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Definitions Hand-Over Phase

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DEFINITIONS HAND-OVER PHASE

Definitions used during the hand-over phase of a project are described in this document. In the Project Construction Plan; the Project Commissioning & Start-up Plan and also in the Instruction of the OIP Plan relevant definitions are founded in this document. Definitions used in this document are in line with the NEN-EN-IEC 62337.

Document naam Document type Document nummer Revisie Revisie datum Status

Definities overname fase Werkinstructie .. 1.1 30 november 2009 Concept

Functie

Naam

Datum

Handtekening

Opsteller

Senior Asset Engineer Manager Construction Manager QA/QC BU director Essent Projects BV

F. Hamers S. Copinga H. Martens J. Duijvestijn

Controle

Controle Autorisatie

Confidential This document is made available subject to the condition Post address: PB 689, 5201 AR that the recipient will neither use for disclosure the content s-Hertogenbosch except as agreed in writing with the copyright owner. Essent B.V., 2009 all rights reserved

Address Essent Projects BV:

Visit address: Willemsplein 4 5211 AK s-Hertogenbosch

Definitions Hand-Over Phase

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INDEX

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Address Essent Projects BV:

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Definitions Hand-Over Phase

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TYPICAL COMMISIONING PLAN

Project timeline (typical)


FID Engineering Ready Mechanical Complete Technical Complete
PSSR

Ready to operate (total plant )


PSSR

Stable operation PSSR

PSSR

Detail engineer ing

Construction

Cold commisioning

Hot commisioning

Start-up & operation

Manufacturing

Erection

Pre commisioning

Trial oper.

Perf . tests

Timeline
OEM contract

Responsible ; Construction Manager

Responsible ; Commissioning Manager

Plant oper

Care, custody by Essent Projects /EPCM

Engineering ready FAT's Engineering document requirements

Operations participates in CSU

Project team is still active (not

MC

TC Specifications AFC MC protocol, (signed by all parties) RTO TC protocol (signed by all parties )

LOP- list , (no critical items )

LOP-list, (no critical items ) OIP-PSSR done , (no A-items)

Test protocols, (signed by all parties ) Perf. test protocols, (signed by all parties)

OIP- PSSR done , (no A-items)

LOP-list, (no critical items )

Figure 1 Typical commisioning plan (bron; NEN-EN-IEC 62337) EC MC TC PSSR RTO SO PTO Erection Complete Mechanical Complete Technical Complete Pre Start-up Safety Review Ready to Operate Stable Operation Preliminary Take Over
Approved For Construction Commisioning & Start -Up Factory Acceptance Test Final Investment Decision Final Take Over List of Open Points Mechanical Complete Operation Implementation Plan Project Close Out Internal Essent procedure (pre start -up safety review ) Preliminary Take Over Ready to Operate Technical Complete

OIP- PSSR done, (no A-items)

LOP-list, * no crit. items * due date * actionholder

OIP-PSSR done , (no A-items)

Temporary O &M documentation

AFC CSU FAT FID FTO LOP MC OIP PCO PSSR PTO RTO TC

; ; ; ; ; ; ; ; ; ; ; ; ;

= milestone

Note 1; Projectteam is still a Note 2; WARRANTY items

CSU; ref. IEC 62337 Intern specific phases and miles

Procedure CSU 080326 .vsd

Confidential This document is made available subject to the condition Post address: PB 689, 5201 AR that the recipient will neither use for disclosure the content s-Hertogenbosch except as agreed in writing with the copyright owner. Essent B.V., 2009 all rights reserved

Address Essent Projects BV:

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Definitions Hand-Over Phase PRE COMMISSIONING

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Phase during which the activities of non-operating adjustments, cold alignment checks, cleaning and testing of machinery take place. Pre commisioning involves the testing of instrumentation and the involved loops; Instrumentation signals, valve actions etc.
Pre Commissioning means all checking of the construction and installation work, of items, loops and assemblies to ensure that all items are installed to requirements as shown in drawings and documents. The work results in determination of the status Mechanical Complete and ready for Cold Commissioning. The process of Pre Commisioning is performed on every single discreet piece of equipment on the facility, to ensure the integrity of all components and that they have been installed to project standards. At this stage, all circuits, power cables, instrumentation loops, PLC/DCS input and output connections and junction boxes are bell checked without voltage or active auxiliary supplies. All of the Pre Commissioning undertaken on a project can be simply scheduled and reported against on a live basis. 1. Visual Check (Test 2) The Visual Check shall contain the checking of: * Check conformity with design documentation according to P&IDs, Piping Documentation * KKS- Numbering of all main equipment, valves, etc available.

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Definitions Hand-Over Phase MECHANICAL COMPLETION

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Milestone which is achieved when the plant, or any part thereof, has been erected and tested in accordance with drawings, specifications, instructions, and applicable codes and regulations to the extent necessary to permit cold commissioning. NOTE; This includes completion of all necessary electrical and instrumentation work. This is a milestone marking the end of the precommissioning activities.
Mechanical Completion is the gate that must be passed through prior to any system being Energised or pressurised. When all equipment in a small section of the project (sub subsystem) is complete, a Mechanical Completion Certificate is issued. The Mechanical Completion Certificate ties in to the site Permit to Work to control the energisation and pressurisation of any system. The initial energisation / pressurisation of systems is the most safety critical point during the project and must be managed with zero ambiguity. Utilising Mechanical Completion Certificates in conjunction with a simple Permit to Work system is recognised as the most effective way to manage the energisation / pressurisation of systems in an environment where multiple phases of a project are concurrent in the same geographic location.

MC Protocol Document to verify that MC has been carried out for each discipline and part system. - Made by - Checked by - Approved by Contractor Essent technical projectleader/EPCM-er PM Essent

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Address Essent Projects BV:

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Definitions Hand-Over Phase COLD COMMISSIONING

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Phase during which the activities associated with the testing and operation of equipment or facilities using test media such as water or inert substances, prior to introducing any chemical in the system, take place. Cold commisioning involves the hydro testing of piping systems1, the testing of level measurements (trips, alarms etc.) on equipment, testing of pumps etc.
Cold Commissioning is the process of proving that groups of related equipment function together correctly and is performed without process fluids/steam/ hydrocarbons. As Cold Commissioning is required to be a multi discipline activity, there are greater inefficiencies experienced when something does not perform correctly. This is why Pre Commissioning is performed to iron out any small issues and ensure that the impact of equipment failure is managed. Function specific test sheets have to be developed for the cold commissioning phase of the project. This allows most of the work which has been traditionally performed using Commissioning Test Procedure documents to be performed, documented and accepted as the discreet processes that they are. One of the greatest complaints raised against many completions philosophies is the ambiguity of the reporting of the cold commissioning. With function specific testing, these ambiguities are removed, to provide the same detailed level of reporting and data export for much of the commissioning phase as is available for MC and PC. 1. Document Check (Test 1) The Document Check shall contain the checking of: * Quality Control Documentation (Vessel, Equipment, Valve-Test Certificate) * Material Certificates, complete Testing Certificates) available on site. * Vendor Documentation (Operating & Maintenance Manuals, Spare Part List, As-built Drawings (minimum status: red marked-up) available on site. * Commissioning Spare Parts acc. commissioning spare part list available on site. 2. Visual Check (Test 2) The Visual Check shall contain the checking of: * Completeness of equipment for TC status * Correct execution of functional tubing, if any. * Check final function of supports for strain free supporting, correct fixing of piping, etc. 3. Functional Check (Test 3) The Functional Check shall contain the checking of: * Full travel of valves from closed to open position, and vice versa * Correct function of instruments/ measurements/ signals (Final Loop Checks). * Correct reaction of ESD valves, motor operated valves, slam shut valves to system pressures exceeding preadjusted set points (Final Loop Testing) * Correct function/ reaction of motors, pumps and other equipment (Final Loop Testing) * Correct function/ reaction of control valves (Overall Loop Checks). 4. Adjustment / Dry Check (Test 4) The Adjustment/ Dry Checks shall contain of:

Pressure and leakage tests are already performed during pre commissioning. Address Essent Projects BV:

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Definitions Hand-Over Phase

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* Final adjustment of shut valves, pressure control valves, high pressure switches (PSHH), high temperature switch (TSHH) set points, liquid level switches (LAHH, LALL) and all safety related set points on site.

TECHNICAL COMPLETE Milestone marking the end of cold commissioning


Commissioning Test Documents; Test record/ sheets will be issued upon satisfactory completion of the relevant tests. All documentation pertaining to the commissioning tests (Summary Sheet) shall be compiled within the TC- Dossier, arranged according to the relevant system. TC Protocol; - Made by - Checked by - Approved by Contractor Essent technical projectleader/EPCM-er PM Essent

Confidential This document is made available subject to the condition Post address: PB 689, 5201 AR that the recipient will neither use for disclosure the content s-Hertogenbosch except as agreed in writing with the copyright owner. Essent B.V., 2009 all rights reserved

Address Essent Projects BV:

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Definitions Hand-Over Phase PRE-START UP SAFETY REVIEW

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A Pre-Startup Safety Review (PSSR) aids in the transfer of projects from the construction stage to the operations stage. It ensures that both initial start-ups and start-ups following a major turnaround are carried out safely. In particular, a PSSR aims to confirm that what was built and installed conforms to the original design and standard, and that no hazardous situation was created during construction and commissioning. It is an important review of the safety and operability analyses made during the project, and not a technical review. This check will be performed in stages, before cold, hot commissioning as well as before start-up, conform schedule (fig 1).
PSSR is the final confirmation before start-up of a process. It is done to determine that certain key inspections and reviews have been conducted. The pre-start-up safety review must be completed prior to the introduction of hazardous materials into the process and must confirm the following:

Construction and equipment is in accordance with design specifications; Safety, operating, maintenance, and emergency procedures are in place and adequate; For new facilities, a process hazard analysis has been performed and recommendations have been resolved or implemented before start-up; For modified facilities, they meet applicable management of change requirements; and Training for each employee involved in operating the process has been completed.

Confidential This document is made available subject to the condition Post address: PB 689, 5201 AR that the recipient will neither use for disclosure the content s-Hertogenbosch except as agreed in writing with the copyright owner. Essent B.V., 2009 all rights reserved

Address Essent Projects BV:

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Definitions Hand-Over Phase HOT COMMISIONING

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Phase during which the activities associated with the testing and operation of equipment or facilities using the actual process chemical, gas, prior to making an actual production run, take place.
Start Up or Hot Commissioning is the introduction of Process fluids/steam/hydrocarbons into the facility and is generally managed separately. The start up group needs to be very process oriented and include the end operators of the facility. Start up is best managed by a dedicated project team utilising the expertise of the facility operator.

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Address Essent Projects BV:

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Definitions Hand-Over Phase READY TO OPERATE

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Hot commisioning is done. Complete plant/part system are filled with medium and functionally tested. PSSR is done in order to secure a safe start-up of the facility. Punch list contains no A-items or C-items.

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Address Essent Projects BV:

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Definitions Hand-Over Phase PUNCHLISTING

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Punchlisting is the method used to record and manage incomplete / substandard work and damaged equipment. It is imperative for project close out that Punchlisting is started at FATs and carried through the project in a single register.
Punchlisting is performed on Tagged equipment and each punch item must be related to a tag. The primary objective in the Punchlisting philosophy is to repair the fault rather than raise a punch. In some cases this will not be possible and punch will need to be raised. There will also be certain situations where punch will be held off prior to entry into the consolidated Punch List. In the small number of instances where a punch cannot be assigned to an individual tagged item, then the punch will be assigned to a Dummy tag with the subsystem number. Punch lists fall into 4 categories. These categories can be generally classified as; Punch list type A Not safe to energise / Pressurise Punch list type B Safe to Energise / Pressurise Punch list type C Safe to Energise for Commissioning Purposes, but must be cleared prior to start-up Punch list type D Design Change Notice Although many projects only use type A and B punch codes, experience has shown the need for the two extra classifications. See below for detailed descriptions of the punch codes and the ways they are used to improve the overall efficiency of the handover process. Punch list Type A If any item is found to be unsafe, either due to poor installation or subsequent damage, and it cannot be repaired on the spot, then a Punch list type A is raised. No Punch list type A items should be outstanding when any package is handed over. Unsafe refers to the danger of personnel injury, environmental release or damage to plant or equipment. In this instance, the normal process is to isolate and tag out the item in question under a long term isolation permit until the necessary remedial works can be completed. Punch list Type B If any item is found to have minor outstanding works or damage which cannot be immediately rectified and will not impair the operation of the device, a punch list type B is raised. Punch list type C In the case of insufficient hazardous area paperwork, or any question about an installations compliance with hazardous area regulations, a Punch list type C is raised to cover the issue. The concept of type C punchlists is to ensure that all hazardous area issues are correctly closed prior to declaring the plant ready For Start Up. Punch list Type D As a control method to ensure that all Design Changes are captured prior to Mechanical Completion, each Design Change Notice (DCN) which has a direct impact on the installation of any tagged equipment or pipework, is cross referenced in the Punch list as a Punch list type D. This allows the MC Coordinator to easily ensure that all DCNs are complete or managed when a subsystem is signed off as mechanically complete. To facilitate this, when a DCN is raised that impacts a tag or tags, a D type punch list is also raised. The punch list needs no other information than the DCN number, as the DCN will be checked if necessary to ascertain the required scope of work. If the DCN affects more than one tag, then a punch is raised against each tag. Confidential This document is made available subject to the condition Post address: PB 689, 5201 AR that the recipient will neither use for disclosure the content s-Hertogenbosch except as agreed in writing with the copyright owner. Essent B.V., 2009 all rights reserved Address Essent Projects BV:

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Definitions Hand-Over Phase

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FLAWLESS START UP The Flawless Start Up philosophy is based on the systematic elimination of flaws experienced during previous start-ups by:

The rigorous application of a process for capture and dissemination of these flaws from project to project: The implementation of appropriate mitigation measures through the project work scope and execution processes.

Project Teams are responsible for delivering systems and plant facilities on time, safely and fully functional in accordance with the Final Investment Decision (FID). However, the consequences of flaws in design, procurement, subcontracting, planning, construction or testing often do not become apparent until the start-up phase. At that time any flaws can irrevocably affect the safety, functionality, increase production costs, and therefore the ultimate successes of the project. The general approach will be to:

Value proven best practices Apply lessons learnt both by the Company and the Contractors carrying out the work Co-operate with the contractor in the application of the flaw mitigation, risk management and the resulting improvements of work processes. Thorough commisioning and testing.

Figuer 2 Flawless start-up by blocking & catching


Confidential This document is made available subject to the condition Post address: PB 689, 5201 AR that the recipient will neither use for disclosure the content s-Hertogenbosch except as agreed in writing with the copyright owner. Essent B.V., 2009 all rights reserved Address Essent Projects BV:

Visit address: Willemsplein 4 5211 AK s-Hertogenbosch