SECTION 11.

0
 Document No.
Pre-Commissioning, Commissioning &
Start-up Specifications Life Extension A792-000-12-41-BP-03
of Well Platforms (LEWP) Project
(TENDER-03) Page 1 of 19

Pre-Commissioning, Commissioning
& Start-up Specifications
(Revamp Work)

PROJECT : LIFE EXTENSION OF WELL PLATFORMS

(Tender-03)

LOCATION : MUMBAI HIGH NORTH & SOUTH FIELDS

CLIENT : ONGC, MUMBAI

CONSULTANT : ENGINEERS INDIA LTD, DELHI

EIL JOB NO. : A792

0 06.11.2015 Issued for BIDS SK SK AS

Rev. Prepared Checked Approved
Date Purpose
No by by by
 Document No.
Pre-Commissioning, Commissioning &
Start-up Specifications Life Extension A792-000-12-41-BP-03
of Well Platforms (LEWP) Project
(TENDER-03) Page 2 of 19

INDEX
1. SCOPE ............................................................................................................................. 4

2. DEFINITIONS ................................................................................................................... 4

2.1 MECHANICAL COMPLETION....................................................................................... 4

2.2 PRE-COMMISSIONING ACTIVITIES............................................................................. 5
2.3 READY FOR COMMISSIONING .................................................................................... 5

3.0 DOCUMENTS FOR PRE-COMMISSIONING / COMMISSIONING ................................ 6

3.1 OPERATING MANUAL .................................................................................................. 6
3.2 PRE-COMMISSIONING AND COMMISSIONING NETWORK ...................................... 8
3.3 PRE-COMMISSIONING MANUAL ................................................................................. 8

4.0 OTHER REQUIREMENTS ............................................................................................. 9

5.0 MANUFACTURER'S REPRESENTATIVE................................................................... 10

6.0 REVIEW / CHECKLISTING / INSPECTION CO-ORDINATION ................................... 10

7.0 A TYPICAL APPROACH TO WITNESS / INSPECTION OF PRE-COMMISSIONING

ACTIVITY BY PMC / OWNER............................................................................................ 12

8.0 FINAL INSPECTION BEFORE START OF COMMISSIONING ................................... 12

9.0 COMMISSIONING ........................................................................................................ 12

10.0 SPARES AND CONSUMABLES ............................................................................... 13

11.0 SPECIAL REQUIREMENT......................................................................................... 14

12.0 SAFETY ..................................................................................................................... 14

13.0 STAFFING OF FACILITIES ....................................................................................... 14

14.0 CHECK LISTING ........................................................................................................ 14
ANNEXURE - I ................................................................................................................... 15
F O R M A T - I ................................................................................................................... 16
F O R M A T - II .................................................................................................................. 17
 Document No.
Pre-Commissioning, Commissioning &
Start-up Specifications Life Extension A792-000-12-41-BP-03
of Well Platforms (LEWP) Project
(TENDER-03) Page 3 of 19

F O R M A T - III ................................................................................................................. 18
F 0 R M A T - IV.................................................................................................................19
F 0 R M A T - V.................................................................................................................. 20
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1. SCOPE

It shall be the responsibility of the Contractor to carry out pre-commissioning, commissioning of

the ONGC’s LEWP Project – Revamp Work Facilities, belonging to OIL & NATURAL GAS
CORPORATION LIMITED ( COMPANY) in association with COMPANY’s operating personnel.
Details of the facilities are described elsewhere in the BID PACKAGE.
This document is intended to broadly define responsibility of the contractor with respect to pre-
commissioning, commissioning and performance test run of the system in the contractor’s scope.
Also, the contractor shall prepare a detailed operating manual for the contractor’s scope (defined
elsewhere in the bid document) and associated Basic Engineering Design Packages, attached
with the bid documents.

2. DEFINITIONS
2.1 MECHANICAL COMPLETION

Mechanical Completion of systems shall mean that all installation works of the system have
been completed and hydro-tested in accordance with approved construction drawings,
approved specification, applicable code as defined in the BID package, accepted international
good engineering practices and all the activities have been completed in a comprehensive
manner by the Contractor. Contractor's competent representative (i.e commissioning,
operational & maintenance personnel) shall check the system/sub-system so that
facilities/system/sub-system meets the process requirement and is constructed as per the
approved drawings. After liquidating the checklist Contractor shall submit certificate (with
contractor’s competent representative’s checklist and it’s liquidation report) as per
FORMAT-I (attached in Annexure-I) stating system/sub- system, which is mechanically
completed. Checklist generated by Contractor representative and test certificates connected
with the system/sub-system shall form a part of the FORMAT-I. Certificates of various statutory
bodies for relevant portion of the work completed shall be made available by the Contractor as
part of mechanical completion. COMPANY / CONSULTANT representative shall check the
system along with Contractor’s representative and shall issue FORMAT-II (as per format given
in Annexure-I) which includes deficiencies / modifications required for the portion of the
work that is declared by the Contractor as mechanically complete. All checklist raised by
COMPANY/CONSULTANT/ are to be liquidated by contractor and issue the FORMAT-III
(as per format given in
Annexure-I). Any exceptions which will not affect the pre-commissioning start-up activities and
which is acceptable to COMPANY/ CONSULTANT with a plan to completing the same to be
recorded.

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2.2 PRE-COMMISSIONING ACTIVITIES

EPC contractor shall prepare a detailed Pre-commissioning activity for all the system which are
required to be performed after completion / installation, inspection, hydro-testing etc. of
equipment / system to make it ready for commissioning. EPC Contractor shall start pre-
commissioning activities after acceptance of FORMAT-III by OWNER / PMC. This shall include
but shall not be limited to activities such as system checking as per P&IDs/drawings, site
modifications, internal inspection of equipment/vessels, flushing/steam blowing, air blowing of
pipelines including gasket blowing, purging of system using inert gas, leak test, calibration of
instruments, checking of the electrical equipment for proper earthing, continuity, insulation
resistance, conducting operability test on individual equipment/system, charging of lubes & other
chemicals. Fabrication and supply of temporary facilities, for example, temporary bypasses,
spools, blinds, jump-overs, vents, strainers, screens etc. which shall be required to carry out
pre- commissioning activities shall be in the scope of the EPC Contractor. It is the responsibility
of the EPC contractor to call the vendor representative whenever required for successful
commissioning of the equipments. All the pre- commissioning activities shall be carried out by
EPC Contractor. Before start-up of the pre-commissioning activities, safety audit to be
conducted by EPC Contractor and OWNER / PMC for entire facility. Checklist/deficiency
generated by safety audit team shall be corrected / rectified by EPC Contractor at no time &
cost impact.
The EPC Contractor shall submit the list of systems and prepare list of pre- commissioning
activities to be performed for all applicable disciplines against each system including flushing
schemes for the piping sub-systems. The above details shall be prepared and submitted to
OWNER / PMC at least 60 days before start of the pre-commissioning activities.

2.3 READY FOR COMMISSIONING

The process systems shall be considered `Ready for Commissioning' when all the facilities
have been completed along with their auxiliaries and support facilities in every respect
including charging of lubes, chemicals, preparation of solution, any last minute modifications,
if any, as recommended by the OWNER
/ PMC. All temporary structures, scaffolding etc. used for carrying out the pre- commissioning
works shall be removed, all the blinds shall be put into position as required by P&IDs and
all systems as recommended by OWNER / PMC shall be purged and pressurized. All pre-
commissioning and other documents including blinds list, set pressures of PSVs and
their test certificates etc. (Testing shall be done at site) shall be handed over to the OWNER
/ PMC.
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The EPC Contractor shall issue a certificate of ready for commissioning of process systems for
acceptance by the OWNER / PMC in standard format, FORMAT-IV (as per format given in
Annexure-I) with all exceptions resolved.

After the facility has been declared as `Ready for Commissioning', the EPC Contractor shall not
carry out any hot work in the facility without prior written permission of the OWNER.

3.0 DOCUMENTS FOR PRE-COMMISSIONING / COMMISSIONING

3.1 OPERATING MANUAL

The EPC Contractor shall prepare facility specific draft-operating manual. This should include
procedure related with package items if any and submit to OWNER / PMC for review at least
150 days prior to mechanical completion. Five copies of draft operating manual in English (also
5 CDs of the same) shall be submitted by the EPC Contractor for review. In particular, following
information shall be covered as a minimum.
1. Design basis of facilities.
2. Chemistry of the process.
3. Detailed process / facility description.
4. Pre-start checks.
5. Pre-commissioning procedures
6. Start-up procedure.
7. Normal operating procedure.
8. Shutdown procedure (normal & emergency).
9. Facility
10. Operating parameters and set points of alarms and trips.
11. Operating conditions of different cases of operation.
12. Effect of operating variables on the process.

13. Functional description of all complex control schemes

14. Details of interlock logic, trip etc.
15. Functional description of safe shut down systems.

16. List of emergencies and emergency handling procedures.

17. Dosage rate of chemicals used and other related operating information.
18. Initial requirement of chemicals for first start-up.
19. Safe handling precautions for chemicals used.
20. List of equipment and their major details.
21. Relief valve schedule, tag numbers, location, set pressure, capacity basis, failure
scenarios considered etc.
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22. List of blinds for shut down and start-up.

23. Approved/ final PFDs / P&IDs, plot plan, equipment layout and equipment datasheets
etc.
24. Any other special conditions / instructions / information, etc.
25. Summary of chemical consumption.
26. Summary of utility consumption.
27. Lubrication schedule.
28. Gas Detectors
29. Hydrocarbon/chlorine detection and associated safety system.
30. Use of life saving devices
31. Fire and safety system
32. Laboratory analysis requirement and procedure with sampling schedule.
33. Procedure for preparation of equipment hand over
34. Work permit procedure
35. Chemical solution preparation procedure
36. Safe handling of chemicals
37. MSDS of chemicals
Review of operating manuals shall be done by OWNER / PMC within 30 days after receipt of
draft operating manuals. All the changes, additions, deletion required by the OWNER/PMC
shall be discussed with the EPC Contractor and shall be incorporated in the final operating
manual by the EPC Contractor. Twenty copies of final operating manual in English, (along
with 3 CDS of the same) shall be submitted by EPC Contractor. The same shall also be
forwarded in CD in MS
Office / PDF format. The manuals shall be submitted to OWNER / PMC at least 90 days prior
to mechanical completion. These operating manuals shall be followed during start-up and
commissioning of the facilities. Instructions in operating manuals provided by equipment
suppliers shall not form a part of this operating manual. However, key information shall be
provided.
In case of any revisions due to any reason, the same shall be incorporated and submitted as
revised sheets during the start-up and commissioning stage. However, revised operating
manual incorporating changes shall be submitted within one month after the commissioning
has been completed.

3.2 PRE-COMMISSIONING AND COMMISSIONING NETWORK

The EPC Contractor shall submit the pre-commissioning and commissioning schedule in the
form of network detailing therein the sequence of all the pre- commissioning and
commissioning activities and time taken by each individual activity to be carried out in each
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equipment / sub-system. This shall be submitted to OWNER / PMC prior to start of pre-
commissioning activities. EPC Contractor shall submit weekly progress report and the status
of pre-commissioning and commissioning activities, likely slippage and action being taken by
the EPC Contractor to contain this slippage.

3.3 PRE-COMMISSIONING MANUAL

It shall be the responsibility of the EPC Contractor to prepare detailed checklist of pre-
commissioning and commissioning activities for each equipment, subsystem, system and
facilities as a whole. The EPC Contractor shall submit the said format for approval to the
OWNER / PMC. This checklist shall indicate the checks / test to be carried out on each
equipment / system and shall also indicate the sequence and schedule of the activities.
For the purpose of execution of these pre-commissioning activities, the facilities shall be
divided into system and sub-systems so that pre-commissioning activities of each system/sub-
system can be progressively carried out along with the construction activities. The pre-
commissioning document shall contain the following as a minimum:
i) Systemisation
ii) Pre-commissioning and start-up schedule
iii) Detailed procedure for the various pre-commissioning activities i.e. flushing, blowing,
purging, drying, leak checking, system tightness, equipment operability test with forms to
record the observation of each of the activities to be carried out.
iv) Procedure and forms for operability tests of equipment and system as a whole,
wherever applicable.

v) Lube schedule indicating manufacturer, quality, initial fill recommended, and frequency
of changing the lube oil.
vi) Detailed procedure for carrying out passivation of cooling water system/compressor circuit
shall be approved before implementation. Requirement of tanks, pumps, chemical dosing
arrangement and apparatus for chemical analysis shall be detailed out by EPC Contractor
and shall be in EPC Contractor's scope.

The EPC Contractor shall submit the draft of above mentioned pre- commissioning
documents 180 days before the activities are to be carried out. The document shall be
reviewed by the OWNER / PMC. The EPC Contractor shall submit 120 days prior starting
of activities, a revised document after incorporating OWNER / PMC's comments. The
documents shall be followed till the project is completed.

Commissioning of the facilities shall not be permitted till all the documents have

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been submitted by the EPC Contractor to the OWNER. Any delay in commissioning on
this account shall be considered as a delay in commissioning by the EPC Contractor.

4.0 OTHER REQUIREMENTS

EPC Contractor shall ensure that all safety devices like pressure safety valves,
emergency shut down valves are tested, witnessed and certified in the presence of
representatives of OWNER / PMC at site . These certificates are to be handed over to
OWNER / PMC prior to start-up of the facilities. The EPC Contractor shall install `No
Smoking' boards & boards for other instructions at designated areas. EPC Contractor is
required to maintain and follow all safety practices, equivalent or better than those being
practised by OWNER for the complex during pre- commissioning and commissioning.
The contractor shall submit the complete description, detailed procedures and time
schedule for all of the following activities, as applicable, for approval of the
Owner/PMC.
i) Pre-commissioning checks
ii) Dewatering
iii) Swabbing
iv) Flushing/ Blowing
v) Leak test with Air / Nitrogen (at maximum operating pressure)
vi) Leak check with water at a operating pressure

vii) Idle time preservation (if applicable), including removal of preservers

All these documents should be prepared covering all aspects of HSE, quality
assurance and quality control plans.

The contractor shall ensure that his documents are related to “as-built”
conditions of the pipeline, equipment and structures involved.

Documents shall also contain all safety plans, procedures to be followed while
carrying out the activities.

Upon successful completion of the work, the contractor shall prepare a final report of
the work which shall include necessary charts, diagrams, graphs, calculations,
recordings, daily logs, measurements, details of the operation etc. Report shall
also include all certificates of calibration of instruments required, together with records
of calibration performed at site prior to the start of any operation and the approved
pre-commissioning and commissioning formats and check sheets.

5.0 MANUFACTURER'S REPRESENTATIVE Copyright EIL – All rights reserved

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It shall be the responsibility of the EPC Contractor to arrange for services of

manufacturer's installation / commissioning engineer at site during mechanical completion
/ pre-commissioning & commissioning of all the major equipment and systems listed as
under:
i) All critical pumps i.e. hydrocarbon pumps, vacuum pumps, chemical injection pumps, utility
pumps etc.
ii) All blowers, centrifuges, vacuum filters, agitators etc.
iii) All package type items, i.e., all types of compressors / chemical injection facilities,
crystallizers, dryers etc.
iv) Specialist for supervision of cooling water system passivation Gas (hydrocarbon
and H2) detection system, fire detection systems and safety equipment.
v) DCS
vi) Any other critical/proprietary equipment, for which it is felt necessary to call
Vendor's representative for proper commissioning.

6.0 REVIEW / CHECKLISTING / INSPECTION CO-ORDINATION

A general guideline on OWNER / PMC interaction with respect to facility pre-start up

activities is given below. However, OWNER / PMC reserve right to witness all works at any
stage.
1. Review of pre-commissioning documents and network (as detailed in section 3.2 and
3.3 above).
2. Review of operating manual (as detailed in section 3.1 above).
3. Check listing (system-wise)
a. Preliminary checklist on system completion.
b. Final checklist before start of pre-commissioning activities.

7.0 A TYPICAL APPROACH TO WITNESS / INSPECTION OF PRE-

COMMISSIONING ACTIVITY BY PMC / OWNER

Activities Witness/Inspection
a) Installation of safety device Complete
b) Provision of temporary strainers and blind at critical locations Complete
c) Water flushing and air blowing of pipelines Random
d) Instrumentation interlock checks Complete
e) Operability test for a system/equipment Complete
f) Blind list as per start up requirement/normal operation Complete

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i) Chemical cleaning of compressor suction line & lube oil circuit Complete

Witness/ inspection / approval of OWNER / PMC is not an obligation but a right with no
change in EPC Contractor's liabilities.
At the discretion of OWNER / PMC, the extent of witness / inspection may be
extended/ reduced as deemed fit.
8.0 FINAL INSPECTION BEFORE START OF COMMISSIONING

OWNER / PMC shall carry out a final inspection of the facilities. Record of liquidation of checklist
points, test records etc, shall be submitted by the EPC Contractor to OWNER / PMC. Any
deficiency/ changes required in the offered system shall be liquidated by the EPC Contractor.

9.0 COMMISSIONING

It shall be the responsibility of the EPC Contractor to commission the facilities under the scope
of the EPC Contractor. Commissioning shall be carried out under necessary guidance and
overseeing of representatives of OWNER / PMC after mechanical completion is over
successfully, all pre-commissioning activities are carried out and certificate of “Ready for
commissioning” is accepted by OWNER / PMC. Representatives of designer/ process
licensor shall provide necessary co-ordination during start up and they shall furnish technical
clarifications, as and when required. Commissioning of the process systems shall mean taking
the feed, passing it through the normal route; establishing the process control parameters first
at turn down & then at design value stipulated in the process package along with
supplementary instructions, if any, from OWNER / PMC.
The Process systems shall be considered to be commissioned successfully when the facilities,
with instrumentation / control systems, process, utilities and support systems have been on
uninterrupted stable operation for not less than 72 hours. Whether the
72 hours operation has been successful or not, shall be decided by the OWNER based
on observations recorded during 72 hours. The countdown for 72 hours operation shall
start only after the facilities have been on stable operation with all controls and safety system
in normal operation for a period of not less than 48 hours. Three months prior to starting
commissioning, the EPC Contractor shall submit proposal to the OWNER / PMC giving
details of the programme to be followed during commissioning. This shall be reviewed by
OWNER / PMC. The EPC Contractor shall arrange trained operation team comprising of
commissioning manager, shift in-charge, main control room operators (DCS and local
panels), field operators, mechanical, electrical and instrument engineers / foreman etc. to

carry out facility start-up and commissioning and for process operations and maintenance.
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The EPC Contractor is also required to provide on the job training to OWNER’s operation
personnel by associating them in all the day to day pre-commissioning, commissioning and
maintenance activities and process operations, however, responsibility for adequate manning
the facility shall be that of EPC Contractor. After successful commissioning of the facility as
above the same shall be handed over to the OWNER for operation. In case of any constraint
in achieving the above process parameters in the facility, the same shall be communicated by
the EPC Contractor to the OWNER / PMC in writing. This shall be reviewed jointly by
OWNER / PMC to arrive at a decision on whether the constraint is on account of reasons
attribute to EPC Contractor or not. The action in either case shall be according to the relevant
provisions provided elsewhere in the contract.
EPC Contractor in some cases may be required to do part commissioning of the
mechanically completed sections of the facilities as per directives from the OWNER. Upon
successful commissioning of the facilities the same shall be taken over by the OWNER for
day to day operation and maintenance only. Final takeover shall be subject to compliance
to all the contractual obligations by the EPC Contractor. Once the facilities are successfully
commissioned, EPC Contractor shall issue FORMAT-V (as per format given in Annexure-I) to
OWNER / PMC for take over the of the facilities from EPC Contractor

10.0 SPARES AND CONSUMABLES

EPC Contractor shall be responsible for the supply of all spares and consumables for start-up, pre-
commissioning and commissioning. Excess spares shall be handed over by EPC Contractor to the
OWNER after commissioning. EPC Contractor shall be also responsible for supply of lubes,
chemicals and other consumables, as discussed elsewhere in this package.
The utilities to the extent of normal consumption during operation of facilities like air, nitrogen,
power, water, and steam during pre-commissioning /commissioning shall be provided to the
EPC Contractor at the battery limit of the facilities by OWNER. It shall be the EPC Contractor's
responsibility to repair any damage to the system occurred during storage, installation, pre-
commissioning and commissioning stage. EPC Contractor shall submit catalogues for all the
lubricants and chemicals being charged for commissioning.

11.0 SPECIAL REQUIREMENT

All the utilities like air, cooling water, raw water, steam, power, instrument air etc. shall be
provided at the conditions and locations given in the package and drawings. Any upgrade, if
required, either for pre-commissioning or commissioning shall be carried out by the EPC
Contractor at his own cost. Hook-ups required between various EPC Contractors shall be
provided by the EPC Contractor wherever it is shown in his scope.
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12.0 SAFETY

The EPC Contractor shall follow OWNER's safety practices during execution of pre-
commissioning / commissioning works. EPC Contractor is required to maintain and follow
all safety practices equivalent or better than those being practised by OWNER for the complex
during pre-commissioning and commissioning.

13.0 STAFFING OF FACILITIES

EPC Contractor to identify and submit manning requirement (category) and the facility
operation organisation structure to OWNER/PMC for effective operation and maintenance of
the facilities.

14.0 CHECK LISTING

The procedure for the Check listing as well as verification of liquidation shall be developed by
EPC contractor & submitted for the approval of OWNER / PMC.

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ANNEXURE - I

FORMAT TO BE USED DURING PRE-COMMISSIONING AND COMMISSIONING

(TOTAL 5 FORMATS)

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FORMAT-I

INTIMATION REGARDING SYSTEM COMPLETION

PROJECT: OWNER : FACILITY:

Following system/sub-system has been mechanically completed in all respects with

exceptions noted below. The system/sub-system can be taken up for checking and
preparation of checklist.

SYSTEM NO.

SYSTEM DESCRIPTION:

EXCEPTIONS:

SIGNATURE DATE

Contractor

The system is ready / not ready for Check listing

OWNER/PMC :

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F O R M A T - II

CHECKLIST

PROJECT: OWNER : FACILITY:

SYSTEM/SUB-SYSTEM

CHECKLIST TYPE PRELIMINARY/FINAL

SL.NO. CHECKLIST ITEMS REMARKS

SIGNATURE DATE

PMC :

OWNER:

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F O R M A T - III

READY FOR PRE-COMMISSIONING CERTIFICATE

PROJECT: OWNER : FACILITY:

SYSTEM/SUB-SYSTEM

This is to certify that the following facilities/system/sub- system as detailed below is

completely installed and all the Checklist points are carried out except for minor details
as given in the attached list.

DESCRIPTION ON FACILITIES/SECTION/SUB-SECTION

SIGNATURE DATE

CONTRACTOR’S CONSTRUCTION
CO-ORDINATOR:

CONTRACTOR’S COMMISSIONING
CO-ORDINATOR

The system is ready / not ready for pre-commissioning

PMC :
OWNER:

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F O R M A T - IV

READY FOR COMMISSIONING CERTIFICATE

PROJECT: OWNER : FACILITY:

SYSTEM/SUB-SYSTEM

This is to certify that all the necessary pre-commissioning activities for the system /
sub-system as detailed below have been completed and the system/sub-system is ready
for commissioning except for the minor details as given below which shall not affect the
commissioning trial runs.

DESCRIPTION OF SYSTEM/SUB-SYSTEM

SIGNATURE DATE

CONTRACTOR’S COMMISSIONING:
CO-ORDINATOR

SIGNATURE DATE

PMC:

OWNER:

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FORMAT-V

COMPLETION OF COMMISSIONING CERTIFICATE

PROJECT: OWNER : FACILITY:

SYSTEM/SUB-SYSTEM

This is to certify that the system/sub-system as detailed below has been successfully
commissioned and is under operational control of OWNER. The minor items, which shall
not affect the normal operation of the system/sub-system, are given in the attached list.

DESCRIPTION OF SYSTEM/SUB-SYSTEM

SIGNATURE DATE

CONTRACTOR’S COMMISSIONING:
CO-ORDINATOR

SIGNATURE DATE

PMC

OWNER

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