Confirm that steam of a minimum pressure of 931 kPa(g) is available at the inlet of the forwarding heaters 41HZZ052 A/B. Keep the manual isolation valves for steam supply and condensate closed at this point.

60. Select pre-heater 41HZZ052A for operation with self-cleaning filter 35MAJ051A.

61. Start forwarding pump 67PBE072A from the control panel. Use the manual throttle valve in the common pump discharge line to provide a back pressure on the pump as seen at 43PT0042 and a suction pressure slightly higher than atmospheric as seen on 43PG 0028.

62. Adjust control valve 43PV0002 to a pressure level that induces a flow rate of 30 m3/hr, as seen at flow transmitter 43FT0061 upstream of the static mixer.




66. Check the function of self-cleaning filter 35MAJ051A by initiating a high differential pressure on 43PDS0001 and confirm the following; i. Correct adjustment for timers for cleaning cycle ii. Correct adjustment for timers for pulse lengthener iii. Correct adjustment for timers for dump cycle

67. Stop the ‘Line A’ forwarding skid equipment in operation through the PLC.

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68. Select pre-heater 41HZZ052B for operation with self-cleaning filter 35MAJ051B.

69. Start forwarding pump 67PBE072B from the control panel. Check the system back pressure on 43PT0042 and if required use the manual throttle valve in the common pump discharge line to provide a back pressure on the pump as seen at and a suction pressure slightly higher than atmospheric as seen on 43PG 0029.

70. Check the flow rate of 30 m3/hr, as seen at flow transmitter 43FT0061 upstream of the static mixer still exists. Adjust 43PV002 as necessary.




74. Check the function of self-cleaning filter 35MAJ051B by initiating a high differential pressure on 43PDS0002 and confirm the following; i. Correct adjustment for timers for cleaning cycle ii. Correct adjustment for timers for pulse lengthener iii. Correct adjustment for timers for dump cycle

Treated Crude Inhibitor

75. Confirm the loading of the tote tank in the designated bay and correct fitment of inhibitor chemical specific hoses;

i. EI/13P-0079 ii. EI/13P-0085

76. Line out the treated crude inhibitor injection system from pump 67PBE073A to the treated crude static mixer. Start the pump with the stroke at 95% and then increase to 100%. Using the calibration pot, record the pump discharge flow rate at the following adjusted stroke settings; 100% Stroke, Flow recorded: (Lt/s) (gpm) 75% Stroke, Flow recorded: (Lt/s) (gpm) 50% Stroke, Flow recorded: (Lt/s) (gpm) 25% Stroke, Flow recorded: (Lt/s) (gpm) 10% Stroke, Flow recorded: (Lt/s) (gpm)

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77. Line out the treated crude inhibitor injection system from pump 67PBE073B to the treated crude static mixer. Start the pump with the stroke at 95% and then increase to 100%. Using the calibration pot, record the pump discharge flow rate at the following adjusted stroke settings; 100% Stroke, Flow recorded: (Lt/s) (gpm) 75% Stroke, Flow recorded: (Lt/s) (gpm) 50% Stroke, Flow recorded: (Lt/s) (gpm) 25% Stroke, Flow recorded: (Lt/s) (gpm) 10% Stroke, Flow recorded: (Lt/s) (gpm)

78. Confirm that treated crude inhibitor injection pumps 67PBE073 A/B will only operate in automatic mode as controlled by the PLC when; i. The treated crude to static mixer flow transmitter 43FT0061 indicates a flow ii. Treated crude return to Hull COF tanks valve 91XV0146 is in the closed position

Boiler Crude fuel Skid

79. With the boiler fuel system lined up to circulate fuel (diesel will be used for commissioning) to the boiler burned units and back to the fuel skid, start crude fuel pump 67PBE056A through the FPSO PCS.

80. Confirm the boiler fuel system is circulating at a delivery pressure of 2000 kPa(g) as regulated by control valve 43PCV0064. Record the boiler fuel pressure at the local burner units for; i. Boiler A __________kPa(g) ii. Boiler B __________kPa(g) iii. Boiler C __________kPa(g)


81. Prepare the Topsides diesel distribution ring main for accepting diesel fuel from the Hull diesel oil service pumps by isolating the end user supply lines from the distribution header. Confirm the block valves for the following equipment supply lines are in the closed position; i) Pedestal Crane 19CRN001 ii) Pedestal Crane 19CRN002 iii) Pedestal Crane 19CRN003 iv) Pedestal Crane 19CRN004 v) Pedestal Crane 19CRN005 vi) Power Generator 97LAN001A vii) Power Generator 97LAN001B viii) Crude Oil Washing Package 97FT010 ix) Treated Crude Feed package 97FT011 & Boiler Crude Fuel Skid

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97FT002

82. Place control valve 43PV0809 in manual control and drive the valve fully open. Open the control valve inlet and outlet block valves and close the bypass valve.

83. Introduce diesel from the Hull diesel oil service pumps into the Topsides diesel distribution and return ring main by opening the following block valves; i) Supply header valve A ii) Supply and return header isolation valve G iii) Return header valve F

84. Place control valve 43PV0809 in auto control and confirm that the valve is maintaining the diesel distribution supply header at a pressure of 689 kPa (g) (100 psi).

85. Slowly introduce diesel into the Topsides end user supply lines from the distribution supply header by opening the block valves in the supply lines to the following; i) Pedestal Crane 19CRN001 ii) Pedestal Crane 19CRN002 iii) Pedestal Crane 19CRN003 iv) Pedestal Crane 19CRN004 v) Pedestal Crane 19CRN005 vi) Power Generator 97LAN001A vii) Power Generator 97LAN001B viii) Crude Oil Washing Package 97FT010 ix) Treated Crude Feed package 97FT011 & Boiler Crude Fuel Skid 97FT002

86. Confirm the self regulating valve 43PCV0786 is correctly set to maintain the diesel supply pressure to the Crude Oil Washing Package 97FT010 at 689 kPa(g).

87. Confirm the self regulating valve 43PCV0787 is correctly set to maintain the diesel supply pressure to the Treated Crude Feed package 97FT011 & Boiler Crude Fuel Skid 97FT002 at 689 kPa(g).

88. All system Operating Tests for the Crude Oil & Diesel Fuel System that involve hydrocarbons will be carried out during the Offshore Start-up phase and will be covered in the “Initial Start-up Procedures”, Document no. HOLD.

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15.0 REFERENCES

15.1 General Procedures The following documents referred to in this procedure cover 'general' procedures. Document No. Title R048-13P-GAA-G-PRD-0000050 Topsides Completions Manual R048-13P-GAA-G-PRD-0000053 Permit to Work Procedure R048-13P-GAA-G-PRD-0000054 LOTO Procedure K1-13P-GAA-AN-PLN-0000001 Topsides Commissioning Execution Plan K1-13P-GAA-AN-PRD-0000001 Topsides Commissioning Manual K1-13P-GAA-AS-PRD-0000001 SMT HSE Plan SMOE Singapore

15.2 Project Document List Listed below are project documents associated with this Commissioning Procedure. This list is not exhaustive and where necessary all other project documents shall be used in support of this procedure. Document No. Title Crude Treatment Package K1-13P-D-MF-FCA-0630 Crude Oil Transfer Pump K1-13P-D-MF-FCA-0631 Crude Oil Heat Recovery & Heating Package K1-13P-D-MF-FCA-0632 Wash Water Skid K1-13P-D-MF-FCA-0633 Crude Oil Washing Line 1 Centrifuge 1 K1-13P-D-MF-FCA-0634 Crude Oil Washing Line 1 Centrifuge 2 K1-13P-D-MF-FCA-0635 Crude Oil Washing Line 2 Centrifuge 1 K1-13P-D-MF-FCA-0636 Crude Oil Washing Line 2 Centrifuge 2 K1-13P-D-MF-FCA-0637 Raw Crude Demulsifier K1-13P-D-MF-FCA-0640 Sht 1 of 2 Treated Crude Coolers K1-13P-D-MF-FCA-0640 Sht 2 of 2 Treated Crude Oil Forwarding Pump K1-13P-D-MF-FCA-0641 Treated Crude Forwarding Skid K1-13P-D-MF-FCA-0642 Treated Crude Fuel Supply Pump K1-13P-B-E-FAA-0566 S7 Electrical Cable Schedule K1-13P-B-E-FAA-0564 P5 Electrical Cable Schedule K1-13P-D-EG-FAA-0058 400V Single Line Diagram FUA28MCC010 P5 K1-13P-D-EG-FAA-0061 400V Single Line Diagram FUA28MCC011 S7 K1-00P-D-ES-FUA-0050 Overall Electrical Schematic & Wiring Diagrams K1-13P-D-MF-GAA-1006 Motor Control Philosophy & Signal Schedule K1-13P-D-E-FAA-0317 Electrical Power Plan Upper Level P5 K1-13P-D-E-FAA-0345 Electrical Power Plan Mid Level S7 Diesel Fuel Distribution K1-13P-D-MF-FCA-0206 Diesel Distribution

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15.3 Seller Document List Listed below are the relevant suppliers’ documents associated with this procedure. The list is not exhaustive and where necessary all other supplier documents shall be used in the support of this procedure. Document No. Title SOK6828467/3 COTP MCC Single Line Diagram SOK6615857/3 COTP Control Cabin One Line Wiring Diagrams SOK6615856/3 COTP Control Cabin Outline Drawings SOK6828469/3 COTP PLC/MCC Outline Drawings SOK6640014/3 COTP E&I Field Wiring Diagrams SOK6828468/3 COTP PLC/MCC Schematic Wiring Diagrams

Documents

FPSO TOPSIDES COMMISSIONING PROCEDURE SYSTEM: 60 & 62