080036 dz pq 001 r3 pre commissioning & commissioning execution plan

PRE COMMISSIONING & COMMISSIONING EXECUTION PLAN

CONTRACTOR ID CODE 080036-DZ-PQ-001

ACVC ID CODE 080036-DZ-PQ-001

ARABIAN CHLOR VINYL PROJECT AL-JUBAIL K.S.A Sheet 1 of 45 Issue 3

This Document is the property of ACV and is lent without consideration other than the Borrower’s agreement that it shall not reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

Pre-Commissioning & Commissioning Execution Plan

EPC CONTRACTOR:

3 For Construction K.S.K Y.T.Y D.G.S C.W.Y 18-Jan-2012

2 For Construction K.S.K Y.T.Y D.G.S C.W.Y 05-Dec-2011

1 For Construction K.S.K Y.T.Y D.G.S C.W.Y 18-Nov-2011

0 For Construction K.S.K Y.T.Y D.G.S C.W.Y 30-Sep-2011

A For Approval K.S.K Y.T.Y D.G.S C.W.Y 03-Aug-2011

Issue DESCRIPTION PREP’D CHK’D APPR’D APPR’D Date






Table of Contents

1. General ............................................................................................................................................ 6

1.1. Introduction ............................................................................................................................ 6

1.2. Objectives .............................................................................................................................. 6

1.3. Pre-commissioning & Commissioning activities ..................................................................... 6

1.4. Units of measurement/language ............................................................................................ 7

1.5. Standards and specifications ................................................................................................. 7

1.6. Key project documents .......................................................................................................... 8

2. Plant overview ................................................................................................................................. 8

2.1. CA plant ................................................................................................................................. 9

2.2 EDC plant ............................................................................................................................. 13

2.3 Utilities ................................................................................................................................. 14

3 System definition .......................................................................................................................... 17

4 Organization. ................................................................................................................................. 17

4.1 Introduction .......................................................................................................................... 17

4.2 Preparation step (documentation step) ................................................................................ 18

4.3 Pre-commissioning step. ...................................................................................................... 20

4.4 Commissioning and start up step ........................................................................................ 21

5 Construction & pre-commissioning ............................................................................................ 23

6 Mechanical completion ................................................................................................................ 25

7 Commissioning ............................................................................................................................. 26

7.1 Introduction .......................................................................................................................... 26






7.2 Schedule .............................................................................................................................. 28

7.3 Work permit control .............................................................................................................. 28

7.4 Lock-out and tag-out ............................................................................................................ 28

7.5 Vendor commissioning activities .......................................................................................... 28

7.6 Spare parts, temporary equipment and consumables ......................................................... 29

7.7 Tightness test ....................................................................................................................... 29

7.8 Drying out / inerting of lines and equipments ....................................................................... 31

7.9 System by system commissioning ....................................................................................... 32

7.10 Plant initial start up(electrolyzer energizing) ........................................................................ 36

8 Ready For Start Up (RFSU) .......................................................................................................... 38

9 Start up .......................................................................................................................................... 39

10 Testing ........................................................................................................................................... 39

10.1 Introduction .......................................................................................................................... 39

10.2 Number of tests .................................................................................................................... 39

10.3 Performance test .................................................................................................................. 40

10.4 Reliability Test ...................................................................................................................... 42

11 Hand-over ...................................................................................................................................... 43

12 Punch and Punch Control ............................................................................................................ 43

13 Vendor’s training at site ............................................................................................................... 44

13.1 Vendor’s technology support. .............................................................................................. 44

13.2 Vendor’s training at site ....................................................................................................... 44

14 Communication ............................................................................................................................. 44

14.1 Radio-communication .......................................................................................................... 44

14.2 Mobile phone ....................................................................................................................... 44






15 Reporting ....................................................................................................................................... 44

16 HSE management ......................................................................................................................... 45

Attachments .......................................................................................................................................... 45

Attachment 1: Pre-commissioning / commissioning & start up schedule

Attachment 2: Pre-commissioning / commissioning process and activities

Attachment 3: Organisation for preparation phase

Attachment 4: Organisation for pre-commissioning phase

Attachment 5: Organisation for commissioning phase

Attachment 6: Completion process flow chart

Attachment 7: Start up flow chart

Attachment 8: EDC Plant Drying & Start-Up Plan

Attachment 9: List of Preparation Plan of Pre-commissioning &Commissioning Documents and Activities






Revision Index

Rev Date Description

3 18-Jan-12 Revision as per SAMAPCO comments(TR-OH-DH-5406, dated on 09-Jan-12)

2 05-Dec-11 Revision as per SAMAPCO comments(TR-OH-DH-6088, dated on 04-Dec-11)

1 18-Nov-11 Revision as per SAMAPCO comments(TR-OH-DH-4884, dated on 27-Oct-11)

0 30-Sep-11 Revision as per SAMAPCO comments(TR-OH-DH-4531, dated on 12-Sep-11)

A 03-Aug-11 Issue for Approval






1. General

1.1. Introduction

The Arabian Chlor Vinyl Plant in the Kingdom of Saudi Arabia, comprising a plant and associated

facilities at Jubail Industrial City including a caustic soda and ethylene dichloride plant and associated

infrastructure, along with utilities and off-sites, with the capacity to process 250,000 MTPA(100%con.

Basis) of caustic soda and 300,000 MTPA of ethylene dichloride. This pre-commissioning and commissioning execution plan covers overall pre-commissioning and

commissioning execution works and provides basic information to SAMAPCO. It will be used as

guidance for the further development of the functional work. This commissioning execution plan describes the organization, philosophy and plans for pre-

commissioning, commissioning, ready for initial start up (electrolyzer energizing), RFSU, start up,

testing, and handover. This plan is to be read together with other plans and procedures which are

written for the project. This plan is a “live” document and will be subject to further periodic review by SAMAPCO and a

commissioning works to reflect project requirement changes or situations.

1.2. Objectives

The objectives of this project are to design, construct and commission the facilities and reach steady

state operation within the agreed project schedule and budget, and deliver CA/EDC facilities to

SAMAPCO that are mechanically complete and operationally proven within the project specifications.

Contractual target dates are;

Plant Initial Acceptance date : 02 Dec. 2012 Taking-Over date : 02 Jan. 2013

For this purpose, the commissioning organization will carry out the following activities.

1.3. Pre-commissioning & Commissioning activities

(1) Preparation of documentation - This includes management documents and procedures, check

lists and system definitions.

(2) Pre-commissioning of the facilities – before Mechanical Completion (MC), pre-commissioning will

be performed by each system as per approved procedures.

(3) Commissioning of the utility - Each utility will be commissioned and energized according to the






approved commissioning procedures. Completion of commissioning and energizing of utilities

shall be done before MC date.

(4) Once utilities are energized and process systems have been dried and inerted with nitrogen,

commissioning team will carry out the following.

Pre start up safety review (PSSR)

Ready for initial start up and operation which allows energizing of the electrolyzer.

Ready for start up, which means the design rate operation of the process systems in which

dynamic tuning of controllers is performed and system functions checks are completed.

Start up – this phase includes initial operation and carrying out of the performance guarantee

test by Contractor to demonstrate the performance characteristics. The plant have been

achieved in accordance with the procedure outlined in contract, reliability operation test of the

plant and all its components are assessed and analyzed.

Reliability test - this will follow after performance guarantee test. (5) Once all basic functions of a sub-system have been functionally tested and all relevant pre-start

up activities for that sub-system are completed, the sub-system will be subject to an operational

test wherever applicable. This operational test brings the equipment into operation under

condition as close as possible to normal. The purpose of operational test is therefore to prove

that the major equipment is mechanically sound, and that each sub-system, as a whole, is ready

for normal operation. ESD tests will be performed. The operating test procedure will be developed

during commissioning preparation phase and submitted to SAMAPCO for approval.

(6) The Contractor will conduct performance testing in accordance with the contents of the contract.

The performance test procedures will be developed by the Contractor and submitted to

SAMAPCO for approval prior to conducting the tests.

(7) Repair and/or corrective measures, both planned, as per agreed project schedules, and

unplanned break down will be performed.

1.4. Units of measurement/language

Metric system shall be used as the unit of measurement and English language will be used on all

official project documents.

1.5. Standards and specifications

In general, the pre-commissioning and commissioning works will be carried out in accordance with;

Arabian law

Royal Commission Environmental Regulations (RCER-2004)






ASTM / ASME /API / TEMA (Tubular Exchanger Manufacturer's Association)

AD-2000 Standard / EN/DIN Standard / UBC 1997 / SMACNA

SAMAPCO project standards (SPCC-M-001-01, SPCC-G-006-02, SPCC-M-004/005/006,

SPCC-A-003/004/0056)

International Electrotechnical Commission (IEC)

SPCC-E-001/E-001-04

National Fire Protection Association (NFPA)

Contractor’s codes and working standards

1.6. Key project documents

Key project documents to be used in conjunction with this pre-commissioning and commissioning

execution plan are shown below.

Contract

Engineering procedure

SAMAPCO Specification

Construction execution plan

Project quality plan

Work permit approval system procedure

Document/equipment numbering system

Project HSE plan

Construction HSE plan

Coordination procedure

2. Plant overview

The Arabian Chlor Vinyl Project is to produce CA/EDC product in the Kingdom of Saudi Arabia,

comprising a plant and associated facilities at Jubail Industrial City including a caustic soda and

ethylene dichloride plant and associated infrastructure, along with utilities and offsite ,with capacity to

process 250,000 MTPA (100% con. basis) of caustic soda and 300,000 MTPA of ethylene dichloride.

The CA/EDC plant is designed to make chlorine and caustic soda from salt electrolysis process and

EDC by react chlorine with ethylene.

The plant consists of salt handling, brine treatment, electrolyzer, chlorine cooling, drying, compression,

EDC reaction, EDC purification, H2 boiler system, demineralized water system, product storage tank,

package items and others.

In addition to these facilities, equipment for electric power, cooling water system, process water,

instrument air, nitrogen storage and vaporization, sewage and waste water treatment, fire water supply

are also provided.






2.1. CA plant

2.1.1. Salt storage and handling

Raw salt will be received at site by trucks. Salt will be unloaded into the salt unloading hoppers. Salt

from unloading hoppers will be transferred to salt storage through belt conveyor. Salt is fed to

saturation pit where salt is dissolved using lean brine having a concentration of app. 205 gpl.

2.1.2. Primary brine system

The CA Plant has a total cell-room production capacity of 768.8 MTPD NaOH 100% as 32% solution.

The primary brine system is designed to produce polished brine containing less than 0.5 ppm of

suspended solids.

For satisfactory operation of membrane cell electrolyzer, ultra pure brine is a must. The primary brine

system comprise of the following system: brine saturation, brine precipitation and Na2CO3 preparation,

brine clarification, brine filtration (anthracite media), brine polishing

2.1.3. Secondary brine purification

In order to warrant trouble-free operation of the membrane cells and a long service life of the

membranes, the cells must be supplied with extremely pure brine. The calcium and magnesium

content in the brine is not allow to exceed a maximum level, which is less than 20 ppb, as the

deposition of these ions in the membrane affects its function and leads to an increased power

consumption. Such low contents can be achieved in a proven technology by using ion exchange

columns.

The columns are filled with a cation exchange resin, with a very high selectivity for calcium,

magnesium and strontium cations. The ion exchange resin absorbs calcium and magnesium ions

present in the brine. Ion exchange nozzles ensure the resin remain in the columns.

2.1.4. Brine dechlorination

The considerable amount of chlorine remaining dissolved in the anolyte, which requires dechloination

unit before the lean brine can be recycled to the saturator. The dechlorination is carried out in two

process steps. The first step is a Cl2 desorption under vacuum. In the second step the remaining free

chlorine in the brine is chemically destroyed by means of sodium bisulphite(NaHSO3).

Bisulphite solution is added in slight excess to ensure that no Cl2 escapes.

2.1.5. Chlorate Decomposition

Electrochemical side reactions in the cell generate the chlorates. As the electrolyte recirculates, a

chlorate decomposition unit is required to prevent the accumulation of NaClO3. This unit forms mainly

chlorine from the chlorate and hydrochloric acid reaction.

2.1.6. Sulphate removal

Amount of sulphates in brine keeps on accumulating and if not reduced then exceeds the maximum

limit for the safe operation of the membrane plant. So part stream from the lean brine pump is sent to

lean brine cooler where lean brine entering cools down and lean brine leaving the Nano filtration unit






gets heated from lean brine cooler.

Brine enters a series of filter for removal of suspended particles. First filter is activated carbon filter and

second one is lean brine filter. After filtration brine goes to the filter feed tank from where brine goes to

sulphate removal system. The reject stream from the unit is then sent to gypsum precipitation tank

where sulphate is converted into gypsum by addition of calcium chloride from CaCl2 tank. The gypsum

thus formed is transferred to gypsum filter by gypsum filter pump. The filtered gypsum is transferred to

B.L.

The permeate lean brine from the sulphate removal system and filtrate from gypsum unit is sent back

to brine saturators.

2.1.7. Cell room and electrolysis

The cell room is designed to produce 768.8 MTPD NaOH 100% as 32% solution and chlorine using 8

electrolyzers containing 171 bipolar cell elements each +21 spare each,.

The electrolyzers normally operate at a load of 16.32KA or 6kA/m2 to produce 768.8 MTPD NaOH

100% as 32% solution. The bipolar cells are capable of very fast load changes, which are only limited

by maintaining a stable chlorine and hydrogen pressure.

Pure brine having a concentration of 300-310gpl flows into the electrolyzer cells

Each electrolyzer cells have two chambers. The anode chamber and cathode chambers of the cell are

isolated from each other by the membrane. Cl2 is liberated at the anode surface and flow to the

anolyte header with depleted brine.

H2 is liberated at the cathode surface and flow to catholyte header with 32% NAOH

2.1.8. Chlorine treatment

In order to improve the heat balance of the electrolysis process, the energy of chlorine from

electrolyzers is recovered first against the brine system, then cooling water and finally chilled water.

Chlorine leaving the cells is about 88℃ and about 200mbar and is saturated with water vapor.

The chlorine gas is passed through chlorine recuperator(E12103) where it exchanges heat with

polished brine.

Chlorine is cooled down whereas polished brine is heated. Chlorine gas at about 65℃ then passes

through Chlorine cooler I(E12104) where it is cooled to 45℃ using cooling water.

The gas leaving cooler I is further cooled to 15℃ in chlorine cooler II (E12105) using chilled water.

Protection of membranes against too low chlorine pressure is achieved by under pressure safety

vessel (D12101), which is connected to chlorine waste air header.

The control valve relieving the excess chlorine pressure to waste gas dechlorination is located

between coolers I and II.

Temperature controller on the outlet of CL2 gas stream from chlorine cooler II controls the chilling

water flow to the cooler.






The gas leaving the cooler II is then passed through the wet chlorine filter (F12101) to remove the

entrained brine aerosol.

Demineralized water is continuously added to the inlet stream to flush away any salt crystals that may

have deposited on the surface of the filter candles and may increase pressure drop.

Part of the stream emerging from wet chlorine filter is withdrawn and sent to HCL synthesis unit as per

requirement.

The moist chlorine gas coming from the wet chlorine filter is dried in chlorine drying tower by means of

98% sulphuric acid to meet final moisture content of about 10ppm wt%. The chlorine leaving the drying

tower flows to the chlorine compressor via a dry chlorine filter to remove entrained H2SO4 droplets.

2.1.9. Chlorine compression

Dry Cl2 gas from dry chlorine filter enters suction side of Cl2 compressor at around 1.02bar(a) and

15℃ and is compressed to about 5 bar(a) and 45℃ in a three stage chlorine compression unit.

After every compression stage, the compressed chlorine is cooled to prevent excessive outlet gas

temperature by chilled water. The compressed chlorine is transferred to EDC plant.

2.1.10. Waste gas dechlorination

The waste gas dechlorination unit serves as a safety system and removes chlorine and traces of HCl

from the waste gases drawn from various parts of the plant. All chlorine bearing waste streams from

the plant are led to the waste gas dechlorination system, where it is rendered free of chlorine in three

stages by absorbing the chlorine in caustic soda solution. The absorption leads to the formation of

sodium hypochlorite (NaOCl).

The first two stages are designed with an ejector each whereas the third stage consists of a final

absorber.

The bleaching lye produced by the waste gas unit is collected in the bleaching lye tanks.

It is then pumped to anolyte system by bleaching lye pumps.Here, NaOCL can be decomposed with

HCL to NaCL and Chlorine. Chlorine will be recovered back into the chlorine system.

2.1.11. Cell work shop

A cell work shop meets the requirements to assemble and dissemble the cell elements and for all

manipulations necessary in the cell room

2.1.12. Rectifier transformer system

Required amount of electricity at required voltage is supplied to the electrolyzers through transformer-

rectifier.

Each electrolyzer is connected to one rectifier. Two rectifiers are connected to one transformer.

Switches are provided for isolation of each electrolyzer.

Thus there are 8 rectifiers and 4 transformers.






2.1.13 Polarization Rectifier

Each electrolyzer is supplied with a polarization rectifier, connected to the bus bars between switches.

The polarization rectifier feeds a small amount of current to the electrolyzer to prevent damage to

cathode coating in presence of chlorine.

Such situation arises especially in case of shutdown. A diode prevents reverse current flow into the

rectifier when the main rectifier is running.

2.1.14 Caustic concentration/ Storage tank

The caustic concentration unit is designed to handle 768.8 MTPD NaOH100% as 32% solution

production from electrolyzer.

32% caustic leaves the electrolyzer through an overflow pipe into the Catholyte Header along with

hydrogen.

Separation of H2 and Catholyte takes place in the Catholyte Header

The Catholyte (32% NaOH) flows under gravity at approx. 88°C to the Catholyte Tank and transferred

to the caustic concentration unit

32% caustic soda is concentrated to 50% in the caustic evaporation package unit by steam produced

in the H2 boiler system.

This unit is based on an optimization of investment and operation costs considering the following

aspects;

•Using heat recuperation of vapour, product and steam condensate to lower the steam consumtion.

•Capacity of quick capacity changes.

•Using special materials to increase corrosion resistance of those parts in contact with caustic soda.

The caustic soda at 50% by wt. of concentration is received from the concentration unit and stored in

the NaOH 50% day tank (TK13301 A/B) with a volume of 1100m3 each.

The tank is located within a dike, designed to hold the content of the tank.

Safety interlocks are provided to stop the feed into tank upon high liquid level and to stop transfer

pumps on low level signal.

From TK 13301A/B, 50% caustic is pumped to the NaOH bulk storage tank (TK35001) with a volume

of 19000m3.

2.1.15 Hydrogen treatment

The hydrogen cooling system is designed to handle a hydrogen load corresponding to 768 MTPD

caustic soda (100%) production from electrolyzer.

The system consists of the treatment section, where cooling and filtering of the gas is done, a

condensate collection system and the hydrogen stack. Hydrogen gas leaving the cells is at a pressure






of about 220 mbarg and a temperature of about 88℃. The gas is saturated with water vapors at these

condition and is cooled to around 45℃ by cooling water in the hydrogen cooler, where most of water

vapor condenses. The cooled gas is passed through hydrogen filter to remove mist and NaOH

aerosols. Most of hydrogen gas feed to the boiler system as a fuel and a part of the gas to the HCl

synthesis unit as per requirement.

2.1.16 HCl synthesis and storage

This unit is designed for the production of 86MTPD of HCl 100% as 32% solution. The HCl synthesis

system consists of HCl synthesis unit with scrubber column and two HCl storage tanks with transfer

pumps.

2.1.17 Waste water treatment (neutralization)

Waste water from process buildings are collected in pits / sumps in various process areas and pumped

via pit pumps or routed via trenches to the waste water pits for chemical treatment.

The waste water unit is designed to treat process effluents from the plant and to send them after PH

adjustment and free chlorine removal to outside for disposal.

2.2 EDC plant

The process plant consists of 3 units.

Direct chlorination unit,

EDC purification,

EDC drying and waste water stripping.

2.2.1 Direct chlorination

Chlorine reacts with ethylene directly to make ethylene dichloride.

The reaction is carried out in a recycle reactor which consists of the U-shaped reaction loop and the

EDC vapors drum which is installed on top of the reaction loop.

Reaction takes places in the upper part of the loop’s riser.

In this process the required chlorine is drawn into the reactor with the ejector J21001 which is operated

with a driving stream of circulation EDC. The ejector is designed in a way to ensure that the required

chlorine flow is brought into the system at partial load conditions that means with reduced driving

stream.

Ethylene is dissolved physically in EDC in the lower part of the riser section of the reaction loop

R21001. Even at partial load conditions the difference in density between the riser and the down

comer section of the reaction loop ensures a constant flow of the reaction medium.

2.2.2 EDC distillation

In order to achieve sales grade EDC quality, reduction of byproducts formed by side reactions in the

direct chlorination process is required. To remove these components, which mainly consist of high






boiling compounds 1.1.2-trichloroethane or 1-bromo-2-chloro-ethane, EDC is purified with two

distillation columns:

EDC column system

Vacuum column system

2.2.3 EDC drying, waste water stripping and incineration

This unit serves the following three purposes:

Drying of EDC (operation mode 1)

Waste water stripping (operation mode 2)

Disposal of process waste gas and waste liquid

Dry EDC is required for the initial filling of equipment like vessels, filters and columns of the EDC Plant

before start up of the plant. Additionally, dry EDC is required for removing moisture inside of the plant.

The second application for the stripper column T27001 is the removal of EDC from contaminated

surface water. This water is collected in several pits located inside the plant area

The waste water enters the waste water stripper, where EDC and other steam volatile organic

components are stripped off from water by heat input through reboiler.

The unit is operated only discontinuously. It can be brought into service whenever it is necessary.

Furthermore, the incineration package unit PK27001 is assigned. The incineration system is used for

the disposal of all continuous process waste gases and non-continuous waste gases (e. g. from

collecting drums system, equipment shutdown, maintenance) containing chlorinated hydrocarbons, as

well as liquid chlorinated waste by-products.

2.2.4 Flare

One low-pressure flare system is installed. The flare is the ignitable vent type. During normal operation,

small operational intermittent releases will be vented through the flare stack. During emergency

condition, the flare will self ignite to properly dispose any emergency releases.

2.2.5 Truck loading

The plant includes a truck loading facilities for send-out 50% NAOH, 32% HCL and 78% H2SO4.

Each loading bay is fitted with an articulated liquid loading arm.

2.3 Utilities

2.3.1 Steam & condensate system

Steam will be generated as MP steam at steam boiler package to match the overall demand of both

MP and LP steam users. A portion of the MP steam will be letdown and desuperheated to LP steam to

balance the LP steam system demand. LP steam is also produced from MP condensate and blow

down. All steam condensate recovered back and recycled.






2.3.2 Cooling water system

The closed cooling water circuit provides cooling water to the various users in the CA/EDC plant and

associated utilities, and returns warm cooling water from the users to the cooling water exchanger

(E4302A~H) which is installed at the outside of the plant via a set of cooling water circulation pumps

in ISBL.

The warm cooling water is cooled through the exchanger by sea water that is cooed by the cooling

tower in the neighbor ALWAHA plant.

2.3.3 Chilled water system

The chilled water circuit provides chilled water to the various users in the CA/EDC plant, and is also

used to provide cooling to the safety shower water. Return water from users is chilled against

refrigerant from the refrigeration unit. The circuit comprises of chilled water supply and return headers,

chilled water supply (TK43501) and return tank (TK43502), circulation pumps (P43501A/B), water

chiller (E43501) and chemical dosing package (PK43501).

2.3.4 Drinking water system

Potable water from off-plot is treated to produce drinking quality water to supply drinking water

fountains, safety showers and eye wash stations. Water is continuously circulated from the safety

shower buffer tank (TK41201) through a drinking water treatment package (PK41101) around a ring

main and back into the tank.

2.3.5 Process water system

The process water distribution system will be supplied with potable water received from Royal

Commission (RC). The water is subsequently distributed to produce demineralised water and to

provide water for various process users and utility stations throughout the plant.

2.3.6 Demineralised water system

The demineralised water plant will be designed to produce water of a high enough quality, which is

distributed to deaerator for production of boiler feed water, the CA and EDC process units and

auxiliary plants.

2.3.7 Fire water system

The process water from OSBL will be used as firewater to fill the storage tank (TK49601). A looped

underground firewater distribution system shall be provided for all areas of the plant.

The plant will maintain a minimum quantity of fire water on site sufficiently to supply the maximum fire

water demand for a specified period according to the basis of design safety philosophy.

Above ground fire water piping is constructed of carbon steel. The fire water main ring is to be buried

in order to minimize risk of damage from collision or explosion. 3 fire water pump P-49602A/B/C (1






electrical and 2 diesel) and 2 fire water jockey pump P-49601A/B were installed.

2.3.8 Boiler feed water system

To provide BFW to steam boiler (PK41801AB), incinerator (PK27001) and desuperheater (E41807),

BFW is prepared in deaerator (D14804) with demineralised water which is preheated by condensate.

2.3.9 Instrument air system

Compressed air is dried in desiccant dryer package (PK46002), to meet instrument air quality.

Instrument air from PK46002 is distributed to users via the instrument air receiver (D46004).

2.3.10 Plant air system

Compressed air (plant air) is generated by 2 air compressor units in the package (PK46001A/B), which

operates in a duty and a standby arrangement. Compressed air is distributed to users via air receiver

(D46002).

Emergency air receiver (D46005) is dedicated to provide plant air to the emergency caustic tank

(D12604) under upset conditions.

2.3.11 Nitrogen system

A supply of gaseous nitrogen (LP nitrogen) is available at the OSBL plant battery limit via a pipeline

from an external supplier. Nitrogen is supplied between 6.0 and 10.0 Bar from OSBL and is distributed

to various users across the CA/EDC plant and associated utilities. Pressure may be letdown locally

according to requirements of the individual users. If it is not available from external supplier,

emergency nitrogen can be supplied by the liquid nitrogen package unit (PK44002), composed of a

standard vertical storage drum, loaded from road tankers, associated with ambient air vaporizers.

2.3.12 Refrigeration system

The refrigerant is used to cool the overhead vapor stream from the EDC column in the EDC column

chiller in order to recover EDC, and to provide the cooling duty required by the chilled water system.

Refrigerant is also used in the EDC vent condenser, where liquid EDC is recovered from tank vents

and returned to storage. The remaining chilled vapor is routed to incineration system.

2.3.13 Fuel gas system

Fuel gas is supplied to the OSBL boundary from the neighboring PP plant via a fuel gas header. Fuel

gas is mainly required by the EDC incinerator located in the ISBL. It is used at start up and to meet

heat input requirements during normal operation. Fuel gas shall first pass through knock-out drum

(D41501) to remove any slugs of particles from the fuel gas supply. A cyclone separator (S41501) and

filters (F41501A/B) are provided for removal of fine particles from the fuel gas supply.

2.3.14 Electric power system

The Plant receives power from the PEA substation.

Battery limit is the bus bar connection to the existing Sahara 230kV GIS Bay.






Supply system is incoming: 230 kV, 3 phases, 3wire, 60 Hz, and 63 kA for 1 second.

Two feeders from the existing Sahara 230kV GIS Bay feed power to the two (2)-230/34.5kV

transformers via underground cables.

The two transformers which shall have on-load tap changing capability will transform the 230kV

voltage to 34.5 kV to supply power to the double -ended, indoor, air insulated 34.5kV switchgear

located in the main substation

The 34.5 kV switchgear is to feed power to the two (2)-34.5/4.16kV transformers which will transform

the 34.5kV voltage to 4.16kV to supply power to all distribution transformers which will step down

voltage to the utilization levels of 4.16kv and 0.48kv.

The 34.5 kV switchgear is also to feed power to the four (4) -34.5kV/544.4V rectifier transformers

which will transform 34.5kV voltage to 544.4V voltage to supply power to the eight (8) rectifiers which

will convert AC voltage to DC voltage.

An emergency diesel generator is provided to start automatically and supply electric power to certain

critical equipment in the event of failure of the power supplies from PEA Substation. An uninterruptible

power supply (UPS) will be provided to safety critical systems.

3 System definition

Designation for separate system/sub-system shall be given in order to increase the accuracy and

expedition of the commissioning of each step and be marked up on P&ID.

The purpose of this designation is to define the systems that will be used for the Project. These

systems will be used as the basis to facilitate progressive completion of construction, pre-

commissioning, Mechanical Completion, commissioning and RFSU of the Contract Plant.

Designation for separate system/sub-system shall be completed by the commissioning team

(responsible for executing pre-commissioning and commissioning).

These system definitions will be detailed in a separate procedure.

System definition (080036-MZ-SD-001)

4 Organization.

4.1 Introduction

The Contractor shall approach step by step with careful preparations by expert on each step because

this plant is a newly built CA, EDC plant which is composed of facilities which are extremely toxic and






explosive.

The Contractor will select key personnel who have experience on commissioning and operation of CA,

EDC facilities with minimum five years and others who will assist the key personnel shall be trained by

the key personnel.

In addition, key personnel such as commissioning manager and discipline leaders shall participate in

the project from the preparation step, whereby the continuity of tasks shall be secured and each step

shall be transferred smoothly to next step.

During the pre-commissioning, commissioning, start up and testing of the plant, an integrated

commissioning team will be organized with SAMAPCO personnel if required. During commissioning,

SAMAPCO’s operators shall work under Contractor supervision, but maintenance staff will only

witness during Contractor’s worker do the job.

Punch control team shall be organized for the control of the punch. That team shall be managed under

site manager’s direction and supported by commissioning team.

The timing of the joining of SAMAPCO’s personnel to the commissioning team will be based upon the

staffing plan and the organization chart which will be jointly developed by the SAMAPCO and the

Contractor.

The operation of the Plant up to achievement of Initial Acceptance as per Contract shall be carried out

by Contractor under his sole responsibility and at his expense.

After reliability test operation, systems shall be completed and turned over to SAMAPCO under project

manager’s direction.

For the execution of the project, the organization shall be divided into three steps. Commissioning will

be performed with suitable organization and manpower for each step.

Preparation (documentation)

Pre-commissioning

Commissioning and start up

4.2 Preparation step (documentation step)

This phase where a series of preparatory jobs will be executed includes;

Establishment of the commissioning team and set-up of master schedule with respect to the

overall process

Employment and development of the organization for the commissioning project

Self-training for the commissioning staff related to process design concept and equipment






Development of manuals and procedures for pre-commissioning, commissioning, start up,

performance test, initial operation.

System definitions, including marked up drawings. All equipment, tags, cables etc. should be

allocated to a system or sub-system.

Development of system work packs for both construction and commissioning activities.

Development of specific discipline based on pre-commissioning check sheets.

Key personnel will be assigned with appropriate duties according to their specialties (operation,

maintenance and training). They will prepare the documentation of their own respective disciplines and

provide guidance to the development of relevant procedures and documentation requiring multi

discipline interface involvement. Most documentation will be prepared in home office Korea, but many

technical procedures will be completed at sites by on site team members.

The major duties of key personnel in the preparation step are as follows;

(1) Commissioning manager

Manage the project pre-commissioning and commissioning

Control the overall pre-commissioning and commissioning schedule of the project

Preparation for pre-commissioning dossier and hand over

Integrate commissioning schedule / activities into master schedule

(2) Commissioning coordinator

Coordinate commissioning activities with the construction team and the SAMAPCO

Coordinate commissioning schedule with the construction team

(3) Discipline engineer

Develop the commissioning schedule

Develop and manage all check sheets, procedures and manuals

Develop the system definition list and marked-up drawings

Develop the Vendor schedule

Develop Vendor training schedule for operations and maintenance

Prepare staff mobilization

Perform general services for commissioning control

(4) Commissioning HSE engineer

Establishes commissioning HSE management plan/permit to work system and prepare

relevant procedures/pre-start up audit check list.

Ensures that all established plan and procedures are implemented in commissioning

activities

Provides information and inputs as required into the SAMAPCO's report on protective

measures for operational safety

Performs training to ensure that all relevant personnel, specifically commissioning personnel






fully understand the commissioning plan and procedures

(5) Environmental specialist

Produces and complies with an environmental monitoring and mitigation report

Prepares and implements the environmental control procedures for site

Monitors the implementation of mitigation measures during construction and commissioning

period

Ensures that all environmental aspects and impacts are identified, mitigation measures are

determined properly.

Manages environmental monitoring program

Manages environmental compliance inspection

Monitors the implementation of the plans for water quality protection, air quality

4.3 Pre-commissioning step.

The major duties of key personnel in the Pre-commissioning step are as follows.


Manage the project pre-commissioning activities

Control the pre-commissioning schedule

Manage safety and direction of the team of specialist, Vendors and the related construction

work.


Coordinate pre-commissioning activities with the construction team and SAMAPCO

Coordinate pre-commissioning schedule with the construction team and SAMAPCO

(3) Discipline engineer

Supply consumables necessary for pre-commissioning work.

Develop the pre-commissioning schedule

Maintain records of the pre-commissioning activities

(4) Operation supervisor

Supervise pre-commissioning activities

Supervise control room activities

Arrange documentation related to pre-commissioning

(5) Commissioning supervisor

Perform the pre-commissioning activities

Support Vendor test runs

Perform pre-commissioning check






(6) QA/QC manager

Plan, monitor and perform all field quality verification and inspection activities

Prepare QA-QC records

Supervise subContractors QA-QC program

Monitor adherence of work to the drawings and specifications / material control procedures

Manage the documents

Reviews generated punch list

(7) Turnover coordinator

Manage the punch

Prepare turnover documents

4.4 Commissioning and start up step

The major duties of key personnel in the commissioning and start up steps are as follows.


Manage the project commissioning and start up

Control the commissioning schedule

Manage safety and direction of the team of specialist, Vendors and the construction team

Manage operation test and performance tests

Manage the initial operation.

Manage the acceptance test and reliable test operation.


Coordinate commissioning activities with the construction team and the SAMAPCO

Coordinate commissioning schedule with the construction team and the SAMAPCO

Manage the training schedule.

Coordinate and support vendor specialists' site works in link with each relevant

commissioning activities.

(3) Commissioning Engineer

Supply consumables necessary for commissioning, operation test and performance tests

Develop the commissioning, operation test and performance test schedules

Input records of the commissioning, operation test and performance tests

Coordinate on-the-job training

Arrange documentation related to commissioning

(4) Operation supervisor

Supervise commissioning and start up

Supervise control room activities

Perform the safe induction of hydrocarbons into the facilities to start up






Execute the operation test and performance test of equipment

Responsible for operation test and performance test on each item of equipment and facilities

of each system and the plant.

(5) Commissioning supervisor

Support Vendor test runs

Perform commissioning and start up check

Perform preventive inspection and maintenance of the plant

Support the operation

Input records of maintenance

Support operation test and performance tests on each item of equipment and facilities

(6) QA-QC manager

Plan, monitor, and perform all field quality verification and inspection activities

Prepare QA-QC records

Supervise subcontractor’s QA-QC program

Monitor adherence of work to the drawings and specifications / material control procedures

Manage the documents

(7) Turnover coordinator

Manage the punch

Prepare turnover documents






5 Construction & pre-commissioning

Construction & pre-commissioning include all those activities, as indicated in the tables of general

requirements for quality checks, (3.0 division of responsibilities-project standard specification

No.SPCC-G-008-02), required to achieve the mechanical completion milestone.

Construction & pre-commissioning also include those activities required to execute the functional tests

and performance tests (as per Annex K, part 5 Para 21, of the Contract, related to utility package units,

where feasible), for the SAMAPCO to issue a test result statement in relation to the same.

At or near construction completion of each system/subsystem (including process and utilities

systems/subsystems), Daelim will submit official notice to the OWNER that the system/subsystem is

ready for punching. OWNER’s punch team(s), including all applicable disciplines, will punch each

system/subsystem, compile a master punch list, and establish the priority categories (A, B, C, etc) for

each punch item and submit the list to Daelim. Daelim will then begin closing out the punch items and

all “A” punch items must be closed out before pre-commissioning of the system/subsystem.

All Punch Items should be defined as three Categories (“A”, “B” and “C”) and it should be included in

Punch Control Procedure.

Within the context of this project, pre-commissioning for the process is the term used to encompass

the activities before mechanical completion.

In case of utilities, pre-commissioning is the term used to encompass the activities includes start up.

All categories “A” punch items shall be corrected and closed out before pre-commissioning of the

system/subsystem begins

At the end of construction following activities should be completed:

Contract Plant or any section of the Contract Plant should be mechanically and structurally

completed in accordance with the Contract including all drawings specifications, and applicable

laws, codes and standards by Contractor.

Pre-commissioning activities include:

The non-operating adjustments and cold alignment checks.

It means all checks, cleaning, drying, and testing of any portion of the Contract Plant which can

be implemented without introducing raw material and/or auxiliary fluids as well as permanently

energizing said parts. These activities verify the completeness of the installed equipment

/components.

All activities associated with preparing or operating the utilities or part thereof with auxiliary fluids,






prior to initial start up (electrolyzer energizing).

During this phase, electrical equipment will be finally energized, and equipment / circuits will be

pressurized and tested to check as far as possible their performance. During this period all utilities

shall be ready with quantities and qualities. All plant safety system shall be in service.

Main activities of pre-commissioning are as follows and marked up in the subsequent tables.

For process;

Pipe line flushing and blowing

Reinstatement

Cold alignment(final alignment and coupling of rotating equipment)

For utility;

All plant safety system , fire water and protection system etc, shall be in service

Pipe line flushing and blowing

Reinstatement

Cold alignment(final alignment and coupling of rotating equipment)

Tightness test

Testing and check-out of fire and gas detection facilities

Function testing of control systems (instruments and electrical)

Energizing and testing of switchboard

Installation of temporary strainers and permanent gaskets after reinstatement

Loading of packed bed.

Dry-out and inerting

Start up and operation before Mechanical Completion

(N2, process water, drinking water, instrument air, plant air CTW, boiler, demineralized water,

fire water, refrigerator, chiller, fuel gas, etc.)

Detailed descriptions of each pre-commissioning activity will be prepared separately for each

operational system.

Necessary documentation

Effective pre-commissioning requires a variety of technical documentation, which must be up-to-date

and available for the commissioning group, before pre-commissioning activities commencement.

The following list is indicative of what is required.

Process flow diagrams (PFD)

Piping and instrument diagrams (P&ID)

System dry-out and inerting procedures

Vendor installation, operating and maintenance manuals






Instrument function testing procedures

Equipment list

Electrical distribution drawings

Functional logic diagrams

Trip and alarm summary

Detailed equipment manufacturers drawings

Detailed vessel internals drawings

Lubrication list and schedule

Material safety data sheets

Instrument tag list and piping list

• Tightness test procedure

6 Mechanical completion

Mechanical completion occurs when the Contract Plant or any section of the Contract Plant has

finished:

All activities listed in SPCC-G-008-2-quality checks required to achieve the MC milestone.

General requirements for quality checks during pre-commissioning (including functional tests)

and Mechanical Completion.

All deficiencies that could prevent safe and orderly commissioning activities and determinable

without the use of feedstock have been corrected by Contractor.

It is recognized that minor painting, insulation (not affecting plant safety and operations) as part of the

project scope must be finished by Contractor until the issuance of a taking over certificate under the

Contract.

It is also possible that sections of the total Contract Plant can be mechanically complete before the

entire Contract Pant is declared mechanically complete.

Certificate of Mechanical Completion (MC)

Certificate of Mechanical Completion will be issued by SAMAPCO for each system or sub-system once

the following activities have been completed;

Constructed in accordance with project design drawings

Mechanical Completion activities have been completed.

All necessary check sheet, documents and drawings are duly filled and signed by Contractor and

SAMAPCO.

All safety devices such as pressure safety valves (PSV) are tested, witnessed and certified by the

representative of the Contractor and SAMAPCO.

System is punch listed and confirmed complete (punch “A”).

• Completely documented and inputted into commissioning management system by the

construction group or administrator






　

At the end of the Mechanical Completion the Contractor shall submit a request to SAMAPCO for an

issue of certificate.

Along with it the Contractor will enclose all system definition, tag list, mark-up P&ID, calibration

documents, check sheets, cleaning /flushing documents and test results documents (such as

hydrostatic testing and pneumatic testing documents) duly filed and signed.

Also a master blind and record of set pressure of all PSV's should be provided.

These documents shall be completed by the Contractor system wise and a copy of the same shall be

submitted to SAMAPCO.

Once satisfied that Mechanical Completion is successfully completed, the SAMAPCO shall issue a test

result statement in accordance with the Contract.

If Mechanical Completion is not successfully completed, The SAMAPCO shall notify Contractor of any

deficiencies.

In the event of such deficiency Contractor shall promptly rectify the deficiency and the provisions of

sub-clause 9.3A of the Contract shall apply.

Minor works mutually agreed between the parties and listed on the punch lists, which will not hinder

the start of commissioning activities, will not prevent the release of the Mechanical Completion

Certificate.

At plant Mechanical Completion, Contractor shall hand over as-built documentation for the Contract

Plant as described in Contract appendix 215, in section C part 2.

7 Commissioning

7.1 Introduction

Commissioning encompasses all the required checks, tests and proving of a system that can be

implemented for the introduction of process fluids or the permanent energizing or pressurizing of a

system.

Within the context of this project, commissioning is the term used to encompass the activities from

Mechanical Completion to ready for start up (RFSU).

Detailed descriptions of commissioning activity will be prepared separately for each operational system.

The commissioning team is responsible for all aspects of pre-commissioning and, therefore, for

preparing the plant systems and / or sub-systems for commissioning.

Commissioning team will also direct the sub- Contractors (mechanical, electrical and instrument) and






Vendor representatives involved in their activities required during the commissioning phase.

Prior to commence commissioning, the commissioning team, especially turnover coordinator, will

ensure that the relevant QC checks have been carried out by the construction group sufficiently to

enable commissioning to commence.

To enable this process works effectively there are specific documents and checks required to be

confirmed which will include documentation such as Mechanical Completion check sheet, QC check

sheet, discipline acceptance certificate, relevant site queries, relevant engineering queries and agreed

outstanding punch list.

Commissioning will follow the approved commissioning procedures together with the completion of the

relevant commissioning check sheets and recording sheets.

Commissioning will commence by system as follows

Issuance of Mechanical Completion certificate.

All fuels, lubricants, chemicals, preservatives, and any other consumables necessary for the

operation of the entire system have been installed.

Completion of any punch “A” raised in MC stage.

All necessary documentation and permits in place

“Commissioning” means all activities associated with :

Preparing the Contract Plant to receive salt and 32 % NaOH for chlor-alkali plant and

hydrocarbon for EDC plant such as:

drying out of lines and equipment;

tightness tests of lines and equipment at operating pressure;

Steam out and/or purging of lines and equipment with nitrogen.

Introduce process feed into the Contract Plant.

Operating the Contract Plant or part thereof with raw material /hydrocarbons charge from

reduced up to design rate.

During this phase all instrumentations shall be “tuned up “for proper functioning.

The Commissioning phase terminates when the Contract Plant starts to operate at design

capacity producing products (i.e. as mentioned in technology documents) matching with process

specifications and the SAMAPCO issues a Test Result Statement to this effect in accordance

with sub-clause 9.3B of the Contract.

At the end of commissioning phase the Contractor will notify the SAMAPCO that the Contract

Plant “is ready for start up”.

During the commissioning phase the SAMAPCO will put at disposal of Contractor sufficient and

qualified personnel for section and/or Contract Plant operation and maintenance.

.






7.2 Schedule

Both the pre-commissioning and commissioning schedules have been integrated into the overall

project schedule and attached in this plan.

The commissioning team shall keep commissioning progress according to the commissioning

schedule.

To minimize any loss in time, the commissioning team shall submit a detailed schedule to the

SAMAPCO for review.

If any modification of schedule and procedure is needed due to an unexpected impact, the

commissioning team shall discuss it with the SAMAPCO.

Level 1 overall project schedule and level 3 detailed pre-commissioning/commissioning schedules

have been developed. These schedules will be updated and submitted to reflect the actual progress of

pre-commissioning/commissioning activities.

7.3 Work permit control

As construction progresses the emphasis changes from completion by area to completion by system.

Construction will arrive at a state of completion which will commence permit activities.

At this point the system or area is barricaded and sign-posted to indicate the area is designated an

"operational" area and a strict entry control is exercised.

At this stage of project the system will be transferred to commissioning team with its responsibility for

the system. As such the work permit control comes into effect.

Work permit approval system procedure (080036-xx-xx-xxx) will be used during commissioning. This

system will be controlled by the HSE manager and commissioning team.

7.4 Lock-out and tag-out

Lock-out and tag-out procedure shall be used to de-energize or render inoperable any valves,

switches, equipment, and/or process for the purposes of pre-commissioning, commissioning, repair,

maintenance, or operation. The procedure also prevents the unplanned/unscheduled start up or

operation of de-energized machinery, equipment or processes.

Lock-out and tag-out procedure shall be submitted to SAMAPCO for approval. This Lock-out and tag-

out will be detailed in a separate procedure.

Lock-out and tag-out procedure (080036-xx-xx-xxx).

7.5 Vendor commissioning activities

Commissioning expertise will be required from a number of equipment Vendors. The commissioning

manager will coordinate with procurement group; the requirement, timing, and duration of various

Vendor representatives to the plant. These will include, but not necessarily limited to, representatives

for the following equipment.






Flare stack

Electrolyzer

Chlorine compressor package

Demiwater package

Sulfuric acid concentration package

Sulphate removal system.

HCl synthesis unit

Boiler package unit

Air compressor and dryer

Nitrogen storage and vaporization unit

Emergency power generation package.

Brine polishing filter package

Ion exchange package

Anthracite filter package

Fire water pump package

Incinerator package.

Gypsum filter

Sludge filter

Refrigeration compressor

Hydrogen compressor

Caustic concentration unit

Others

　

Vendor representatives’ schedule (include Vendor training schedule for operations and maintenance)

shall be submitted to SAMAPCO for review.

7.6 Spare parts, temporary equipment and consumables

Each specialist, as part of his duties in the preparation phase, will confirm the quantities of

consumables required for the pre-commissioning, commissioning, start up, operation test,

performance test and testing of various facilities as well as the initial operation phase.

All spare parts, temporary equipment, measuring equipment and consumables list of oil, diesel,

propylene, chemicals, etc. including the first fill of the facilities, will be prepared before commencing

the pre-commissioning and commissioning.

SAMAPCO will review commissioning spare parts and confirm received spare parts.

7.7 Tightness test

After cleaning, the plant units may be subjected to leakage tests performed to detect and eliminate

leaks. For this purpose the units are pressurized to working pressure with a suitable agent. However,






this leak test does neither replace the pressure test stipulated by the technical supervision authorities

nor the pressure test to be performed during erection.

A leak test shall be performed always after the system has been dismantled on hydrostatic pressure

test (e.g. removal of blinds, installation of safety valves or opening of machines for inspection) and is

part of the commissioning.

The leakage test can only be performed in a completely erected unit (with installed electrical

equipment and instrumentation).

Before putting into service the chlorine system should finally be tested in order to guarantee perfect

leak tightness.

The following general instruction should be followed:

The unit to be tested is to be isolated from other units. However, for this purpose it is not sufficient

just to close the shutoff valves. The equipment is slightly pressurized to detect major leaks up to

max. Pressure of 0.5 bar g for gaseous media and normal operating pressure for liquid media.

All flange connections (e.g. connections between pipes and equipment, instrumentation) are

covered with a suitable leak detection solution.

In the first step the system to be checked is brought to a pressure of approx. 0.5 bar g by means of

nitrogen.

Leakage can be detected by formation of bubbles in the leak detection solution (soap or special

spray) and must be eliminated.

If the stuffing boxes of valves are leaky, care shall be taken to ensure that the valves may be

operated easily even after tightening the stuffing boxes.

If no further leaks are detected, the unit remains pressurized over several hours. The pressure

drop is recorded taking into account possible temperature differences.

Before bolts at the graphite equipment are tightened see the instructions of the manufacturer and

use a torque wrench.

If liquid is used for leak testing, in the second step, the pressure is slowly increased up to the

operating pressure of the system to be checked and all connections are checked for leakage.

When pressurising with gaseous agents leaks can be detected by application of a leak detection

solution

During pressurising and depressurising it must be ensured that no damages occur to internals.

The gas velocity must not exceed that of normal operation inside of packing materials.

After completion of tests, no vacuum (e.g. heat exchanger) is allowed to occur.

Sufficient breathing has to be ensured.






7.8 Drying out / inerting of lines and equipments

All process systems shall be dried in accordance with the project specification dew point. The activity

will be done by systems and by the individual equipment items. Dry-out will be done using dry air

supplied by 100% oil free air compressors and dryer packages.

All process systems shall be purged in accordance with the project specification. The activity will be

done by systems and by individual equipment items. Inerting will be done by using the project nitrogen

system or temporary nitrogen system to comprise a liquid nitrogen tank, nitrogen vaporizers and

heating equipment capable of producing gaseous nitrogen heated to the required temperature.

To assure proper dry-out and inerting, all ball, globe and gate valves shall be manipulated to

open/closed position several times to displace any free water. Butterfly valves shall be thoroughly

dried while being left in full open position.

All bypass line shall be dried and purged. To assure bypass line dried out,block valves in main line

should first be blocked or throttled to allow flows through the bypass line. When the bypasses are dried

and purged, the block valves in the main line should be opened wide.

Also all safety relief valve line, branch line and tubing for instrument shall be dried and purged. The

dry-out and inerting procedure will be carefully planned and sequenced so that a minimum amount of

air and nitrogen will be required to dry and inerting the overall piping and equipment effectively the

procedures, marked-up drawings and work schedules for dry-out and purge shall be subject to the

SAMAPCO’s approval.

Dry-out and purge/inerting works shall be performed prior to introduction of the hydrocarbon product,

and the dried and purged condition should be maintained thereafter. Dry-out and inerting for pipelines,

equipment and facilities shall be executed by dry air and nitrogen gas until reaching the target dew

point and oxygen limit.

Once the facilities are dried out and purged, the facilities shall remain in a condition such that positive

pressure of nitrogen is supplied to inhibit the entrance of foreign matter into previously purged systems.

Pressures on these completed systems should be monitored on a regular schedule to assure that a

positive inert pressure is being maintained.

The chlorine system downstream of the drying tower must be thoroughly dried. To dry the system the

chlorine compressors are started alternately and input air/ nitrogen is sucked through the drying tower

and blown through the entire system purging the air out at the EDC plant.

Special care is to be taken that all dead spaces and dead pipe sections are likewise dried. If this

cannot be accomplished dry instrument air should be fed in.

If there is a risk of water having accumulated in dead spaces of valves, fittings and other items of

equipment of the dry chlorine section, the latter are to be opened, dismantled as far as necessary and

then dried. Dry compressed air or nitrogen should be used for drying larger equipment.






In the EDC Plant all systems in contact with fluids containing traces of HCl have to be dried out before

the initial start up or after any shutdown in which there is a chance that the equipment has become wet,

all equipment must be thoroughly dried out because the simultaneous presence of water and HCl will

cause rapid corrosion.

The water content in the system has to be lowered to a value < 20 ppm wt. to avoid any corrosion.

The first step in drying out the equipment is to drain all equipment and lines at the lowest point and

blow out all the vessels and lines with plant air to eliminate pools of water.

The second step is to replace possible air in the system by nitrogen and the oxygen content has to

be checked.

The oxygen content must be below 0.5 % by vol. before EDC can be introduced.

For drying EDC resistant hoses must be available.

7.9 System by system commissioning

7.9.1 Utility

The commissioning of the utility system shall be prioritized during the latter construction stages to

which they are required to be commissioned for their utilization in the Mechanical Completion and

commissioning of process facilities and dry-out and inerting of the piping.

The commissioning sequence of utility system is as follows;

(1) Energizing of electric power receiving and distribution systems

The power receiving system and distribution systems shall be energized and commissioned

before Mechanical Completion of the other systems.

(2) Air supply system

As soon as electric power is available, air compressors and drying facilities for instrument air shall

be promptly commissioned. Impurities in the pipeline for supplying instrument air will be removed,

dried and pressurized. In addition, temporary air compressors and air dryers for cleaning and

drying of the equipment and piping shall be prepared.

(3) Nitrogen supply system

As early as possible, nitrogen shall be brought in and commissioned in order to be used in drying

and inerting of process facilities. Besides, in view of the necessary nitrogen unavailable, for drying,

temporary nitrogen vaporizers and liquid nitrogen tanks shall be prepared.

(4) Water and seawater intake system

When power systems have been energized, utility systems such as utility pumps, effluent

treatment systems, seawater pumps and fire water pumps shall be commissioned.






(5) Potable and Service water

Potable and service water tanks shall be cleaned and filled with fresh water. After pumps are

commissioned, the distribution system of the pump outlet shall be cleaned.

(6) Seawater

Seawater intake and header shall be cleaned and filled with seawater. After seawater pumps

are commissioned, seawater filtration and chlorination systems are commissioned.

(7) Diesel oil supply system

Diesel oil for fire engine pump and emergency generator shall be brought in and diesel oil storage

tanks and related facilities shall be commissioned.

(8) Expected consumption schedule of utilities

A utilities and raw material consumption schedule for commissioning shall be prepared by the

Contractor and submitted for the SAMAPCO’s approval.

(9) Commissioning of boiler system

Steam blowing for the steam line is necessary in the pre commissioning activities. Brine and

process fluid is needed to heat up to meet pre start up condition.

So boiler system shall be commissioned prior to process system commissioning.

Fuel gas shall be supplied from near plant via pipe line for the commissioning and start up in

accordance with manufacturer’s recommendation.

(10) Demineralized water system commissioning

Demineralized water is used in the process for multi-purpose.

So demineralized water should be available before boiler commissioning.

Start up shall be carried out in accordance with Vendor’s instruction.

7.9.2 Process commissioning

(1) Brine system

Complete brine circuit as mentioned below is running at 70℃-75℃

Saturator

Buffer vessel

Raw brine pump

Precipitation tanks

Clarifier/clarifier brine pump

Anthracite filters

Filtered brine tank

Filtered brine pump

Polishing filters






Polished brine pump

Chlorine recuperator

Ion exchanger

Pure brine

Brine heat exchanger

Head tank

Cell header bypass

Anolyte tank

Dechlorination

All controllers will be working in auto mode.

Anthracite filter sequence is streamlined.

Exchanger is ready for operation; with ion exchange resin filled in and duly regenerated.

Required laboratory analysis procedures for salt / brine are established along with the

laboratory equipment/instrument.

Regular analysis is to be carried out at various sampling points.

Start up with salt: start charging salt into the brine saturator whichever is in operation.

(2) Anolyte dechlorination and chlorate destruction.

Following prerequisites are to be ensured before start up of anolyte system and chlorate

destruction unit:

Pure brine is available

Temperature of pure brine is maintained at 70℃ - 75°C.

NaCI concentration in pure brine is greater than 270 gpl.

18% HCI is available.

Sodium bisulphite (NaHSO3) is available

18% caustic soda is available

All controllers in auto mode.

(2) Chlorine cooling & drying

Prior to start up of the chlorine cooling section, following prerequisites must be fulfilled.

Following systems should be in operation:

Cooling water circulation

Chilled water circulation

Demineralised water system

Instrument air

Waste gas dechlorination unit

All controllers in 'auto' mode

Process air sparging in 78% sulphuric acid day tank

H2SO4 drying tower

Dry chlorine compressor by N2






Following systems should be ready for operation:

Rectifiers / electrolyzers

Chlorine downstream system like HCI synthesis unit.

Brine & catholyte cycle

(4) Caustic system (catholyte)

Following pre-requisites are to be ensured before start up of catholyte system.

Instrument air, nitrogen, demineralized water and low pressure steam should be in operation

Rectifier, electrolyzers should be ready for operation

All controllers are in auto-mode

Confirm the purity of demineralised water and caustic 32%.

(5) Hydrogen system

Prior to start up of the hydrogen cooling section, following prerequisites must be fulfilled:

Demineralized water

Cooling water

Nitrogen and instrument air

LP steam

All controllers in "auto mode"

Following systems should be ready for operation

Rectifier / Electrolyzer

HCI synthesis unit

(6) Waste gas dechlorination

Following preparations are indispensable to ensure safe and trouble free start up of the unit.

Filling of heat exchangers

Chilled water side of the heat exchangers must be filled with chilled water. Take care that

exchanger is vented via vent valve.

Filling of suction tank and final absorber sumps and caustic safety tank, and emergency

caustic tank with 18%NaOH.

Prior to start the waste gas dechlorination system, following systems must be operating:

Chilled water cycle/chilled water unit

Instrument and plant air.

NaOH dilution system and inventory of 18% NaOH in 18% caustic safety tank.

(7) Incinerator

Incinerator should be in operation prior to introduction of EDC to EDC process system.

7.9.3 Fire fighting systems commissioning






Fire fighting systems shall be proven and operational prior to introduction of fuel gas or H.C. The fire

water system shall be flushed and all pumps, hydrants, monitors and sprinkler facilities shall be

commissioned and certified by the authorities.

Also, fire detection systems shall have been tested to satisfy local code requirements.

7.9.4 Commissioning of flare stack

The flare system directs the fuel gas and process H.C to the flare stack for safe disposal. The excess

gas is ignited by the flare pilots and burned at a safe distance from the plant. So, the flare stack shall

be commissioned prior to the introduction of fuel gas or H.C.

Ignition of the flare stack pilot shall be carried out and operated before the plant start up.

7.9.5 ESD test

The Contractor shall test all of the control function tests and emergency shutdown (ESD) system. The

tank high level alarms and emergency shutdown (ESD) systems will be tested during pre-

commissioning, commissioning or operation with caustic and EDC in the system.

The high level alarm of each tank shall be tested during the actual operation.

ESD shutdown for the port system shall be initiated during send out operation to ensure that this

system is shutdown safely and in proper sequence.

7.10 Plant initial start up(electrolyzer energizing)

7.10.1 Pre start up safety review (PSSR)

As a condition of achieving initial start up(electrolyzer energizing) and prior to the introduction of any

H.C into the plant, the Contractor and the SAMAPCO shall jointly conduct a pre start up safety review

(PSSR) to ensure system / plant is ready for the safe introduction of chlorine and/or hydrocarbons and

everyone involved in the start up of the plant is trained to understand the entire plant design,

operational procedures, HSE requirements and compliance, emergency response procedures, team

roles and responsibilities during start up of plant.

PSSR shall be done for overall systems related to introduction of hydrocarbon and energizing of

electrolyzer.

The plant is ready for initial start up (electrolyzer energizing) provided that all of the following

conditions have been met and checked:

Development of all procedures plans, schedules, arrangement of personnel are made and these

have been approved.

All Mechanical Completion activities have been completed including all relevant testing.

All commissioning activities defined in the commissioning procedures have been completed.

All punch list items have been completed to satisfaction; with the exception of agreed items.

Construction equipment and scaffolding removed, the plot cleared of all surplus materials and

properly cleaned.

Temporary connections have been removed as appropriate.






Safety inspection carried out with satisfactory result

Buildings, equipment and/or furniture have been installed and the buildings are ready for

occupation.

Ancillary systems ready for connection to a live system where appropriate.

Utility systems are in operation.

All safety valves (pressure safety valves, thermal safety valves, vacuum breakers) shall have

been checked out, be operational and be in service prior to starting the start up activity.

All construction, Mechanical Completion and commissioning dossiers have been accepted.

Fire fighting system and fire detection system has been completely commissioned and operated.

7.10.2 Notification of initial start up(electrolyzer energizing)

When the plant has fully commissioned all systems (completion of operational testing for all

equipment) and the entire plant such that the process system is ready for electrolyzer energizing, the

Contractor shall notify to the SAMAPCO for the initial start up (electrolyzer energizing).

Notifying : (a) the plant has achieved ready for initial start up (electrolyzer energizing), (b) all priority

“A” and “B” punch items related to the plant have been completed or corrected, and (c) the plant has

satisfied all requirements for achievement of ready for initial start up (electrolyzer energizing).

Contractor shall include any additional documentation requested by SAMAPCO or necessary to

demonstrate ready for initial start up (electrolyzer energizing).

7.10.3 Acceptance of ready for initial start up(electrolyzer energizing)

SAMAPCO shall review all documents of ready for initial start up (electrolyzer energizing) submitted by

Contractor.

If the SAMAPCO does not agree that the plant has achieved ready for initial start up (electrolyzer

energizing), SAMAPCO shall notify the Contractor of the reasons that the plant has not achieved ready

for initial start up (electrolyzer energizing), and Contractor shall remedy, complete or correct the

relevant works as necessary to achieve ready for initial start up (electrolyzer energizing) and re-notify

the ready for initial start up (electrolyzer energizing) to SAMAPCO.

If SAMAPCO agrees that the plant has achieved ready for initial start up(electrolyzer energizing),

either initially or upon resubmission by Contractor, then the SAMAPCO shall accept the ready for initial

start up(electrolyzer energizing).

7.10.4 Initial start up (electrolyzer energizing)

Once SAMAPCO accept the ready for initial start up, the Contract Plant is ready for electrolyzer

energizing.

Initial start up (electrolyzer energizing) shall be carried out by Contractor according to the

commissioning procedure with assistance from appropriate Vendor representatives as required.

Technology provider's specialists shall attend at Contract Plant start up as well.

The Contractor shall develop procedures for the start up of the plant which will be provided to the






SAMAPCO for review and approval.

Initial start up (electrolyzer energizing) activities include

All testing activities, including the running tests of the each equipment.

Electrolyzer energizing

Introduce process feed such as brine for CA plant and chlorine/ethylene for EDC plant.

Operating the plant or part thereof with hydrocarbon charge from reduced up to design rate.

All instrument tuned up for proper functioning.

During initial start up (electrolyzer energizing), the operation, maintenance, safety and security of the

plant will remain under the full responsibility of Contractor.

Clearance of certain punch list Items may be achieved during Initial start up (electrolyzer energizing),

subject to the agreement of the SAMAPCO.

The commissioning manager is responsible for establishing the project organization and job

assignment in accordance with commissioning procedure.

During this phase it will acquire any permission required for operation of plant prior to the hydrocarbon

introduction to the system and electrolyzer energizing.

7.10.5 Operating test

Operating test shall be conducted within a period of system commissioning to figure out the features

and capacity. Operating test shall be carried out in accordance with commissioning procedure and

acceptance criteria. The Contractor shall maintain the best condition for the test..

7.10.6 Tuning and stabilization of process

Tuning shall be executed between the completion of load test and the beginning of preliminary

demonstration for performance test. To achieve tuning conditions, operation mode must be set at 'auto

mode' and pressure or flow rate should not be changed. In particular, equipment which may cause

hunting or trip must be stopped before tuning. When all works are completed, all set values should be

restored to their initial status. In addition, all features and details of tunings should be sent to operators

with a printed report produced during tuning. In this step, equipment shall be operated in an automatic

mode. When load changes, equipment has to be stabilized for a required period of time which shall be

recorded. If load tests are completed, operators shall implement tuning. All test data must be recorded

and compiled.

8 Ready For Start Up (RFSU)

Ready For Start Up of any section and /or Contract Plant is the event that occurs when all

commissioning activities have been successfully performed by Contractor to allow commencement of

the production operation and assessed /certified by SAMAPCO.






The plant is fed with process feed to design rate and products, complying with the project specification,

are sent to storage.

At the end of the commissioning phase the Contractor will notify the SAMAPCO that the plant is ready

for start- up (RSFU).

Immediately after establishing that any section and/or the Contract Plant is ready for start up,

SAMAPCO will issue the test result statement to Contractor.

A test result statement stating that commissioning has been successfully completed and RFSU has

been achieved is signed by SAMAPCO and submitted to the Contractor in accordance with sub-clause

9.3B of the Contract.

9 Start up

After RFSU, the start up phase includes initial operation and carrying out of the performance test by

Contractor to demonstrate the performance characteristics of the plant have been achieved in

accordance with the procedures outlined in Annex-K.

Start up is deemed to have been completed on the calendar day on which 100% of daily production is

achieved in the Contract Plant, all performance tests have been successfully completed, and the

SAMAPCO has issued a test result statement in accordance with sub-clause 9.3C of the Contract.

This means Initial acceptance date is hit.

10 Testing

10.1 Introduction

The Contract Plant shall be tested in accordance with the standards adopted for the works as

established in the approved specifications and testing procedures. No later than [three (3)] months

prior to the Mechanical Completion date, the Contractor shall submit a testing protocol (an inspection

and testing procedure) for the plant for review and written approval by the SAMAPCO.

For situations where physical tests are not possible at the time of performance test, a proposed

methodology to demonstrate the performance guarantees shall be proposed in such testing protocol.

10.2 Number of tests

The Contractor may perform any number of tests simultaneously provided that test conditions and

safety requirements of each test are satisfied and observed by both the SAMAPCO and the Contractor.






10.3 Performance test

10.3.1 General

(1) The performance Guarantees shall be proven in a Performance Test run of seventy-two (72)

hours to be performed by the Contractor under SAMAPCO’s supervision and the Technology

Provider’s assistance, consecutively and without interruption, producing the guaranteed

quality of the products at the rated capacity with the consumption figures as detailed in the Annex

K of the Early Works Agreement

(2) The result of each Performance Test shall be recorded in a protocol and signed by both parties

immediately after the Performance Test.

10.3.2 Interruptions

(1) If there is an interruption during the Performance Test which is equal to or less than six (6)

hours, the duration of the Performance Test shall be extended by the actual duration of the

interruption period and the calculation of the result of the Performance Test shall be made on the

basis of the seventy-two (72) hours period during which the conditions of operation have been

normal .

(2) If the period of the interruption during the Performance Tests lasts more than six (6) hours

and the CA Plant and/or EDC plant (as the case may be) has been operating for less than forty

eight (48) hours, the Performance Test shall be repeated by the Contractor

10.3.3 Failure to achieve Performance Guarantees

In the event any Performance Guarantees cannot be reached during the Performance Test, the terms

of Sub-Clause 9.3C [Result of Performance Tests and Retesting] and Sub-Clause 9.4 [Failure of

Performance Tests or Reliability Test] of the Contract shall be applied.

10.3.4 Preparation for the performance guarantee test run

(1) Pre-test activities

After the start up of the overall units, the Contractor shall carry out the necessary fine tuning and

calibrations. All facilities to be tested shall be in steady operation mode for 3 days before the

performance guarantee test run commences.

(2) Feed stock definition

The SAMAPCO shall furnish salt at the quality defined in the Contract and in quantity sufficient to

enable the required test flow rates to be met during the performance guarantee test run period.

Contractor shall submit notice test date before 90 days prior to test as minimum. In the event that

the actual feed stock quality, as determined from laboratory analysis, differs substantially from the

design feed stock, then the Contractor shall request the SAMAPCO to review the situation before

commencing performance guarantee test run.

(3) Utilities






All required utilities shall have been made available, as required for the performance guarantee

test run period. Contractor will be responsible for ensuring the required volume and quality except

if utilities have already been handed over to SAMAPCO. These utilities including fire water,

nitrogen, instrument air, plant air, drinking water, process water, fuel gas, electric power,

demin.water, chilled water, steam, etc.

(4) Chemicals

The Contractor shall make available all the chemicals required for the performance guarantee test

period except if facilities have already been handed over to SAMAPCO.

(5) Laboratory services

Sufficient staff and sampling equipment shall be made available by SAMAPCO throughout the

performance guarantee test run for the handling and rapid analysis of gas/ liquid samples as

required during the tests.

Suitable sample bombs shall be provided by SAMAPCO.

Auxiliaries shall be designed and supported by Contractor.

Calibration and verification of laboratory equipment to be used in sample analysis will be

performed jointly between SAMAPCO and Contractor prior to start up of the performance

guarantee test run.

Analysis will be performed in the new laboratory building.

The analysis should be signed off by SAMAPCO laboratory staff and included in the performance

guarantee test run report.

10.3.5 Performance guarantee test run organization

An integrated performance guarantee test team will be formed with SAMAPCO personnel and the

Contractor/ other parties such as UHDE etc.

Contractor shall be responsible for acting as a leader of the integrated test team so as to perform the

test operation.

The SAMAPCO will supervise the performance test until successfully completed.

The commissioning team must liaise closely with the SAMAPCO to ensure that mutual objectives are

met.

10.3.6 Performance guarantee test run procedure and schedule

The performance tests procedures and schedule shall be developed by the Contractor and submitted

to the SAMAPCO for approval prior to conducting the performance tests.

10.3.7 Measuring and sampling method of data

All instruments that will be used for demonstration of the performance of the Contract Plant will be

checked prior to start the performance guarantee test run period.






Data during the testing period will be recorded at two hour intervals using the plant data historian or

can be manually recorded in log sheet prepared by Contractor.

DCS trend log will be provided specifically to record the performance guarantee test data.

These log sheets will be retrieved from the system with SAMAPCO representative.

10.3.8 Data conversion

Gas and liquid flow readings from flow meters during the performance test shall be corrected for

temperature, pressure, and molecular weight wherever necessary. And general correction equation

and method shall be described on performance test procedure.

10.3.9 Performance guarantee test run report

After the successful completion of the performance guarantee test run, Contractor will prepare the

performance guarantee test run report with all results and conclusions, which demonstrate that the

performance guarantee has been fulfilled.

Contractor will submit this report to SAMAPCO for approval. SAMAPCO shall communicate to the

Contractor, within seven (7) days after the receipt of the report, its acceptance or its rejection and in

the latter case SAMAPCO shall state its reasons in writing.

In the event that the installations do not perform or fail to operate in accordance with the Contract,

Contractor shall carry out appropriate remedial design and construction work and provide the

necessary replacement materials in accordance with the Contract. Upon completion of such remedial

works the performance guarantee test run will be repeated.

10.4 Reliability Test

10.4.1 Tests

The Reliability Guarantees specified in paragraphs 20.2 and 20.3 of the Annex K shall be proven in a

Reliability Test run of [thirty (30) days] to be performed by the Contractor consecutively without

interruption.

The result of Reliability Test shall be recorded in a protocol to be agreed between the Parties and

signed both Parties immediately after the Reliability Test.

10.4.2 Reliability Guarantees for CA Plant

The reliability guarantees shall be as follows;

(a) [95]% of the Performance Guarantees set out in paragraph 3.1; and

(b) the Minimum Performance Standards set out in paragraph 9.1.of the Contract

10.4.3 Reliability Guarantees for EDC Plant

The reliability guarantees shall be as follows

(a) [95]% of the Performance Guarantees set out in paragraph 15.1; and






(b) the Minimum Performance Standards set out in paragraph 18.1.of the Contract

10.4.4 Reliability Performance LDs

In the event that the CA Plant and/or the EDC Plant (as the case may be) fail to meet any of the

Reliability Guarantee during the Reliability Test, then ANNEX K, paragraph 20.4 of the Contract shall

be applied..

11 Hand-over

Following satisfactory completion of the initial operation and performance tests, SAMAPCO shall agree

to a formal hand-over of the facilities. The commissioning team shall compile a systematic hand-over

package, which will include SAMAPCO approved reports demonstrating successful completion,

commissioning, and acceptance of the performance and reliability tests.

Hand-over is the formal transfer of the asset to SAMAPCO.

This hand-over will be detailed in a separate procedure.

Hand-over procedure (080036-xx-xx-xxx)

12 Punch and Punch Control

Punch-out of each of the systems/subsystems by SAMAPCO or in conjunction with SAMAPCO is

critical.

It should be made clear in the plan and schedule when SAMAPCO perform this critical operation.

SAMAPCO shall have final decision concerning punch item categories (A, B, etc) and shall have final

decision as to whether or not the punch item has been corrected and closed out.

A formal “punch-out” of each system and associated sub-system will be performed by the Contractor.

Owner will also perform an independent punch-out as described in sect 5, paragraph 3.

All defective or incomplete items will be recorded on a punch list for the respective discipline system

and associated sub-systems. Where applicable, the equipment tag number and associated drawings

will be used as the prime means of identifying the defect or incompletion. Punch list items will be

registered and tracked electronically by means of an electronic certification management system or

database.






13 Vendor’s training at site

13.1 Vendor’s technology support.

Vendor’s personnel will be required to support pre-commissioning and commissioning activities, and

Contractor will be responsible for scheduling the presence of these specialists on site at appropriate

time.

Contractor shall submit Vendor’s schedule for specialist Vendor support for SAMAPCO approval for all

phases.

Vendor support for package equipment items containing multi-discipline equipment shall include

multiple visits by different disciplines, as advised by the Vendor.

13.2 Vendor’s training at site

The Vendor’s training and required related exercises will be conducted in the designated training

facility and at the site respectively; they will be scheduled at the most appropriate time.

The training officer will coordinate to establish course attendees and schedules to ensure that courses

are arranged to meet attendees’ availability.

This training schedule shall be detailed and submitted to SAMAPCO.

14 Communication

14.1 Radio-communication

The Contractor shall provide adequate explosion proof radios for all pre-commissioning,

commissioning and start up activities.

Contractor shall ensure that enough radios, and channels, are available to support simultaneous pre-

commissioning, commissioning and start up, and are also available for Vendor representative.

14.2 Mobile phone

Contractor shall be responsible for prohibiting use of non-intrinsically safe equipment in areas where

flammable fluids exist prior to initial start up. This equipment includes mobiles phones, cameras, spark

producing tools, electric drills etc. Use of essential tools shall be controlled by appropriate permit to

work procedures.

Mobile phones shall not be permitted under any circumstances after initial start up.

15 Reporting

A site meeting will be held for daily and/or weekly reporting once critical activities commence.

The commissioning team will provide a weekly progress report. The progress report will be submitted

in a format agreed among the parties involved in this report.






16 HSE management

The Contractor generates and develops the HSE management plan for the commissioning including

evacuation plans and procedures.

A permit to work (PTW) system will be set up by commissioning HSE engineer and submitted to the

SAMAPCO for review and approval one month before the date electrolyzer energizing.

Training on PTW system, emergency shutdown, safety philosophy and safety procedures etc. will be

carried out for all personnel involved in commissioning.

The commissioning HSE engineer will prepare and submit commissioning HSE management plan

including all HSE procedures and pre-start up safety review (PSSR) procedure to the SAMAPCO two

months prior to the start of commissioning.

Attachments

Attachment 1: Pre-commissioning / commissioning & start up schedule

Attachment 2: Pre-commissioning / commissioning process and activities

Attachment 3: Organisation for preparation phase

Attachment 4: Organisation for pre-commissioning phase

Attachment 5: Organisation for commissioning phase

Attachment 6: Completion process flow chart

Attachment 7: Start up flow chart

Attachment 8: EDC Plant Drying & Start-Up Plan

Attachment 9: List of Preparation Plan of Pre-commissioning &Commissioning Documents and

Activities

Attachment 1

Mile Stone .

Arabian Chlor Vinyl Project2011 2012 2013

12 Dec 1 Jan 2 Feb 3 Mar 4 Apr 5 May1

6 Jun 7 Jul 8 Aug 9 Sep 10 Oct 11 Nov11 2111 21 1 11 21

Pre-Commissioning / Commissioning & Start Up ScheduleSep/30/2011

Based on System Definition rev.A

No Activity Start(mm/dd)

Finish(mm/dd)

Duration 111 21 1 11 21 111 21 1 11 21 1

12 Dec 1 Jan 2 Feb11 21 1121 1 11 21 111 21 1 11 21 121 1 11 21 1111 11 21 1

10/07/2012 2351 Utility 02/16/2012

1/31 PowerEnerg.

3/ 1 Pre-Comm. Start2/29 DCS SAT

7/31 MCComp. of Comm. Utility

11/2 RFSU 12/2 Initial Accept.

1/2 Reliability Test Ach.Taking Over Certi

5/1 BoilerStart Up

10/1 Electro.Energiz.

14 Commissioning 03/04/2012 03/10/2012 7

10/07/2012 235

Start Up 03/09/2012 03/09/2012 1

10 PSSR 03/06/2012 03/08/2012 3

1

13 Pre-Commissioning 02/25/2012 03/03/2012 8

12 U11 Cooling Water 02/25/2012 03/14/2012 19

11

02/16/2012 02/21/2012 6

4 Commissioning 02/22/2012 02/26/2012 5

5 PSSR 02/27/2012 02/29/2012 3

3 Pre-Commissioning

15


9 Commissioning 02/28/2012 03/05/2012 7

1 Utility 02/16/2012

2 U03 Process Water System 02/16/2012 03/01/2012

6 Start Up 03/01/2012 03/01/2012

7 U10 Sea Water 02/20/2012 03/09/2012 19

1/31 PowerEnerg.





5/1 BoilerStart Up


15 PSSR 03/11/2012 03/13/2012 3

g

19 Commissioning 03/03/2012 03/16/2012 14


17 U15 PA and IA System 02/22/2012 03/20/2012 28

16 Start Up 03/14/2012 03/14/2012 1


22 U17 Fire Water Pump and Distribution 03/02/2012 03/27/2012 26

21 Start Up 03/20/2012 03/20/2012 1

20 PSSR 03/17/2012 03/19/2012 3

27 U05 Drinking & Safety Shower Water 03/19/2012 04/04/2012 17

26 Start Up 03/27/2012 03/27/2012 1

25 PSSR 03/24/2012 03/26/2012 3

24 Commissioning 03/11/2012 03/23/2012 13

1/31 PowerEnerg.





5/1 BoilerStart Up


31 Start Up 04/04/2012 04/04/2012 1

30 PSSR 04/01/2012 04/03/2012 3

29 Commissioning 03/26/2012 03/31/2012 6


35 PSSR 03/31/2012 04/02/2012 3

34 Commissioning 03/24/2012 03/30/2012 7


32 U16 Waste Water 03/19/2012 04/03/2012 16

39 Commissioning 03/31/2012 04/06/2012 7


37 U04 Demin. Water 03/24/2012 04/10/2012 18

36 Start Up 04/03/2012 04/03/2012 1

41 Start Up 04/10/2012 04/10/2012 1

40 PSSR 04/07/2012 04/09/2012 3

1/31 PowerEnerg.





5/1 BoilerStart Up


SAMAPCO CA/EDC Project page-1 of 7

Attachment 1

Mile Stone .







Finish(mm/dd)

Duration 111 21 1 11 21 111 21 1 11 21 1

12 Dec 1 Jan 2 Feb11 21 1121 1 11 21 111 21 1 11 21 121 1 11 21 1111 11 21 1

1/31 PowerEnerg.





5/1 BoilerStart Up


42 U14 Nitrogen 03/30/2012 04/17/2012 19


42 U14 Nitrogen 03/30/2012 04/17/2012 19

47 U06 Fuel Gas 04/11/2012 04/24/2012 14

46 Start Up 04/17/2012 04/17/2012 1

45 PSSR 04/14/2012 04/16/2012 3

44 Commissioning 04/07/2012 04/13/2012 7

51 Start Up 04/24/2012 04/24/2012 1

50 PSSR 04/21/2012 04/23/2012 3

49 Commissioning 04/16/2012 04/20/2012 5


55 PSSR 04/25/2012 04/27/2012 3

54 Commissioning 04/15/2012 04/24/2012 10


52 U02 Hot Relief and Flare System 04/05/2012 05/01/2012 27


58 U07 Boiler system 04/10/2012 10/07/2012 23

57 Start Up with Fuel Gas 05/01/2012 05/01/2012 1

56 Pre-Start Up with Air 04/28/2012 04/30/2012 3

63 Start Up with H2 10/07/2012 10/07/2012 1

62 Pre-Start Up with Fuel Gas 05/01/2012 05/01/2012 1

61 PSSR 04/28/2012 04/30/2012 3

60 Commissioning 04/18/2012 04/27/2012 10

67 PSSR 04/28/2012 04/30/2012 3

66 Commissioning 04/25/2012 04/27/2012 3


64 U08 Steam Distribution 04/18/2012 05/01/2012 14

68 Start Up 05/01/2012 05/01/2012 1

71 Commissioning 04/25/2012 04/28/2012 4


69 U09 Condensate and Collection Tank 04/19/2012 05/02/2012 14


74 U12 Refrigeration Unit 06/27/2012 07/11/2012 15

73 Start Up 05/02/2012 05/02/2012 1

72 PSSR 04/29/2012 05/01/2012 3

79 U13 Chilled Water 07/05/2012 07/21/2012 17

78 Start Up 07/11/2012 07/11/2012 1

77 PSSR 07/08/2012 07/10/2012 3

76 Commissioning 06/30/2012 07/07/2012 8

82 PSSR 07/18/2012 07/20/2012 3

81 Commissioning 07/12/2012 07/17/2012 6



Attachment 1

Mile Stone .







Finish(mm/dd)

Duration 111 21 1 11 21 111 21 1 11 21 1

12 Dec 1 Jan 2 Feb11 21 1121 1 11 21 111 21 1 11 21 121 1 11 21 1111 11 21 1

1/31 PowerEnerg.





5/1 BoilerStart Up


83 Start Up 07/21/2012 07/21/2012 183 Start Up 07/21/2012 07/21/2012 1

87 PSSR 08/02/2012 08/04/2012 3

86 Commissioning 07/28/2012 08/01/2012 5


84 U01 EDC Relief and Vent System 07/10/2012 08/05/2012 11


90 L05 Hydrochloric Acid Storage 03/18/2012 04/07/2012 21

89 Logistic 03/14/2012 10/01/2012 202

88 Start Up 08/05/2012 08/05/2012 1

95 L04 Caustic Soda Storage 03/14/2012 04/03/2012 21

94 Pre-Start Up 04/07/2012 04/07/2012 1

93 PSSR 04/04/2012 04/06/2012 3

92 Commissioning 03/25/2012 04/03/2012 10


99 Pre-Start Up 04/03/2012 04/03/2012 1

98 PSSR 03/31/2012 04/02/2012 3

97 Commissioning 03/21/2012 03/30/2012 10

g

103 PSSR 07/05/2012 07/07/2012 3

102 Commissioning 06/30/2012 07/04/2012 5


100 L02 Propylene Distribution 06/25/2012 07/08/2012 14

107 Commissioning 09/07/2012 09/16/2012 10


105 L03 Sulfuric Acid Storage 07/12/2012 09/20/2012 19

104 Pre-Start Up 07/08/2012 07/08/2012 1

109 Pre-Start Up 09/20/2012 09/20/2012 1

108 PSSR 09/17/2012 09/19/2012 3


110 L06 EDC Storage 07/17/2012 08/10/2012 19

115 L01 Ethylene Distribution 07/22/2012 10/01/2012 19

114 Pre-Start Up 08/10/2012 08/10/2012 1

113 PSSR 08/07/2012 08/09/2012 3

112 Commissioning 07/28/2012 08/06/2012 10

119 Pre-Start Up 10/01/2012 10/01/2012 1

118 PSSR 09/28/2012 09/30/2012 3

117 Commissioning 09/18/2012 09/27/2012 10


123 Commissioning 07/27/2012 08/05/2012 10


121 E06 Incinerator 06/29/2012 08/10/2012 25

120 EDC Plant 06/29/2012 10/01/2012 95


Attachment 1

Mile Stone .







Finish(mm/dd)

Duration 111 21 1 11 21 111 21 1 11 21 1

12 Dec 1 Jan 2 Feb11 21 1121 1 11 21 111 21 1 11 21 121 1 11 21 1111 11 21 1

1/31 PowerEnerg.





5/1 BoilerStart Up


124 PSSR 08/06/2012 08/08/2012 3

127 E05 Waste Water Collection 07/10/2012 09/16/2012 11

126 Start Up 08/10/2012 08/10/2012 1

125 Pre-Start Up with Fuel Gas 08/09/2012 08/09/2012 1

124 PSSR 08/06/2012 08/08/2012 3

131 Start Up 09/16/2012 09/16/2012 1

130 PSSR 09/13/2012 09/15/2012 3

129 Commissioning 09/09/2012 09/12/2012 4


135 PSSR 09/07/2012 09/09/2012 3

134 Commissioning 08/23/2012 09/06/2012 15


132 E01 Direct Chorination Reactor 07/02/2012 10/01/2012 55

137 Pre-Start Up with EDC(EDC Fill Up) 09/24/2012 09/30/2012 7

136 Dehydration (Dry with EDC) 09/10/2012 09/23/2012 14

139 E02 EDC Distillation Column 07/11/2012 10/01/2012 59

138 Start Up with Cl2 & Ehtylene 10/01/2012 10/01/2012 1

p ( p)


142 PSSR 08/24/2012 08/26/2012 3

141 Commissioning 08/14/2012 08/23/2012 10



146 E03 Vacuum Column 07/15/2012 10/01/2012 52

145 Start Up with EDC product 10/01/2012 10/01/2012 1

144 Pre-Start Up with EDC 09/03/2012 09/30/2012 28


149 PSSR 08/31/2012 09/02/2012 3

148 Commissioning 08/21/2012 08/30/2012 10


155 Commissioning 08/07/2012 08/16/2012 10


153 E04 EDC Drying & Stripping System 07/22/2012 10/01/2012 63





156 PSSR 08/17/2012 08/19/2012 3

163 Commissioning 08/19/2012 08/28/2012 10


161 C15 Waste Water Treatment 06/27/2012 09/01/2012 19

160 CA Plant 06/27/2012 10/21/2012 117

164 PSSR 08/29/2012 08/31/2012 3


Attachment 1

Mile Stone .







Finish(mm/dd)

Duration 111 21 1 11 21 111 21 1 11 21 1

12 Dec 1 Jan 2 Feb11 21 1121 1 11 21 111 21 1 11 21 121 1 11 21 1111 11 21 1

1/31 PowerEnerg.





5/1 BoilerStart Up


165 Start Up 09/01/2012 09/01/2012 1


166 C01 Salt Handling 07/03/2012 09/04/2012 15

165 Start Up 09/01/2012 09/01/2012 1

171 C02 Brine Saturation 07/05/2012 09/09/2012 26

170 Start Up 09/04/2012 09/04/2012 1

169 PSSR 09/01/2012 09/03/2012 3

168 Commissioning 08/24/2012 08/31/2012 8

175 Pre-Start Up with Water & Demin-Water 09/02/2012 09/08/2012 7

174 PSSR 08/30/2012 09/01/2012 3

173 Commissioning 08/20/2012 08/29/2012 10



177 C03 Primary Brine Treatment 07/09/2012 09/14/2012 31

176 Start Up with Brine 09/09/2012 09/09/2012 1

179 Commissioning 08/20/2012 08/26/2012 7

g

183 C04 Secondary Brine Treatment 07/13/2012 09/19/2012 31


181 Pre-Start Up with Water & Demin Water 08/30/2012 09/13/2012 15

180 PSSR 08/27/2012 08/29/2012 3


186 PSSR 09/01/2012 09/03/2012 3

185 Commissioning 08/25/2012 08/31/2012 7


191 Commissioning 09/08/2012 09/14/2012 7


189 C05 Anolyte Dechlor.& Chlorate Decom. 07/17/2012 10/01/2012 21


195 C11 Catholyte Circulation 07/21/2012 10/01/2012 21

194 Start Up with Anolyte 10/01/2012 10/01/2012 1


192 PSSR 09/15/2012 09/17/2012 3


198 PSSR 09/18/2012 09/20/2012 3

197 Commissioning 09/11/2012 09/17/2012 7


203 Commissioning 09/16/2012 09/22/2012 7


201 C10 Waste gas Dechlorination 07/25/2012 10/01/2012 19

200 Start Up with Catholyte 10/01/2012 10/01/2012 1


204 PSSR 09/23/2012 09/25/2012 3


Attachment 1

Mile Stone .







Finish(mm/dd)

Duration 111 21 1 11 21 111 21 1 11 21 1

12 Dec 1 Jan 2 Feb11 21 1121 1 11 21 111 21 1 11 21 121 1 11 21 1111 11 21 1

1/31 PowerEnerg.





5/1 BoilerStart Up


206 Start Up with Waste Gas 10/01/2012 10/01/2012 1

207 C07 Electrolyser 07/22/2012 10/01/2012 35

206 Start Up with Waste Gas 10/01/2012 10/01/2012 1

211 Anolyte / Catholyte Fill Up 09/26/2012 09/30/2012 5

210 PSSR 09/19/2012 09/25/2012 7

209 Commissioning 09/04/2012 09/18/2012 15


215 Commissioning 09/10/2012 09/19/2012 10


213 C08 Chlorine Cooling Drying and Comp. 06/27/2012 10/02/2012 28

212 Energizing 10/01/2012 10/01/2012 1

219 C12 Caustic Conc. and Distribution 07/02/2012 10/03/2012 31

218 Start Up with recycle H2SO4 10/02/2012 10/02/2012 1

217 Pre-Start Up with Air / N2 / H2SO4 09/23/2012 09/29/2012 7

216 PSSR 09/20/2012 09/22/2012 3

223 Pre-Start Up with Water / Caustic 09/14/2012 09/23/2012 10

222 PSSR 09/11/2012 09/13/2012 3

221 Commissioning 09/01/2012 09/10/2012 10


227 Commissioning 09/06/2012 09/15/2012 10


225 C14 HCl Synthesis and Distribution 07/07/2012 10/04/2012 28

224 Start Up with Caustic Product (32%) 10/03/2012 10/03/2012 1

231 C09 H2SO4 Concentration 07/12/2012 10/04/2012 28

230 Start Up with H2 & Cl2 Product 10/04/2012 10/04/2012 1

229 Pre-Start Up with Water 09/19/2012 09/25/2012 7

228 PSSR 09/16/2012 09/18/2012 3


235 Pre-Start Up with Water / H2SO4 09/18/2012 09/27/2012 10

234 PSSR 09/15/2012 09/17/2012 3

233 Commissioning 09/08/2012 09/14/2012 7

239 Commissioning 09/12/2012 09/21/2012 10


237 C13 H2 Cooling and Compression 07/17/2012 10/06/2012 26

236 Start Up with recycle H2SO4 10/04/2012 10/04/2012 1

243 C06 Sulfate Removal and Gyp.Filtration 07/22/2012 10/21/2012 31

242 Start Up with H2 Product 10/06/2012 10/06/2012 1

241 Pre-Start Up with Air / N2 09/25/2012 09/29/2012 5

240 PSSR 09/22/2012 09/24/2012 3

246 PSSR 10/08/2012 10/10/2012 3

245 Commissioning 09/28/2012 10/07/2012 10



Attachment 1

Mile Stone .







Finish(mm/dd)

Duration 111 21 1 11 21 111 21 1 11 21 1

12 Dec 1 Jan 2 Feb11 21 1121 1 11 21 111 21 1 11 21 121 1 11 21 1111 11 21 1

1/31 PowerEnerg.





5/1 BoilerStart Up


247 Pre-Start Up with Water 10/11/2012 10/20/2012 10247 Pre-Start Up with Water 10/11/2012 10/20/2012 10

250 RFSU 11/02/2012 11/02/2012 1

249 Initial Start Up / Tunning 10/01/2012 11/01/2012 32

248 Start Up with Lean Brine 10/21/2012 10/21/2012 1

252 Initial Acceptance Test 12/02/2012 12/02/2012 1

253 Reliability Test 12/03/2012 01/01/2013 30

12/01/2012 30251 Performance Test 11/02/2012


UtilityPre-Comm. Start

3/1

MechanicalCompletion

7/31

InitialAcceptance

12/2

RFSU

11/2

ReliabilityTest Achieved

1/2

2013.

▪ Loop Check▪ Hydro Test of Piping

OVERALL SYSTEM▪ "A" Punch Cleared

▪ "B" Punch Cleared▪ PSSR

▪ Plant design rateOperation

▪ Reliability test

Construction Pre-Comm. Comm.Start Up/Operation

ReliabilityOperation

2012.


3/1


7/31

InitialAcceptance

12/2

RFSU

11/2


1/2

2013.

▪ Loop Check▪ Hydro Test of Piping▪ Power Energizing▪ DCS SAT▪ PSV Popping Test▪ Equip. Final Inspection▪ Vessel/Tank Closing▪ Cold Align. Check▪ Install. of Instrument▪ Motor Solo Run▪ OWNER disciplines

to punch all systems /subsystems,compile master punch list, anddecide punchitem categories.

OVERALL SYSTEM▪ "A" Punch Cleared▪ Pipe Cleaning▪ Reinstatement▪ Leak Test▪ Functional Test

(Interlock check for Process, F&G )

UTILITY SYSTEM only▪ "A"&"B" Punch Clear▪ PSSR▪ Tightness Test (at

Operating Pressure)▪ Steam Boiler

Refractory Dty-out▪ Chemical Preparation

and Chemicalin Servicefor Steam Boilers▪ Start Up & All Utility

System in Service▪ Hot Alignment▪ Performance Test

▪ "B" Punch Cleared▪ PSSR▪ Tightness Test (at

Operating Pressure)▪ System Drying Out /

Inerting▪ Catalyst Loading▪ Initial ChemicalFill-up▪ Refractory Dyr Out

(for Incinerator)▪ MRT▪ Load Test(Compressor)▪ Brine System(CA Plant)-Start Up& Operation▪ Electrolyzer-Start Up& Operation▪ Introduce Chlorine /Ethylene Feed forEDC Plant▪ Control SystemTunning


▪ Complete Punch(including "C")

▪ Operational Test

▪ Performance Test


▪ Hand Over- Special Tools- Spart Parts- Final Data Books

▪ DIC shall submitpre-comm./Comm. procedure 6 monthsprior to precomm.



2012.

OJT Traning

Attachment 2 : rev. 2 Dec/5/2011

Pre-Commissioning / Commissioning Process and Activities


3/1


7/31

InitialAcceptance

12/2

RFSU

11/2


1/2

2013.

▪ Loop Check▪ Hydro Test of Piping▪ Power Energizing▪ DCS SAT▪ PSV Popping Test▪ Equip. Final Inspection▪ Vessel/Tank Closing▪ Cold Align. Check▪ Install. of Instrument▪ Motor Solo Run▪ OWNER disciplines

to punch all systems /subsystems,compile master punch list, anddecide punchitem categories.

OVERALL SYSTEM▪ "A" Punch Cleared▪ Pipe Cleaning▪ Reinstatement▪ Leak Test▪ Functional Test

(Interlock check for Process, F&G )

UTILITY SYSTEM only▪ "A"&"B" Punch Clear▪ PSSR▪ Tightness Test (at

Operating Pressure)▪ Steam Boiler

Refractory Dty-out▪ Chemical Preparation

and Chemicalin Servicefor Steam Boilers▪ Start Up & All Utility

System in Service▪ Hot Alignment▪ Performance Test

▪ "B" Punch Cleared▪ PSSR▪ Tightness Test (at

Operating Pressure)▪ System Drying Out /

Inerting▪ Catalyst Loading▪ Initial ChemicalFill-up▪ Refractory Dyr Out

(for Incinerator)▪ MRT▪ Load Test(Compressor)▪ Brine System(CA Plant)-Start Up& Operation▪ Electrolyzer-Start Up& Operation▪ Introduce Chlorine /Ethylene Feed forEDC Plant▪ Control SystemTunning


▪ Complete Punch(including "C")

▪ Operational Test

▪ Performance Test


▪ Hand Over- Special Tools- Spart Parts- Final Data Books

▪ DIC shall submitpre-comm./Comm. procedure 6 monthsprior to precomm.



2012.

OJT Traning

Total

Korean

TCN

ACVCManagement

EngineeringConstruction

DIC Project Manager

K 1

Comm.Manager

K 1 S

Comm.Coordinator

K S

Korean ACVC TCN

Staff GradeNumber of StaffNationality

K : Korean / T : TCN / A : ACVC

S : Supervisor / L : LeaderW : Worker

Procurement

Attachment 3 rev. A Aug/2/2011

Organization for Preparation Phase

ACVCManagement

EngineeringConstruction

OperationSupervisor

K 3 S

OperationSupervisor

K 2 S

OperationSupervisor

K 2 S

CA Plant EDC Plant Utility /Off Site

DIC Project Manager

K 1

Comm.Manager

K 1 S

Comm.Coordinator

K S

Korean ACVC TCN


K : Korean / T : TCN / A : ACVC

S : Supervisor / L : LeaderW : Worker

Lab

ProcessEngineer

K 1 S

ProcessEngineer

K 1 S

ProcessEngineer

K 1 S

LabEngineer

K S

Procurement

Attachment 4 rev. 0 Jan/17/2012

Organization for Pre-Commissioning Phase

Total

Korean

TCN

SAMAPCOManagement

Punch TeamConstruction

TurnoverCoordinator

K 1 S

QA/QC

K 1 S

Operation S/V(Utility)

K 1 S

SAMAPCOMaint. S/V

A 1 S

Operator

K 1 S

Operator

K 1 S

Analyst

K 1 S

MechanicalEngineer

A

ElectricalEngineer

A

InstrumentEngineer

A

Mechanical

T 2 L

Electrical

T 1 L

Operation(Day)

Operation(Night)

Lab.(Day)

Instrument

T 2 L

ControlSystem

T 2 L

Operator

T 3 W

Operator

T 3 W

Analyst

T 2 W

Mechanical

T 8 W

Instrument

T 8 W

DICSite Manager

K 1 S

Comm.Manager

K 1 S

Comm. S/V

K 1 S

Comm.Coordinator

K 1 S

Safety S/V

K 1 S

SafetyEngineer

K 1 S

Korean SAMAPCO TCN


K : Korean T : TCN A : SAMAPCO

Electrical

T 3 W

Comm.Engineer

K 1 S

SAMAPCOOperation S/V

A 1 S

OperationShift A

A

OperationShift B

A

OperationShift C

A

Mechanical

K 1 S

Electrical

K 1 S

Instrument

K 1 S

ControlSystem

K 1 S

OperationShift D

A

OperationShift E

A

S : SupervisorL : LeaderW: Worker

Attachment 5 rev. 0 Jan/17/2012

Organization for Commissioning Phase

Total

Korean

TCN

SAMAPCOManagement

Punch TeamConstruction

TurnoverCoordinator

K 1 S

QA/QC

K 1 S

Operation S/V

K 1 S

SAMAPCOMaint. S/V

A 1 S

Operator

K 8 S

Operator

K 6 S

Analyst

K 2 S

MechanicalEngineer

A

ElectricalEngineer

A

InstrumentEngineer

A

Mechanical

T 2 L

Electrical

T 1 L

Operation(Day)

Operation(Night)

Lab.(Day)

Instrument

T 2 L

ControlSystem

T 2 L

Operator

T W

Operator

T W

Analyst

T W

Mechanical

T 8 W

Instrument

T 8 W

DICSite Manager

K 1 S

Comm.Manager

K 1 S

Comm. S/V

K 1 S

Comm.Coordinator

K 1 S

Safety S/V

K 1 S

SafetyEngineer

K 1 S


Electrical

T 3 W

Comm.Engineer

K 1 S

SAMAPCOOperation S/V

A 1 S

OperationShift A

A

OperationShift B

A

OperationShift C

A

Mechanical

T 1 S

Electrical

K 1 S

Instrument

K 2 S

ControlSystem

K 1 S

OperationShift D

A

OperationShift E

A

Korean SAMAPCO TCN

K : Korean T : TCN A : SAMAPCO

S : SupervisorL : LeaderW: Worker

QCCheckSheet

NDTRecords

MaterialIdentification

ShopInspection

Report

PrepareQC Dossier

Prepare Pre- Comm./ Comm. Dossier

Review byACVC

ACVCApproval

Procedure forCleaning, Leak TestDrying, Function, etc.

Prepare Start Up, Comm.,& Performence Test

Dossier

System Certified

QCCheckSheet

NDTRecords


ShopInspection

Report

PrepareQC Dossier


Review byACVC

ACVCApproval



Dossier

Final IssueSystem Certifiedas Mechanically

Complete

ConstructionCompletion

Pre-Comm.Activities

Multi DisciplinaryPunch List

Pipe Cleaning,Function Test

Utility Start Up, etc.

Punch ACleared

Witness /Sign Off

MECHANICALCOMPLETION

Finalize QCDossier

CommissioningActivities

Punch A should becleared beforeM/C sign off.

ConstructionCompletion CheckList, Site Reports

Tightness TestDrying, etc.

PrepareQC Data

WitnessSign Off

Summary ofTesting &Inspection

QCCheckSheet

NDTRecords


ShopInspection

Report

PrepareQC Dossier


Review byACVC

ACVCApproval



Dossier


Complete


Pre-Comm.Activities




Punch ACleared

Witness /Sign Off


Finalize QCDossier





PrepareQC Data

WitnessSign Off


System Comple.Dossier

Submit Sys. Dossier to

ACVC


ACVCApproval

PunchA/B

Cleared

PSSR

EnergizingElectrolyser

Ready fo Start Upfor Cl2 / EDCDown Stream

Initial Start UpComm. Procedure

RFSUInst. TunningLoad Up to

Design Rate

Comm. AcitiviesCompletion

Product to Storage

START UP100% DailyProduction

Operation Manual

QCCheckSheet

NDTRecords


ShopInspection

Report

PrepareQC Dossier


Review byACVC

ACVCApproval



Dossier


Complete


Pre-Comm.Activities




Punch ACleared

Witness /Sign Off


Finalize QCDossier





PrepareQC Data

WitnessSign Off




ACVC


ACVCApproval

PunchA/B

Cleared

PSSR





Design Rate


Product to Storage

START UP

PerformanceTest

100% DailyProduction

Operation Manual

Performance TestProcedure

Special ToosSpare PartsHand Over

ACVCApproval

PerformanceAcceptance

Punch CCleared

ACVCApproval

SubmitFinal Data Book

InitialAcceptance

Reliability Test

Taking OverCertificate

Issued by ACVC

FINALACCEPTANCE

Attachment 6 Completion Process Flow ChartCompletion Process Flow ChartCompletion Process Flow ChartCompletion Process Flow Chartrev.A Aug/2/2011

QCCheckSheet

NDTRecords


ShopInspection

Report

PrepareQC Dossier


Review byACVC

ACVCApproval



Dossier


Complete


Pre-Comm.Activities




Punch ACleared

Witness /Sign Off


Finalize QCDossier





PrepareQC Data

WitnessSign Off




ACVC


ACVCApproval

PunchA/B

Cleared

PSSR





Design Rate


Product to Storage

START UP

PerformanceTest

100% DailyProduction

Operation Manual

Performance TestProcedure

Special ToosSpare PartsHand Over

ACVCApproval

PerformanceAcceptance

Punch CCleared

ACVCApproval

SubmitFinal Data Book

InitialAcceptance

Reliability Test


Issued by ACVC

FINALACCEPTANCE

Completion Process Flow Chart

Start Up Flow Chart

Dmin. Water Sys.Start Up

H2SO4 Con. Sys.Pre-Start Up

Preparation for Commissioning

▪ Prepare the precom,comm,start up procedurePC&C

Start Up Flow Chart


BoilerPre-Start Up(Fuel Gas)

Salt Handling Sys.Start Up

Anthracite Filter SysStart Up

Polishing Filyer Sys.Start Up

Ion Ex. Resin SysStart Up

Electrolyser

Sulfate Removal Pre-Start Up


Cl2 CompressorPre-Start Up

Cl2 EmergencyScrubber S/U

EDC ReactorEDC Filling Up

EDC Plant Dryingwith EDC

EDC PurificationPre-Start Up

Rectifier Power

Salt


▪ Prepare the precom,comm,start up procedure▪ Prepare the performance test procedure▪ Prepare the vendor engineer schedule▪ Ready for tools,consumable,test equipment▪ Ready for temp.equipment and piping installation▪ Ready for consumable utility items

PC&C

Team

Mobilization

Control & SWGR Bld. HAVC▪ Punch and physical checks▪ Balance▪ Energize & running test

230KV Power Incomming▪ Punch and physical checks ▪ Cable isolation check▪ E power available

34.5KV Switch Gear▪ Punch and physical checks▪ E-bus isolation procedure▪ E power available

IncineratorPre-Start Up

Start Up Flow Chart







ElectrolyserCatholyte / Anolyte

Filling

INITIAL START UP(Energizing)

Cooling / Drying /Compressing

Start Up

EDC Reactor Sys.Start Up

EDC PurificationStart Up

Instrument Tuning100% Production

Sulfate Removal Pre-Start Up







NaOH EvaporationStart Up

NaOH EvaporationPre-STart Up

NaOH Storage

NaOH

Rectifier PowerReady for ON

H2 CompressorStart Up

BoilerStart Up (H2)

HCl Synthesis Sys.Start Up

HCl Storage

Incinerator Sys.Start Up

Salt

NaOHH2

Cl2

Cl2

EDCEDC Storage



PC&C

Team

Mobilization




MV/LV (4.16/0.48KV)Switch Gear▪ Punch and physical checks▪ E-bus isolation procedure▪ E power available

AC/DC UPS System▪ Punch and physical checks▪ Charge batteries▪ Discharge/Recharge tests

Control System (DCS)▪ Punch▪ Energize all system▪ Energize checks/soft ware ▪ Checks / Function checks▪ OPC checks▪ Communcation check

Control System (F&G)▪ Punch▪ Energize for F&G system▪ Loop test▪ Cause and effect test

Instrument Air▪ Punch list▪ Compressor runs▪ Line blowing▪ Air available

Control System (SIS)▪ Punch▪ Energize ESD system▪ Loop test▪ Cause & effect test


Attachment 7 Sep/30/2011Start Up Flow Chart







ElectrolyserCatholyte / Anolyte

Filling

INITIAL START UP(Energizing)

Cooling / Drying /Compressing

Start Up

EDC Reactor Sys.Start Up

EDC PurificationStart Up

Instrument Tuning100% Production

RFSU

Performance Test

Performance Acceptance

InitialAcceptance

ReliabilityTest

Sulfate RemPre-Start U

oval p







NaOH EvaporationStart Up

NaOH EvaporationPre-STart Up

NaOH Storage

NaOH

Rectifier PowerReady for ON

H2 CompressorStart Up

BoilerStart Up (H2)

HCl Synthesis Sys.Start Up

HCl Storage

Incinerator Sys.Start Up

Salt

NaOHH2

Cl2

Cl2

EDCEDC Storage



PC&C

Team

Mobilization




MV/LV (4.16/0.48KV)Switch Gear▪ Punch and physical checks▪ E-bus isolation procedure▪ E power available

AC/DC UPS System▪ Punch and physical checks▪ Charge batteries▪ Discharge/Recharge tests

Control System (DCS)▪ Punch▪ Energize all system▪ Energize checks/soft ware ▪ Checks / Function checks▪ OPC checks▪ Communcation check

Control System (F&G)▪ Punch▪ Energize for F&G system▪ Loop test▪ Cause and effect test

Instrument Air▪ Punch list▪ Compressor runs▪ Line blowing▪ Air available

Ready for N2▪ N2 system service

All System Pre-Com▪ Loop check/Sequence test▪ Valve stroke test▪ MCC auto function test▪ C&E test/Utility start up/run

Commisssioning▪ Tightness test▪ Drying/Inerting▪ Functional Test

PRE START UP SAFETY REVIEW (PSSR)

Control System (SIS)▪ Punch▪ Energize ESD system▪ Loop test▪ Cause & effect test



EDC PLANT DRYING & START-UP PLAN

0

10/01

1

09/24

2

09/17

3

09/10

4

09/03

5

08/27

6

08/20

7

08/13

8

08/06

9

07/23

10

07/16

11

07/09

12

07/02

13

06/25

14

06/18

M/C

M/C

Attachment 8

Items Preparation Plan

1.1 Section definition (System Definition) Preparaed and issued to Owner(Document No. 080036-MZ-SD-001)

1.2 Detailed pre-commissioning (includingFUNCTION TESTS) procedure

1.2.1 Box-up procedure Will be prepared by 29th Feb. 2012

1.2.2 Loop test procedure Will be prepared by 29th Feb. 2012

1.2.3 Electrical pre-commissioning procedure Will be prepared by 29th Feb. 2012

1.2.4 Motor solo run procedure Will be prepared by 29th Feb. 2012

1.2.5 Pipe cleaning procedure

1) Air blowing procedure

2) Water flushing procedure

3) Steam blowing procedure

4) Chemical cleaning procedure

1.2.6 Tightness test procedure with marked-up P&ID Preparaed and issued to Owner(Document No. 080036-DZ-PQ-011)

1.2.7 Functional test procedure Will be prepared by 29th Feb. 2012

1.2.8 Drying & Inerting Procedure Preparaed and issued to Owner(Document No. 080036-DZ-PQ-010)

1.2.9 MRT procedure Preparaed and issued to Owner(Document No. 080036-DZ-PQ-012)

1.2.10 Reliability Test procedure Preparaed and issued to Owner(Document No. 080036-DZ-MP-003)

1.3 Detailed pre-commissioning planning by sectionand discipline

Will be prepared by 31th Mar. 2012

1.4 Detailed commissioning / ready for start-upprocedures

Will be prepared by 31th May 2012

1.5 Detailed commissioning planning by section anddiscipline

Will be prepared by 30th June 2012

1.6 Pre-commissioning and commissioning technicaldatabase

1) Pre-commissioning : will be prepared by 31st Mar. 20122) Commissioning : will be prepared by 30 June 2012

1.7 Pre-commissioning and commissioning check &test sheets

1) Pre-commissioning : will be prepared by 31st Mar. 20122) Commissioning : will be prepared by 30 June 2012

1.8 Detailed pre-ready - for start-up activitiesprocedure

Will be prepared by 30th Sep. 2012

1.11 Performance test procedure Will be prepared by 31st Oct. 2012

1.13 Operation manual Preparaed and issued to Owner(Document No. 080036-VZ-MP-01 / 080036-VZ-MP-002 /080036-VZ-MP-003 / 080036-VZ-MP-OO4 / 080036-VZ-MP-005)

1.14 Maintenance manual Will be prepared by 30th April 2012

Attachment 9

List of Preparation Plan of Pre-commissioning &Commissioning Documents and Activities

1. Preparation of pre-commissioning and commissioning documents as per Plant Completion of Project Standard Specification (SPCC - G - 008)

Preparaed and issued to Owner(Document No. 080036-DZ-MP-002)

1 / 2

Items Preparation Plan

1.15 Turnover procedure Will be prepared by28th Feb. 2012

1.16 List of consumable to use during pre-commissioning and commissioning activities

Will be prepared by 31st March 2012

1.17 Pre-commissioning and commissioning schedule Schedule have preparaed and issued to Owner, updatedschedule will be issued by 30th Apr. 2012(Document No. 080036-DZ-PQ-001)

1.18 Start-up schedule Schedule have preparaed and issued to Owner, updatedschedule will be issued by 30th June. 2012(Document No. 080036-DZ-PQ-001)

2.1

2.2

2.3

2.4

2.5

2.6

2.7

Optimize detailed pre-commissioning and commissioning procedures

Manage and execute pre-commissioning and commissioning activities in field as per detailed procedure

Coordinate vendor specialists and the TECHNOLOGY PROVIDER's site attendance during plat pre-commissioning, mechanical completion, commissioning and ready for start up phases.

Coordinate and execute plant start up, initial operation and performance tests with OWNER andTECHNOLOGY PROVIDER's respective personnel

Training on the job to OWNER personnel in accordance with CONTRACT.

Taking-over of the PLANT by the OWNER after successful performance test and reliability tests.

2. Pre-commissioning and commissioning site activities List

Schedule for site attendance of vendor specialists

2 / 2