COM. JOB No. COMPANY DOC. No. REV.

Mellitah Oil & Gas BV

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1
CON. JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
DATE 31 July 2010 SHEET 1 OF 13
WAFA GATHERING
PROCEDURE

DISTRIBUTION
COMPANY
MFO-TRIPOLI
MAN FIA
2
GEISENHEIM
MAN

FERROSTAAL
CLIENT 5
Pre-Commissioning and Commissioning Manual

INTERNAL
PM 1
PPM
PEM
PKM
PCM
PQM 1
PHM (Surface Facilities for 3 Infilling Wells at WAFA FIELD)
SM
PSM
ME
DCC 1
MFG
MFS
LE
PROPOSAL
PLANNING
CIVIL
INSTRUMENT
TION
ELECTRICAL
PIPING
PROCESS
CONTROL
SALES
ADMINISTRA
TION
SHIPPING

PLANT SITE 1

REV. DATE PAGE DESCRIPTION PREPD CHKD APPD CLIENT

P1 11.07.09 ALL For Approval E. Espiritu W.Melis Dr. Rodies
Clients Comments Incorporated
OTHERS P2 01.08.09 ALL E. Espiritu W.Melis Dr. Rodies
LT/ON/WIP/FP/109/09
F1 31.07.10 ALL As-Built E. Espiritu W.Melis W.Marschick

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 2 OF 13
PROCEDURE

Main Index

Pages

1. FOREWORD.. 3
1.1 Scope
1.2 Disclaimer

2. PURPOSE.. 3

3. DEFINITIONS AND ABBREEVIATION.... 4

3.1 Definitions
3.2 Abbreviations

4. PROCEDURES.... 5

5. SCOPE OF APPLICATION... 5
5.1 Pre-Commissioning Phase
5.2 Commissioning Phase

6. HSE POLICY. 9

7. HSE OBJECTIVES..10

8. REFERENCE DOCUMENTS.. 10

APPENDIX A PRE-COMMISSIONING FLOW DIAGRAM ... 11

APPENDIX B COMMISSIONING FLOW DIAGRAM . 12

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 3 OF 13
PROCEDURE

1. FOREWORD

1.1 Scope

This manual describes and contains the procedures, process and equipment for the project
phases required for carrying out mechanical pre-commissioning and commissioning process.

1.2 Disclaimer

This document has been developed to organize the compilation and presentation of QA
documentation for the entire project with a view to achieving mechanical completion.

Also to describe how pre-commissioning and commissioning of satellite station, well site and
equipment is planned and carried out in order to achieve:
Safe operation
No damage performance
Acceptance by the Client

2. PURPOSE

Pre-Commissioning/Commissioning is a comprehensive and systematic process to verify that

the systems perform as designed to meet the project requirements. Commissioning during the
construction and warranty phases is intended to achieve the following specific objectives:

1. Verify and document that equipment is installed and started per manufacturers
recommendations and the technical specification requirements.
2. Verify and document that equipment and systems receive complete operational
checkout by Contractor with the assistance of Companys representatives.
3. Verify and document equipment and system performance to detect trouble in advance
that may occur during normal operation.
4. Verify and mark that all related Documentation are approved without comments.

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 4 OF 13
PROCEDURE

3. DEFINITIONS AND ABBREVIATIONS

3.1 Definitions
Within the scope of this document the following definitions shall apply.

Company Mellitah Oil & Gas BV, Libyan Branch

Contractor MAN Ferrostaal Oil & Gas Ltd., Libya

Pre-commissioning - Means all checks, cleaning and testing of satellite station and well
site and its implementation without introducing hydrocarbons or permanently energizing or
pressurizing satellite station and well site equipment and machinery. Pre commissioning
includes all activities implemented between Construction Completion and Ready for
Commissioning.

Commissioning - Means all activities associated with satellite station and well site
preparation or (overall or single sections) Operation prior to initial start-up.

Start-up - Means introduction of feedstock into process satellite station and well site with
the express intention to produce a product for the first time: it can be referred to also as
hydrocarbon in stage. Start-up includes all activities implemented between end of
commissioning and initial operation.

Initial Operation - Means the period after Start-up during which final adjustments to
optimize and troubleshoot the performance of satellite station and well site are made and
Performance test is conducted.

Performance tests - Means all tests carried out on the satellite station and well site (or
part thereof) to verify the capability of the satellite station and well site (or part thereof) to
meet performance guarantees.

3.2 Abbreviations

PM - Project Manager
SM - Site Manager
Constr. - Construction
Mech. - Mechanical

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 5 OF 13
PROCEDURE

Inst. - Inspection and Test Plan

QA - Quality Assurance
QM - Quality Management
SAT - Site Acceptance Test
DCC - Document Control Center

4. PROCEDURE

The activities and responsibilities of Pre-Commissioning and Commissioning are describe in

the flow diagrams in Appendix A and Appendix B

Appendix A Pre-Commissioning Flow Diagram

Appendix B Commissioning Flow Diagram

5. SCOPE OF APPLICATION

5.1 PRE-COMMISSIONING PHASE:

1. Re-tightening of bolts on the flanges and valves.

2. Checking of valves for close-open position:
a. Close the 4dia. Ball Valve on the blow down line (2D-150-100-BD-4-AA730-
Z) and marked with PLEASE DONT OPEN.
b. Close the 3dia. Ball Valve on line 2D-150-3446-CO-3-CA1130-Z and
marked with PLEASE DONT OPEN.
c. Close the 2dia. Ball Valve on line 2D-150-384-CO-2-CA1130-Z and marked
with PLEASE DONT OPEN.
d. Close the 8dia. Ball Valve on line 2D-150-381-CO-8-CA1130-Z and marked
with PLEASE DONT OPEN.

5.2 COMMISSIONING PHASE:

1. Preparation of Arnica 22 oil to be filled up at main tank of W.H.C.P

check for main level of oil at level gauge maximum.

2. Energization of W.H.C.P supply at 400V. Instrument cable signals at 24

VDC. Switch Oil Pump A & B to test to run.

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 6 OF 13
PROCEDURE

3. Pressurized V.H.P., H.P., L.P Accumulators at 360, 240, 10 bar

respectively. Adjusting V.H.P. at pressure switch-003 synchronized with
pressure transmitter at 360 bar inside W.H.C.P.

4. Pressurization of:
a. Wing Shutdown Valve
b. Flowline Valve
c. Master Valve SSV
d. Downwell Valve SSSV
e. Fusible Circuits A and Circuit B
Check for local/remote function.

5. Pressurization of Pilot Valves, checked for:

a. Reset Pressure for PSH
b. Reset Pressure for PSL

6. Checking of Emergency Shut Down(ESD)

a. Local Emergency Shutdown at W.H.C.P.
Associated with : SSSV Down Well Valve
SSV - Master Valve
Wing Valve SDV
Flowline Valve SDV
b. Remote Emergency Shutdown Control Room
Associated with : SSSV Downwell Valve
SSV - Master Valve
Wing Valve SDV
Flowline Valve SDV

7. Checking of Process Emergency Shutdown (PSD) at W.H.C.P.

a. Local Process Emergency Shutdown
Associated with : SSV Master Valve
Wing Valve SDV
Flowline Valve SDV

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 7 OF 13
PROCEDURE

8. Checking of Fusible Circuit A and Circuit B

a. Local At Well Head Control Panel
Associated with : SSSV Downwell Valve
SSV - Master Valve
Wing Valve SDV
Flowline Valve SDV
b. Remote at Control Building
Associated with : SSSV Downwell Valve
SSV - Master Valve
Wing Valve SDV
Flowline Valve SDV

9. Depressurizing Pilot Valves

a. Local At Well Head Control Panel
b. Remote at Control Building

10. Flowline and Process Instruments should be Loop Checked.

Simulating signals from field to DCS Interface at Control Room.

11. Motorized Valves should be supplied at proper voltage rating.

Functional test for local/remote signal for open/close. Manual hand
wheel for Open/Close should be checked.

12. Pneumatic Shutdown Valve should be checked for Open/Close

associated with Pneumatic Panel. Limit switches should be checked.

13. All hand switches should be function test for local and remote.

14. Energization of UPS shelter as per manufacturers instruction.

Check for:
a. Charging of battery.
b. Interior lighting.
c. Convenience outlet
d. HVAC energization
e. UPS main supply
f. 24VDC supply

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 8 OF 13
PROCEDURE

15. Functional Test of SCADA/RTU Panel

a. Internal lighting
b. Inside/Outside Temperature
c. Ventilation

16. Check the Graphical representation of the Wells / Facilities on the operators
Consoles (DCS workstation)

17. Communications link between RTU and Master Station in control building.

18. Illumination of Perimeter Lighting.

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 9 OF 13
PROCEDURE

6. QUALITY POLICY

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 10 OF 13
PROCEDURE

7. HSE POLICY

During Pre-Commissioning and Commission activities HSE policy should be implemented.

The purpose of HSE policy statement is to state and to communicate the Contractor
Commitment to HSE to all project personnel, Company, sub-contractors and Vendors.

The policy will be distributed to all project personnel, displayed on notice boards at each work
location and copies provided to Company and sub-contractors.

8. HSE OBJECTIVES

Contractor is fully aware that to implement the HSE policy and to realize the above objectives
it is essential to:
Educate and train the personnel in all pre-commissioning and commissioning
activities;
Motivate the personnel to ensure their constant awareness of the objectives;
Provide access to Process Safety Information;
Develop a Plan of Action for implementation of Employee Involvement;
Properly plan and execute the pre-commissioning and commissioning activities;
Consult with employees on the conduct of the Plan of Action.

10. REFERENCE DOCUMENTS

MN-052-P-Q-1023-00 Mechanical Completion and Pre-Commissioning Procedures

MN-052-P-Q-1026-00 Safety Manual
MN-052-P-Q-1003-00 Project Quality Management Plan (PQP)
MN-052-P-Q-1017-00 Punch Listing
MN-052-P-I-1000-00 Instrument Calibration and Loop/Logic Test Procedure
MN-052-P-I-1104-00 RTU SAT Procedure and Specification
MN-052-L-I-1109-00 RTU560 SW Configuration Program List(A34H)(SCADA
Package By ABB)
MN-052-L-I-1110-00 RTU560 SW Configuration Program List(A38)(SCADA
Package By ABB)
MN-052-L-I-1111-00 RTU560 SW Configuration Program List(A45H)(SCADA
Package By ABB)
MFI-M-VA-103 Commissioning
30262-M-VA-512 Engineering Queries

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 11 OF 13
PROCEDURE

APPENDIX A
PRE-COMMISSIONING FLOW DIAGRAM

01 Plan is drawn up for pre-commissioning

Activities in all applicable discipline and
Start expediting. This includes schedules for all
Pre-commissioning vendor assisted activities.

02 / 03 / 04

Pre-commissioning starts when a

individual system have been signed
SM 01 off as mechanically complete.
Planning Remaining punch list items are
worked off during this phase unless it
is specifically agreed that they can be
completed later. All ITP items which
are part of the pre-commissioning
phase completed QM dossiers are
signed off by DFE and Company.
DFE Inst. 02 Each system is reported Ready for
Commissioning on receiving the
Loop checks for Company Endorsement on the
Instrumentation completed QM dossier.

05 When all systems have been signed off

with any remaining punch items agreed.
The plant is ready for commissioning.
Vendor Rep. 03

SAT for Vendor

Supplied Systems

DFE Mech.
04

Vendor-assisted
Pre-commissioning
activities

CM
05

Pre-commissioning
Activities are
coordinated to
ensure timely
completion of all

CM
06

The completed
dossiers for all
systems are collated
and added to the
mechanical
catalogue

END
Pre-commissioning

MAN FERROSTAAL OIL & GAS LTD.

 Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 12 OF 13
PROCEDURE

APPENDIX B
COMMISSIONING FLOW DIAGRAM

Start
Commissioning

PM 01 PEM

Allocation of Operating Manual

resources
01 Operating manual includes:
- commissioning procedures
- detailed level 3 planning schedule and
SM 02 personnel resources requirements which have
Start of site activities been integrated by PCM into overall project
safety and HSE schedules and approved by PM and Client as
training of operating appropriate
personnel Plant is ready for commissioning; Mechanical
Completion certificate has been signed. Status
of the plant is contractually defined

SM 03 02 When the plant is ready for commissioning the

Check deliveries of Site Material SM will also be responsible for site
chemicals and other Receiving management.
consumables
03 Chemicals and other consumables will have
been ordered according to the requirements
specified in the operating manual
SM
04
04 Contacts with the Client
Establish measures for
Co-ordinate client supplies and services
co-operation with
Meeting and reports schedule

06 Agreement of commissioning team with punch

SM 05 list produced when plant is ready for
Check pipes, vessels, commissioning
machinery, electrical
equipment &
instrumentation

yes
Significant Engineering Query
deviation

no

LSE
06
Update documentation
to include any minor
differences between
07 Gradual start-up of plant to rated capacity.
SM Tightness inspection
07
Start-up of systems
per operating manual
08 Check list for the commissioning phase will be
project specific according to contract
requirement
SM
08 Input from
Start trial and carry out Engineering Query
activities which could
not be done during
pre-commissioning

Continued on
page 11, step 09

MAN FERROSTAAL OIL & GAS LTD.

Mellitah Oil & Gas BV COM. JOB No. COMPANY DOC. No. REV.

Libyan Branch C/0579/WA/08 MN-052-P-Q-1028-00 F1

CON JOB No. CONTRACTOR DOC. No. REV.
520 08 30375 QM-4-PR-MFO-2028 F1
WAFA GATHERING SHEET 13 OF 13
PROCEDURE

Continued from
page 10, step 08

09 Set optimum process parameters

Record plant parameters
SM 09 Set optimum process parameters
Optimise plant in
preparation for
guarantee runs

PEM
yes
Modifications Input from technical
required query/eng. change
procedure
no
10 Record and confirm data
SM 10 PEM Balancing consumption figures
Carry out performance Output from technical Determine emission date
guarantee runs query/eng. change Compare actual plant data to contractual
procedure requirement
Discuss results with Client

11 Punch list is agreed with Client

SM Solve or clarify with Client
11 Handbook for
Clear punch list performance
Guarantee Test
12 Apply for provisional completion certificate

SM
12
Hand over plant to
Client

End
Commissioning

MAN FERROSTAAL OIL & GAS LTD.