K2S-CW230907-KOLS1-BA5711-00002 - A01 - Commissioning Plan

Originating Company MORPOL ENGINEERING SERVICES LIMITED
Project Installation of Back-up

up Power and Ancillary Works
for K2S Project
Document Title
Document Number K2S-CW230907-KOLS1-BA5711-00002

DCAF Control ID NA
Security Classification Restricted
Owning Discipline BA Construction.
Document Date 12/19/2020
Proprietary Information: This document contains proprietary information and may not be partly or wholly
reproduced without prior written permission from Shell Petroleum Development Company
Company..
Revision Date Description Originator Checker Approver
K2S-CW230907-KOLS1-BA5711-00002 K2S COMMISSIONING PLAN Page 1 of 1
This document is controlled electronically and uncontrolled when printed

ADDITIONAL AGREEMENT/APPROVAL RECORD
Party RefInd Name Sign Date
Revision Philosophy
All revisions for review will be issued at R01, with subsequent R02, R03, etc as required.
All revisions approved for issue or design will be issued at A01, with subsequent A02, A03,
etc as required.
Documents approved for Construction will be issued at C01, C02, and C03 respectively.
Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc.
Narrative sections revised from previous approved issues are to be noted in the table
below and/or highlighted in the RH margin (using the appropriate revision status) thus: |
A02
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding'
the affected areas and by the use of a triangle containing the revision status.
Revision History
Revision No. Date of Reason for change

issue

TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 PURPOSE
3.0 SCOPE
4.0 DEFINITIONS AND ABBREVIATIONS
5.0 REFERENCE
6.0 COMMISSIONING ORGANISATION AND RESPONSIBILITY
7.0 COMMISSIONING STRATEGY
8.0 COMMISSIONING MANAGEMENT SYSTEM (CMS)
9.0 COMMISSSIONING PREPARATION ACTIVITIES
10.0 PRE-COMMISSIONING
11.0 COMMISSIONING
12.0 START-UP
13.0 VENDOR SPECIALIST SERVICES
14.0 COMMISSIONING MATERIAL/TOOL
15.0 COMMISSIONING HSES MANUAL
16.0 PRE-START-UP AUDIT
17.0 TECHNICAL DOCUMENTATION
18.0 COMPLETION AUDIT

1. INTRODUCTION
Backup Power to the four (4) SPDC’s Kolo Creek Oil and NAG host communities of Imiringi,
Elebele, Otuasega and Oruma in the event of power outages from the Kolo Creek Power Station
(KCPS) turbines.
Currently, there are two 350KVA and two 87.5 KVA gas generators supplies power at the Kolo
creek manifold with fuel gas supplied via the kolo creek fuel gas scrubber (V-6901). The current gas
consumption rate for the four generators is circa is 0.3MMscfd. The new project intends to replace
the two 87.5KVA gas generators with two 3.5 MVA generating set, which will increase the fuel gas
demand from circa 0.3MMscfd to 1.6MMscfd
The Commissioning activities will be jointly performed by the Commissioning Team consisting of
Morpol and Shell personnel in accordance with the Contract requirements.
2. PURPOSE
This document describes the sequence, responsibilities and controls for the commissioning of the
Backup Power to the four (4) SPDC’s host communities ( Kolo Creek Oil and NAG host
communities of Imiringi, Elebele, Otuasega and Oruma )in the event of power outages from the
Kolo Creek Power Station (KCPS) turbines.
Currently, there are two 350KVA and two 87.5 KVA gas generators supplies power at the Kolo
creek manifold with fuel gas supplied via the kolo creek fuel gas scrubber (V-6901). The current gas
consumption rate for the four generators is circa is 0.3MMscfd. The new project intends to replace
the two 87.5KVA gas generators with two 3.5 MVA generating set, which will increase the fuel gas
demand from circa 0.3MMscfd to 1.6MMscfd.
This plan provides all parties with an understanding of the processes for verifying functional
integrity and of their responsibilities and requirements to meet the overall commissioning
management goals of the project.
3. SCOPE OF WORK
This plan covers all those activities necessary to control mechanical completion, pre-commissioning,
commissioning and start-up. Detail relevant commissioning procedures will be prepared and
developed during construction stage and related other procedure will be coordinated with this
procedure.
4.0 ABBREVIATIONS AND DEFINITIONS
4.1 K2S- Kolo creek to Soku
4.2 CTQ – Construction/Commissioning Technical Queries.
4.3 DCC – Document Control Center
4.4 SPDC – Shell Petroleum Development Company


4.5 CMS- Commissioning management system
4.6 F&G – Fire and Gas
4.7 FAR- Field auxiliary room
4.8 PTW- Permit to work.
4.9 ISO – ISOMETRIC
4.10 QC – Quality Control
4.11 PPE – Personnel Protection Equipment
4.12 HVAC – Heating, Ventilation and Air Conditioning
4.13 PEFS – Process Engineering Flow Scheme
4.14 OSD – Operation Shut Down
4.15 ESD – Emergency Shut Down
4.16 DEP- Design and Engineering Practice
4.17 KCPS –Kolo creek Power Station
4.18 MMscfd- Million standard cubic feet per day
4.19 ITP- Inspection test plan
4.20 RFSU- Ready for start-up
4.21 SAC – System Application Products
4.22 SER – Sequence of Events Recorder
4, 23 SIT – System Integrated Test
4.24 TEG – Tri-Ethylene Glycol
4.25 UCP – Unit Control Panel
4.26 UPS – Uninterruptible Supply


4.27 PAU – Pre-Assembled Unit
4.28 PAS – Plant Automation System
4.29 HVAC – Heating, Ventilation and Air Conditioning
4.30 IC&A – Instrument Control and Automation
4.31 MAC – Main Automation Contractor
4.32 NAG – Non-Associated Gas
4.33 FAT – Factory Acceptance Test
4.34 FOC – Fibre Optic Cable
4.35 HAZOP – Hazard and Operability
4.36 HIPPS – High Integrity Pressure Protection System
4.37 CONOPS – Concurrent Operations
5. REFERENCES.
● Shell DEP 70.10.70. 11. - Preservation of old and new equipment.
● ASME B31.3 - Process piping
● Shell DEP 32.31.09. 31. - Instrumentation for Equipment Package
● K2S-CW230907-GEN-BA6070-00037 - Method statement for decommissioning works
● K2S-CW230907-GEN-VA6036-00001 - Material preservation procedure
● K2S-CW230907-GEN- HS5798-00001 - Project HSE plan
● K2S-CW230907-GEN-BA6070-00006
● DEP 34.51.90.10-Gen - Demolition of storage tanks


6.0 COMMISSIONING ORGANISATION AND RESPONSIBILITY
The execution of all commissioning activities is to be managed and performed by the Integrated
Commissioning Team consisting of MORPOL commissioning engineers, technicians and SHELL
commissioning engineers, SHELL operations staff and vendor specialists. Composition of the
integrated team will be defined by MORPOL for approval by SHELL. MORPOL will develop lists
of qualified and authorized signatories (to be held within CMS) for Permit to Work controls, control
of electrical Energization, handover certification, issue of Commissioning Spares from warehouse
and for any other relevant control procedures.
At all times from mechanical completion to the end of the ninety (90) day reliability run
MORPOL retains responsibility for the performance and technical integrity of the facilities
MORPOL is responsible for demonstrating that the facilities have satisfactorily passed the seventy-
two (72) hour performance test, followed by the ninety (90) day reliability run in accordance with
performance guarantees
.
Throughout MORPOL is responsible for managing the interface between construction,
Commissioning and Vendor activities and for implementing procedures for safe and
progressive hand-off responsibilities from Construction team to Commissioning team, and from
commissioning team to SHELL. A critical element of this is the management of the shift in HSES
emphasis to additional safe systems of work as commissioning activities commence concurrently
with the remaining Construction work.
For all activities up to Ready for Start-Up (RFSU), the MORPOL-led integrated commissioning
team (comprising MORPOL and SHELL personnel) shall control activities, while a SHELL-led
integrated start-up team (SHELL and MORPOL) shall assume responsibility from start-up, up to the
end of the ninety (90) day reliability run.
Commissioning Lead/Engineer
The Commissioning Lead/Engineer reports their detail commissioning activities to the COM and is
responsible for the safe and efficient commissioning of all project equipment and manpower for pre-
commissioning, commissioning and start-up
Operation Supervisor
• Responsible for the safe introduction of hydrocarbons into the facilities to start up
• To arrange documentation related to commissioning
• Responsible for the functional and operational test of equipment

• Responsible for 72-hour performance test
• Operation of production and utility facilities
• Supervision of control room activities

• Maintaining the records of operation facilities
Maintenance Supervisor
• Supporting the functional and operational test of equipment
• Supporting vendor test run
• Supporting 72 hours performance test
• Performing the preventive inspection and maintenance of the facilities
• Maintaining the records of maintenance
CMS Administrator
The CMS Administrator reports to the commissioning lead and his responsibility is to handle and
develop, for review and approval by SHELL, CMS that will be achieved by the use of a transparent
system which will be supplied and operated by the MORPOL
His exact roles and responsibilities will be defined in detail depending on CMS software
Electrical Engineer
The electrical engineer will be responsible for the electrical pre commissioning and commissioning
and testing of all electrical systems such as Power Generation and Distribution Systems including
UPS, Low Voltage systems, High Voltage systems, lightings and FAT. He shall report to the COM.
Mechanical/Piping Engineer
The Mechanical/Piping Engineer shall ensure that all valves including check valves, ESD valves,
Control valves, HIPPS and MOVs are supplied and installed as per specification/design and tested.
He shall also ensure that all mechanical static & rotating equipment packages, flow lines, piping
systems, headers, manifolds are pre-commissioned commissioned and tested as per approved
procedure
7.0 COMMISSIONING STRATEGY

All mechanical completion, pre-commissioning, commissioning and start-up activities shall be
performed strictly in accordance with SHELL Engineering Codes, SHELL DEPs, Industry Codes
and vendor recommendations.
To ensure the effective and efficient execution of each of the steps required (i.e. from design,
Construction, Pre-commissioning, Commissioning to final handover) are met, the process of
execution we are adopting on this project will be as follows:
• Identification of Required Activities
• Definition of who is responsible for each activity
• Identification of required resources:
• Incorporation of the above into our strategy
The Commissioning process will be broken down into three main elements, which consist of the
following:
1) Planning and Preparation Phase to be executed during the Early stages of Detailed
2) Design, shall include the following
- Completion of Commissioning Planning and Preparation Procedures in accordance with
Pre-commissioning, Commissioning and Start-up, To be executed during the early stages of
detailed design.
- Obtaining a thorough understanding of the facilities to be commissioned
- Identifying the required component phasing of systems for each including Piping, utilities and
equipment
- Identifying the resources needed to commission the K2S facilities (Manpower, Tools and
calibrated test equipment.
- Developing and agreeing test methods in line with the Project Specifications regulatory
documents and contractual obligations.
- Preparation of the Pre-Commissioning / Commissioning Test pack dossiers.
2) Testing the facility in accordance with the agreed methodology
3) Final Handover to the Gbaran / Ubie Asset Team

The Commissioning team will be made up of integrated experienced operations and commissioning
specialists to perform the commissioning as a focused unit with clear performance tracking and
reporting functions.
In order to achieve the project objectives of providing Backup Power to the four (4) SPDC’s host
communities (Kolo Creek Oil and NAG host communities of Imiringi, Elebele, Otuasega and
Oruma) in the event of power outages from the Kolo Creek Power Station (KCPS) turbines as
defined in this contract, SHELL proposes the site installation works to be phased and facilities
commissioned as summarized below as a base case. Morpol and SHELL shall in the course of
detailed engineering, review these phasing with the aim to confirm its validity or re-align the
installation sequence for achieving the target back up of power to host communities. The details of
the facilities anticipated to be within each phase is described below:
Phase 1: All systems required for safe operation of the fuel gas scrubber to the gas generators.
Phase 2: All systems required for safe operation of the gas generators to substations
Phase 3: All system required for safe operation from substations to KCPS -Kolocreek Power Station
to host communities.
These must be finalized and approved by SHELL ready for population with test results thirty (30
days prior to the commencement of pre-commissioning phase 1 of the project. There shall be clear
demarcation between the construction completion, pre- commissioning and mechanical completion.
The commissioning Dossiers will cover all activities preceding the mechanical completion phase of
this project.
Each System Commissioning Dossier shall include as a minimum:
• System description and limits, associated systems and statement of intent
• Safety precautions to be taken during work on the system, include work permit system
• Mechanical Completion procedures, system cleaning and integrity check procedures, water
sources, characterization and disposal mean, ‘A’ work instructions, discipline and system
check sheets and resource requirements
• Pre-commissioning procedures, resource requirements, ‘B’ work instructions, discipline and

system check sheets
• Factory Acceptance Testing strategies and procedures and acceptance criteria
• Vendor support requirements in line with the vendor call-out register
• Preservation, lay-up and de-preservation procedure
• Commissioning spares and consumables requirements


• Test equipment and temporary supplies
• Commissioning and start-up procedures, manuals (F&G, HVAC, Instrument, Safety Equipment,
etc), defining the pre-requisites and the commissioning steps leading to the full commissioning of
a system and acceptance criteria and defining the resource requirements this procedure shall
describe steps for documenting and recording commissioning performance and define system
hand over requirements including witnessing of steps by SHELL
• Testing requirements and procedures, indicating parameters to be measured and performance

evaluation mechanisms and acceptance criteria for individual plant/equipment and for systems
• Drawings and vendor data requirements
• Handover strategy, documentation and protocols
The systems and sub-system activities will be executed and documented using the above structure.
These dossiers for the various systems will form part of the handover documents to SHELL.
Commissioning Dossiers shall be set up in advance from CMS to define the work to be done by
system, by node for later population as systems are handed over from Construction.
The objective of the CMS is to assist us in the management and control throughout the lifecycle of
the project. This will be achieved by the use of a transparent system which will be supplied and
operated by the MORPOL under the agreement of Commissioning Team. This system will allow us
to achieve the following:
• Ensure that the PROJECT is Constructed, Commissioned and Certified ready for safe operation.
• The PROJECT is provided with a complete and comprehensive set of data for input into the
Commissioning test pack dossiers. These dossiers will form part of the Handover package to
SHELL Asset Owners.
The CMS will be a structured database management system for maintaining the engineering data and
certification status for the Project. With the allocation of the Equipment register it will be clear to all
from the offset what the scope of works are therefore allowing us to plan well in advance for all
phases of our work.
The administration procedures, strategies, schedules, plans, start-up procedures, test pack dossiers,
evaluation and acceptance criteria will be developed in line with the commissioning requirements
8.0 COMMISSIONING MANAGEMENT SYSTEM (CMS)

CMIS (Commissioning Management Information System) will be applied as Commissioning
Management System (CMS) tool. This software is for populating commissioning database,
scheduling and tracing all certification. Software will be installed in the computer server of
commissioning team and CMS operator will get adequate training in order to get knowledge of how
to use and develop project data base. The main keys for successful use of this software are depended
on correct data base development. MORPOL will manage this CMS application process in
accordance with the following.
• Software installation and study by CMS operator
• Check sheets development using Data base in Software.
Based on the CMS software database, the check sheets will be developed. However, this check
sheets is not for specific SHELL DEP and specification requirement, but for global user purpose.
Therefore, lead of each commissioning discipline will review and develop all required check sheets
with SHELL lead Commissioning Engineer When standard check sheets are successfully developed,
these will be submitted to SHELL for Approval before implement for all system. The standard check
sheets will be applied for all plant commissioning activities. “A” check sheet will be developed by
Quality Control (QC) Engineer and reviewed by the commissioning lead and “B” check sheet will be
developed by commissioning team for SHELL’s approval.
• System segmentation, numbering and putting engineering data in CMS
When engineering data are issued, the lead engineer will segment system for handling. When PEFS
and single line diagram are issued, COM will mark system boundary in these drawings including sub
or sub-sub system also. These marked drawings are basic document for definition each system
boundary. All instruments, cables, piping, junction boxes, equipment’s, detectors, control loops, etc.
will be entered into the CMS data base by commissioning team with system number. This inputting
activity will be commenced when “For approval drawings” are issued and closed-out at “As-built
drawings” are issued.
• CMS Operation
When all data base and library are built-up, all CMS internal Map and system data including library
will be issued to SHELL as ready for use status. And thereafter, any activities for check and test will
be inputted by individual commissioning discipline after review of the lead commissioning engineer.
The CMS allows multi access if proper password is applied. During this period, SHELL and
MORPOL commissioning members can access CMS database and print current status, check sheets,
etc. But in order to manage correct progress management and avoid wrong CMS operating, input
into CMS system shall be by only authorized personnel. MORPOL will assign a CMS operator who
can input any conclusions derived from test and check. Other commissioning team member can read
only database and progress report. CMS operator will print and forward the progress report to the
COM in daily basis.

• Database Handover
Since CMS software tool is not long-term basis program (yearly basis), MORPOL will utilize this
program until completion of Ninety (90) days reliability run and only final CMS database will be
submitted to SHELL as a Hand-Over package while software will be expired
9.0 COMMISSIONING PREPARATION ACTIVITIES
Preparation of all Administration Pre-commissioning / Commissioning Documents
The commissioning preparation activities to be carried out in Home office identified as follows;
• CMS Installation and database set-up
• Segment the facilities in the systems and identification of the segmented system boundary on
PEFS or other suitable Engineering Drawing.
• The list of systems and marked-up PEFSs will be included in the Pre-
commissioning/Commissioning manuals and development of system based on logic sequences
(Based on phased start up objectives) required to drive construction completion.
• Prepare generic procedures for all pre-commissioning and commissioning activity
• FAT procedure review and FAT witness, and SIT procedure development and witnessing, if
necessary.
• Define the applicable procedure for all system. The procedures for the various tasks will be
included in the pre-commissioning and commissioning manuals
• Preparations of the blank forms of the record sheets associated with general procedures and
CMS database, and define applicable CTP’s for relevant packages.
• Preparation of training plan and schedule
• Preparation of pre-commissioning and commissioning detail schedules
• Produce pre-commissioning and commissioning manpower mobilization schedule and

histogram
• Review operation, maintenance manual supplied by vendors and applies to various

commissioning manual

The Commissioning lead and Commissioning Engineers will join engineering office occasionally
in order to review design pertaining to commissioning and attend operability review such as
HAZOP, SAFOP, and etc.
10.0 PRE-COMMISSIONING
10.1 Construction Completion
As construction is completed by system and Quality Control (QC) check sheets are filled up and
signed by SHELL, Construction team will handover predefined systems to commission lead. The
Commissioning lead will review construction related documents such as “A” check sheet and punch
status with SHELL Commissioning lead whether system is ready for pre-commissioning or not.
The Commissioning lead will review Mechanical Completion Dossiers and CMS status reports by
system for verification of readiness for Pre-commissioning.
But due to early progress of site, partial hand over basis of system can be applied with SHELL
Commissioning lead agreement. That means, if any systems of “A” check sheets are fully finished,
that system can be handed over to commissioning team even though another system is still in
construction. To ensure a smooth transition during partial handover the facilities shall be split into
Systems and Sub-systems.
Before commencing any pre-commissioning activity, the Commissioning lead will issue system
punches and ask construction team for correction. If “A” punches are in list, Construction team shall
clear them before hand over site to the Commissioning lead and shall submit the schedule to correct
remaining punches.
When the Commissioning lead agrees to commence pre-commissioning activity for such systems, it
means related responsibilities on related systems are handed over from the Construction to the
Commissioning. But even pre-commissioning stage, the COM has a right to issue additional punch
to construction team. “A” check sheets status will be clarified by CMS using database or QC
inspection sheets
10.2 Measurement Tool
The Pre-commissioning activities will include the single discipline, non- operating checks,
inspections, testing, cleaning, flushing, blowing, drying, adjusting, cold aligning, etc. of equipment,
piping, instrumentation and electrical systems and also include multi discipline operational checks
which will allow the system to be ready in every aspect to receive permanent Hydrocarbons or
Operational fluids. (RFSU)
The completion of these activities will bring the system Ready for Start Up

(RFSU) CMS B check sheets will be filled up in this period.
Whenever any equipment, instrument, junction box, etc. are passed pre-commissioning test as
described in “B” check sheet, Discipline Commissioning Engineer will fill up “B” check sheet and
get SHELL approval
CMS operator will get this signed “B” check sheet from Commissioning
Engineer and input CMS system within one day
In addition to CMS check sheet control, MORPOL will apply field tagging system. When
equipment, instrument, etc. are passed pre-commissioning check, pre-commissioning pass tag is
attached on the equipment with commissioning engineer signature and finishing date. This makes
site check avoid duplicate test and give attention to others.
Once “PASSED” tag is attached, nobody is allowed to open box or modify anything without signed
engineer’s written consent. Tag list will be developed as a serial numbering basis and only
authorized personnel can attach or remove tag under the Commissioning lead’s control.
This tagging system also will be applied to manual valve control. After commissioning engineer
locates valve position as per his work requirement, in order to prevent change the valve position by
others, he can put valve location tag with signature and date.
10.3 Pre-Commissioning General
Pre-commissioning activities will be carried out on a single discipline basis for efficient equipment
disposal and successful completion of preliminary tests and inspections and also include multi
discipline operational checks which will allow the system to be ready in every aspect to receive
permanent Hydrocarbons or Operational fluids. (RFSU). Detail required work will be developed and
populated from CMS in the status index. Commissioning team will verify documentation to support
proper Mechanical completion is in place, so that work will not be repeated.
Pre-commissioning activities will not normally be repeated on site if inspection and test
activities on engineered or manufactured items are completely carried out and properly
documented during Off-site pre- commissioning or FAT. All equipment requiring load testing will
be tested at the point of manufacturer. All electrical load tests will be verified by the manufacturer
during FAT and there will be no site load test for successfully verified equipment in factory. All
lifting equipment will be retested in the field after assembly as per the site safety guidelines
The water management plan will be maintained to prepare and segregate water for testing and
flushing carbon steel and duplex stainless systems, covering: water quality analysis, verification of
chloride content, monitoring, control, estimated water volumes, temporary storage facilities, ultimate
treatment and disposal.
Common

• Independent registration, calibration and testing of Pre-commissioning test equipment
• Work permit controls – block permits for pre-commissioning not involving permanent
Energization
• Preservation Maintenance (continue construction preservation routines)
Mechanical & Piping
• Thorough cleaning and flushing of the internals of the system piping and vessels to ensure no
debris
• The construction team will carry out cleaning and flushing piping and equipment to get rid of
debris.
• Dewatering, drying out and lay up of vessels and piping systems with the installation and removal
of temporary blinds as necessary including the leak testing of the Process facilities with
Nitrogen (This to be done prior to the RFSU)
• The construction team will take task of dewatering and drying which shall proceed after hydro
test and be responsible for the tasks on attaching and detaching accessories of pipe including
blind flange.
• Alignment checks in accordance with the manufacturers’ requirements
• The alignment for special equipment such as gas turbine with large capacity shall be performed
by the technicians from manufacturing companies.
• No-load running tests of driven machinery should be commenced in accordance with pre-
commissioning test procedure by commissioning team.
• Mechanical test-runs / string tests / performance tests at the vendor’s works
• Pursuant to commissioning test procedure, the commissioning team will perform running test,
string tests and performance tests, for the items not fully verified in the Factory.
• Installation of final gaskets, tightening of flanges
• Construction team will carry out installation of final gaskets and tightness of flanges according to
commissioning teams requires.
• Verification of UCP interfaces with PAS
• Testing of power and instrument cables (continuity and earth resistance tests)

• The construction team will operate insulation test and continuity test of power and instrument
cable.
• Manual rotation of prime movers and driven equipment
• Manual and hand turning of prime movers and driven equipment shall be performed at once a
week under the supervision of construction team until start-up of rotating machine.
• For piping systems, installation and removal of temporary blinds as required and accurate
maintenance of SLIP BLIND SCHEDULE
• If it is necessary to install and remove the temporary blind and gasket for commissioning and
start-up of plant, the construction team will handle it by the request from commissioning team.
• Installation of safety equipment and ensuring they are charged and fully functional
• The construction team will perform installation of safety equipment and ensuring they are
charged and being fully functional by the request of commissioning team.
• Manual valve function test
• The operation test of manual valve to be executed before commissioning and shall be done by
commissioning team.
• Installation of permanent filters
• Strainer inspection and installation register of temporary start up screens
• Restriction Orifice installation inspection & calibration checks and inspection
• Functional test of HVAC system
• Pre-commissioning cleaning, inspection, de and final closure of vendor packages
• Pre-commissioning of PAV’s
• Seat leak testing of critical valves
• Removal of all temporary start up screens after start up but before performance acceptance test
• Preservation maintenance (Mechanical & Piping)
Instrumentation
• Reinstatement of control valve, relief valves and orifice plates as removed for above
• The reinstatement of all kinds of control valve, relief valve and orifice plates installed on
piping shall be performed by construction team by the request from commissioning team.
• Calibration and testing of all instruments including those installed on packages or skids

• The calibration and testing of all instruments including those installed on packages or skids
in the early stage before installation shall be performed by construction team while it shall be
performed by commissioning team for the purpose of breakdown or confirmation after
operation start up.
• After calibration, the instruments will be clearly identified by sticker with date of test as a
control on further interference.
• Calibration and installation of relief valves not more than 60days before placement in service
• Relief and safety valve pressure setting shall be calibrated by SHELL
• Approved company and calibration certificate will be available.
• Instrumentation loop checks and verification of communication protocols
• Pursuant to commissioning test procedure, commissioning team will perform instrument loop
checks and verification of communication protocols.
• Function testing of monitoring and control loops and third party interfaces
• The communications among systems shall be performed among manufacturing companies

as being considered one of the important parts in the operation and commissioning team will
support it.
• Testing of alarm and shutdown devices and verification of alarm management system
• Pursuant to commissioning test procedure and standard of manufacturing companies,

commissioning team will test and manage alarm management system.
• Testing of event time stamping in Sequence of Event Recorder, and synchronization of

entire system time.
• Pursuant to commissioning test procedure and the standard of vendors, commissioning

team will test and manage event time stamping in sequence of events recorder,
synchronization of entire system time.
• Stroking test of valve
• The inspection before installation of control and shut-down valve shall be performed under
the supervision of commissioning team at the field-site, and stroking test shall be made
during loop checking
• Complete cause and effect physical check to be executed on the facilities prior to RFSU.

Electrical
• Testing of all electrical system components including switchgear, transformers, battery

systems and primary injection testing of protection systems;
• But In case Module or Package substation equipment and already pre-commissioned in
offsite, same test will be not be repeated on site.
• Pursuant to commissioning test procedure, pre-commissioning and commissioning with the

cooperation of construction team shall execute various tests of all electrical system
components switchgears, transformers, battery systems, primary injection testing of
protection system.
• Functional and load testing of equipment in compliance with manufacturer’s
requirements, including all motors, electrical systems, alarms and shutdown devices;
• Functional and load testing of equipment in compliance with manufacturer’s requirements,
including all motors, electrical systems, alarms and shutdown devices shall be proceeded by
commissioning team with the support of manufacturing companies.
• Power generation system, the power management systems, the switchgears including all
protection relays and devices
• The full load test will not be done on site if full load test was completed and accepted during
FAT or off-site pre-commissioning period.
• Miscellaneous checks on equipment, where appropriate, such as fuse ratings, polarity, etc;
• Uncoupled and coupled runs of all electric motors;
• Load test on various kinds of motor and pumps installed at the field-site shall be executed
pursuant to the operation procedure manuals.
• Power and control cable checks and tests including integrity checks of HV and fibre-optic
cables. If tests were done during construction period by QC department and documented A
check sheet, this test will not be repeated.
• Electrical loop test and electrical power initial energizing
• The loop test shall be done by commissioning team with the support of construction team
after the construction is completed. And the pressurization of switch board at early stage
shall be executed by commissioning team with the support of construction team after pre-
commissioning is completed.
• Preservation Maintenance (of transformers, cable drums, JB’s etc)

• The results of these tests shall be documented on Check Sheets known as 'B' Check
Sheets, which will be recorded in CMS and retained in handover test pack dossiers to
ensure asset integrity can be verified and demonstrated.

• In order to carry out driven machinery no load test, HVAC running, etc., Utility facility such
as electrical system has priority to fix. Pre-start up Audit for utility will be done before
introduction of continuous well fluid to provide the necessary utilities for start-up.
10.4 Material / Equipment Storage, Control, Inventory and Surplus.
MORPOL is responsible for all materials and equipment designated for incorporation into the works.
MORPOL shall operate a computerized system of material control and tracking to monitor the status
of all materials at any time. The system shall monitor material and equipment from the point of
dispatch from any vendor’s works, through the collection and onward shipment of the materials and
equipment through to final issue for construction/installation. MORPOL’s system shall be
compatible with the SHELL SAP R3 system. SHELL shall be given access to this database.
MORPOL is responsible for recording and transferring material and equipment serial numbers and
relevant data onto each sub-component of the original piece.
MORPOL shall ensure that all materials and equipment for incorporation into the WORKS are
segregated and that access is only possible via MORPOL stores personnel and that all areas are
secured against unofficial access.
All materials and equipment will be packaged, preserved and protected against deterioration and
damage. MORPOL will provide any necessary temperature and humidity control where required
for preservation of the materials and equipment.
MORPOL will nominate preservation engineer who will regularly inspect and maintain all materials
and equipment, wherever located, for the duration of the CONTRACT.
MORPOL will provide a weekly updated materials and equipment inventory for the following:
• Materials commitments;
• Purchases;
• Materials on site.
11.0 COMMISSIONING
Once Pre-commissioning activities are successfully completed and documented in “B” check sheets
with SHELL approval systems, Facilities will be advanced to Commissioning stage.
Commissioning is the multi-disciplined, energized testing of systems to demonstrate
functionality and safeguarding prior to placing the system in permanent service. It shall be carried
out progressively by system by a team of engineers and operations staff and will be executed in line

with pre-prepared procedures requiring the introduction of process fluids and operation of the
system.
• This phase will also include the successful completion of the electromagnetic compatibility
study, power system study and the pre-start up audit.
• Communication of each installation related to operation will be performed pursuant to

operation procedure.
• Gas replacement and pressurizing the facility
• The exchange of gas and pressurizing will be the most important task relating to equipment
operation and be required to be exercised by keeping the regulations of ordering company.
• Preparation of temporary jumper log book in order to hand over to Start-Up stage
• Preparation of temporary override log book to hand over Start-Up stage
• Preparation of Spectacle blind/blind control book
• Utility test and operation using utility fluid (In order to supply electrical power, utility fluid from
well comes to fuel gas package and turbine generator) including gas for flare and flare purge
• The commissioning lead with SHELL will review all document and walk down site to decide
whether pre-commissioning is successfully completed and safety arrangement is enough to
commence commissioning or not. The walk down will be done with check sheet attached in
operation Readiness Plan (Attachment #9). Commissioning stage means that some fluids
are in plant for testing purpose specially utilities.
• As equipment manufacturers have a significant role in commissioning, commission lead will

mobilize manufacturers’ manpower in line with commissioning schedule commissioning
schedule will include the following tests for commissioning by steps and locations
Running Test:
Running test will be conducted if there is no mechanical and electric fault at Pre-commissioning
Step.
For the test, processes on the site must remain at operational condition. Commissioning team will
operate for twenty (20) to thirty (30) minutes with a minimum load during running test.
Manual Test:
Manual test is to check operational condition and load capacity prior to load test. In the test, features
of equipment must be carefully looked into. Load test will be carried out from minimum to

maximum capacity of the equipment. When any abnormal noises and mechanical vibration are
detected, immediate actions must be taken.
Load Test:
Load test will be conducted at the end of commissioning to figure out features and capacity of
equipment. It is recommendable to maintain the best condition for the test, because load increases as
time goes. In particular, a series of preparatory actions can be taken against any incidents.
Auto Test:
In the test, equipment will be operated automatically. When one intends to adjust load, he has to
record data and change load into next step, if equipment is stabilized for five (5) minutes after
changing the step.
If load test is completed, each of the equipment will run for about twenty (20) to thirty (30) minutes
at the maximum load, then operators will implement tuning and conduct 72 hours test. All test data
must be recorded and compiled.
Tuning and Stabilization of Process:
Tuning will be executed between the completion of load test and the beginning of 72 hours
performance test
To make a tuning condition, operation mode must be set at ‘Auto Mode’. And pressure of flowrate
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
turning.
During operation of phase 1 production, remaining works (for completions of phases 2 & 3) may be
subject to concurrent operations controls and/or will need safe segregation from the operating plant.
Precautionary measures will be put in place to enable remaining works associated with phase 2 & 3
to be safely completed.
This will require some commissioning activities to have started on phase 2 activities whilst phase 1
work is proceeding as defined in the schedule.
Again, to meet this target some phase 3 activities will need to be in progress at the time of phase 2
start up as defined in the schedule
Corrective action such as gasket replacement and flange tightness will be carried out resulting from
leaks to ensure no gas leak during start-up phase

Pre start up audits will be carried out for each phase and will include the closing out of any remedial
actions associated with the above prior to the RFSU milestone being achieved.
MORPOL will undertake the following checks in preparation for the introduction of hydrocarbons
and / or operating fluids. This should include but not be limited to;
• Verification of F&G and SGS system
• Commissioning team will perform and confirm as being helped by construction team.
• Complete Full Cause & Effect check (Logic test)
• With the support of manufacturing company, commissioning team will perform Cause and
Effect checks including commissioning of all safety detection systems such as fire detection,
smoke detection, gas detection, public address system, manual alarm / call points pursuant
to commissioning test procedure.
• Full emergency shutdown systems test
• Tests relating shut-down signal and trip which are interconnected will be performed by
commissioning team with the support of manufacturing company.
12.0 START-UP
Start-up refers to the period from the introduction of permanent operating fluids, through the
seventy-two (72) hour performance test up to the end of the ninety (90) day reliability run for each
phase. The start activity will be managed in compliance with the Flawless Start-up Initiative
The Flawless Start-up Initiative is a formalized programmed of preparation to achieve the objective
of world-class commissioning, start-up and operational performance for the total project including
first cycle operation. It encompasses a systematic approach to ensure a successful commissioning,
start-up and first cycle operation of the Facility. It means that more than 99.9 % of the functionality
needs to be first-time right-on demand.
Once all commissioning activities are successfully finished and signed off by SHELL, Facilities will
be declared as Ready for Start Up (RFSU). Start Up period means that permanent Gas/Oil will be
produced continuously with allowable shortage period. But before stabilization of plant for
continuous operation, individual equipment/package shall be tested by well fluids step by step.
From this stage SHELL led start up team Comprising MORPOL and SHELL will take
responsibilities to managing start up and operation. Seventy-two (72) hours performance test and
ninety (90) day reliabilities test will be carried out this stage by SHELL led start up team
Comprising MORPOL and SHELL. In order to support this start up team, MORPOL will provide
under listed personnel with proper PPE and tools. But the personnel listed will remain with the
Project from the commencement of the RFSU through to the end of the 90day reliability run.

• PAS Control Room Technician 2
• Instrument Engineer 1
• Instrument Technician 2
• Mechanical Engineer 1
• Mechanical Technician 2
• Electrical Engineer 2
• Electrical Technician 3
• Vendor Representatives As identified in the call out schedule.
At the point of RFSU, responsibility for start-up of the facility will be pass to SHELL, who shall be
responsible for the introduction of continuous well fluids into the facilities, and for continuous
operation of the facility from that point. MORPOL will retain care and custody of the facilities, until
COMPLETION. All operation logs and trip logs will be jointly reviewed between SHELL and
MORPOL. In order to avoid any un-convenient situation, such as HSE issue and schedule delay,
MORPOL Commissioning lead will get daily meeting with SHELL Commissioning to discuss daily
topic.
During this period, MORPOL will demonstrate achievement of the follow objectives;
•Demonstrate compliance to the Flawless start-Up Process
•Bring the item or system into service and hand it over to the asset owner;
•Confirm equipment has not deteriorated during transportation, storage and installation;
•Prove the integrity and performance of the WORKS as a whole and re-confirm that the integrity and
performance recorded by the individual modules/ packages during the fabrication yard pre-
commissioning phase is maintained and/or improved upon;
•Establish/confirm the performance of the Plant/Systems via a seventy-two (72) hour performance
test of k2S facilities
•Establish/confirm the reliability /availability of the WORKS via a ninety (90) day reliability run;
•Demonstrate and record that equipment or systems that have been modified or newly installed are
able to perform in accordance with specified requirements;
•Monitor alarm and event reporting for potential flooding of Sequence of Events Recorder (SER)
12.1 Seventy-Two (72) Hour Performance Test
After the system associated with phase 1 to phase 3 have reached a twelve (12) hour stabilize state
condition, i.e. when the required production level has been reached and maintained for twelve (12)

hours, the defined performance evaluation criteria will be demonstrated. This will be achieved using
the seventy-two (72) hour performance test.
During first start-up period, seventy-two (72) performance test will be carried out. Any temporary
jumpers and overrides shall be removed and the process lined up at maximum continuous rating. In
this period, MORPOL will demonstrate capability of the individual systems, combined as a whole;
fulfill the performance requirement for all mode of operation. All necessary parameters will be
logged and analyzed by MORPOL. Process shall verify that a field check-out has been performed for
all mechanical systems to ensure that the systems conform to the process design. Process shall verify
the correct equipment operation and performance before testing. Equipment not performing
its specified duty or with other problems should be corrected before testing.
Performance Tests are conducted after the unit has been successfully started-up but while the
equipment is still in a “new” condition. Process Engineering and the SHELL must agree on when the
unit is ready for the test. The test must be completed within a duration specified in the contract. The
facility must be in stable operation at conditions specified in the contract before the performance
tests are begun. Additionally, there should be provision of sufficient feedstock, utilities, product and
by-product take-off, and waste handling removal and containment for the test period.
The Commissioning Team will collect samples, record data, provide laboratory services, maintain
the plant in good condition, and perform other activities necessary to conduct the performance test.
Process Engineering will witness the performance test in order to independently validate the test
results and officially report unfavorable plant conditions and request corrective actions as necessary.
Process Engineer may provide technical advice or exercise technical control during the performance
test.
The following extracted from the Technical Practice lists the elements of the commissioning
precedence network:
• List the tests to be performed and period of the testing
• Define the period of time allowed for test completion
• Define the process conditions under which the tests are to be performed
• Identify the risks and develop plans for their mitigation or containment
• Perform necessary tests and perform sampling and laboratory analysis.

Details of the laboratory analysis methods should be clearly stated. Generally accepted
standards or SHELL standards should be used if deemed adequate. Samples of feed and products
should be retained for independent analysis if required
• Establish with the SHELL the transfer of required data from DCS and laboratory results,
including the data frequency, accuracy and format

• Describe the procedures for testing, sampling and test evaluation
• Establish the basis for the unit’s condition and catalyst at the time of testing
• Define the sampling and frequency. Generally accepted standards or SHELL standards should be
used if deemed
•Ensure that instruments are calibrated before the tests begin. Verify that the instrumentation is
adequate to support the Performance Tests or whether additional instrumentation is required
• Agree proposed remedy for unit upsets during the test
•Establish provisions for dealing with schedule delays in performing the tests
• Analyze the feed before the test to confirm that it is suitable. Be sure that there is enough feed
available for the unit performance tests. Be aware of compositional issues including contaminants
• Verify that adequate utility and environmental data will be collected during the test. Data may
include cooling water, flow rates and temperatures, steam flow rates and pressures, ambient
air temperatures, fuel gas flow rates and heating values, etc. This data will be required to evaluate
the performance of the unit and its equipment
For spare equipment, any individual item shall be placed on ‘standby' for only one week at a time.
This shall ensure that each item is in operation and tested for a significant part of the ninety (90)
days period. The reliability of each item shall be recorded separately. All change-over shall be
recorded (logged).
During this period, should MORPOL require shutdown of units or systems to perform work to
optimize the performance of the facilities or correct faults, MORPOL shall submit to SHELL a
written request for the shutdown. Such requests will be considered by SHELL on a case-by-case
basis in relation to SHELL’s integrated activity plan. SHELL will, at its sole discretion, decide
upon the timing of the shutdown.
If a unit or system is shut down for maintenance or correction of a fault, MORPOL will immediately
effect such maintenance or correction and advise SHELL when the unit or system is reinstated and
ready for operation.
The ninety (90) day reliability run will be accepted provided that the availability percentages
indicated below are achieved during the specified periods.
Type A Equipment Type B Type C

Weeks
Equipment Equipment
1-4 80% 80% 95%
5-8 85% 90% 99%

9-13 95% 95% 99.85%
The ninety (90) day reliability run shall continue until the availability criteria in the above table are
met for all equipment. A fault rectified during the ninety (90) day run will be classified as minor,
and shall constitute a ‘clock- stop’ event only without reset to ‘zero-time’. Occurrence of a
substantial fault during the test period shall constitute a failure and a new ninety (90) day reliability
run period for each item of equipment shall commence once the fault has been rectified.
A substantial fault will be defined, for the purpose of each item of equipment’s ninety (90) day
reliability run, as a failure or malfunction of the facilities which gives rise to any of the following
circumstances:
• Any fault causing a hazardous or potentially hazardous situation;
Any fault that can only be rectified using non-standard maintenance procedures;
• Repeated trips causing standby equipment to be brought on-line;
• Repeated trips or faults requiring operator intervention in automated functions;
• Repeated faults preventing gas export;
• All other faults shall be designated minor faults for the purpose of the ninety (90) day reliability
run. Minor faults shall not constitute a failure of the ninety (90) day reliability run, however the test
shall not be complete until all minor faults have been rectified or rectification measures put in place
to the satisfaction of SHELL.
Interruption of the ninety (90) day reliability run attributable to SHELL or with written SHELL
agreement shall not constitute a failure of the test.
12.3 Documentation of the 90 Day Reliability Run
For the entire duration of the ninety (90) day reliability run, SHELL and MORPOL shall
respectively assign a full-time representative to the plant control room whose duty shall be to
maintain a Logbook of Plant Operations. The logbook shall record all facilities operations and the
time at which each event occurred. Additionally, a separate detailed log shall be kept for each and
every fault, separately identifying intentional shutdowns required by SHELL’s operations
programmed. Times shall be recorded to the nearest minute. Detailed notes of any differences in
opinion between SHELL and MORPOL of the causes of faults or shutdowns shall be recorded
separately and attached to the logbook.

At the end of each shift, the SHELL representative and MORPOL representative shall both sign and
date the logbook before handing over to the next shift. In the event of any dispute regarding the
content of the logs, MORPOL’s opinion shall also be noted in the logbooks.
13.0 VENDOR SPECIALIST SERVICES
MORPOL will provide vendor specialists to supervise receipt of materials and equipment at port of
entry and / or at the WORKSITE, to supervise any final adjustments to the equipment and / or to
provide specialist advice for all WORKS carried out up to and including completion of pre-
commissioning and commissioning/start up activities. And vendors to supervise the installation,
SAT and any final adjustments to the equipment up to the end of the 90 day reliability run as the
case may be. As minimum, all equipment with the requirement for FAT
The Commissioning lead shall develop a vendor call-out register for SHELL review and agreement,
detailing the equipment that will require vendor technicians and call-out schedule for assistance
during installation, pre-commissioning and commissioning activities.
MORPOL is responsible for all expediting requirements and appoint a dedicated expediting
coordinator. Expediting responsibilities include, but not be limited to, the following:
• Co-ordination activities for desk and field expediting;
• Desk and field expediting for all materials / equipment;
• Expediting of internal documentation;
• Expediting of all vendor data / drawings;
• Compilation of all expediting reports.
14.0 COMMISSIONING MATERIAL/TOOL
14.1 Commissioning Consumables
When vendor is awarded and vendor prints are issued, the Commissioning Manager will make report
of Consumables list for individual Equipment and submit the same to SHELL for approval. This
Consumable list will include Lubricant list for all equipment and all required consumable and
lubricant will be prepared before commencing pre-commissioning/commissioning. The remaining
stock for consumable and lubricant will be controlled by Commissioning team and reported to
Commissioning manager. This report will be issued to SHELL as a weekly base during
commissioning/pre- commissioning stage.
14.2 Commissioning Spares

All the required commissioning spares will be provided in accordance with CONTRACT (Scope of
work article 7.17) based upon individual approved vendor recommendations. In the event of
breakdown or malfunction during commissioning or the 90-day period, where the spares outside the
range of vendor advised commissioning spares are required, it will be acceptable subject to SHELL
approval, and will be placed of order by MORPOL with re-imbursable by SHELL to utilise the 1-
year operational spare(s).
From the commencement of pre-commissioning activities up to the end of the 90 day reliability run
for each system, The COM shall maintain registers of all spares and consumables, the order status,
delivery dates, location when delivered, usage rates and replacement orders. The records shall be
subject to SHELL review and be available and accessible by SHELL at all times.
Commissioning Spares shall only be issued to those commissioning staff authorized in writing by the
Commissioning Manager according to warehouse stock control procedure.
Any Commissioning spares remaining on the Project Completion shall be handed over to SHELL.
14.3 Commissioning Tools and Test Equipment
A list of all required tools and test equipment necessary to support all the scheduled activities to be
located on each node will be developed and provided to SHELL for approval. Test equipment shall
have information on test equipment type, manufacturer, quantity, serial number, test range,
calibration date, and recalibration date. The test equipment shall also include a bolt tensioning
equipment and vibration monitoring equipment.
A calibration bench will be prepared for instrument and test equipment calibration.
Special tool requirements will be specified at the time of procurement of equipment packages for
separate packaging, identification and delivery with their associated equipment package.
Commissioning tools and test equipment will be clearly identified and stored in a locked, secure,
and segregated area of the warehouse and shall be issued against signature only to commissioning
personnel authorized in writing by the Commissioning lead.
All test equipment and tools required for all pre-commissioning, commissioning and maintenance
activities shall be handed over to SHELL upon Project Completion, in calibration, for future
maintenance activities15.0 COMMISSIONING HSES MANUAL
A Commissioning HSES Manual to define the additional safe systems of work will be developed
and introduced prior to commencement of pre-commissioning and commissioning activities. These
systems and procedures will be prepared, communicated and understood by relevant sections of both
the Construction, Commissioning, Vendor and Operations organizations prior to the commencement
of concurrent pre-commissioning and Construction work.
MORPOL will develop Commissioning Safe Working Procedures to include the following:

• Permit to Work Procedure
• Safe Electrical Energization
• Electrical Lock out and Tag out
• Safe HV cable testing
• Gas Testing
• Concurrent Operations Risk Assessment and Controls
• Introduction of chemicals and Material Safety Data
• Authorization of changes to Alarm and Trip Settings and Logic Sequences
16.0 PRE-START-UP AUDIT
Prior to start up for each phase, an independent pre-start up audit will be conducted by SHELL in
accordance with the Operations Readiness and Assurance process. This will be scheduled in good
enough time to manage any issues or shortfalls identified without adverse effect on the start-up date,
but at a point where the WORK is sufficiently advanced to demonstrate that the WORK, processes,
plans and procedures are working and in control.
Pre-start up Audit for power will be commenced provide the necessary utilities for start-up.
A separate pre-start up audit shall be carried out before hydrocarbon is introduced for the
commissioning of the power generation.
The objective of pre-start-up audit will be to verify that the:
• Facilities are constructed as per design;
• Facilities are compliant to the electromagnetic compatibility requirements (reference DEP);
• Power System Studies has been completed and implemented;
• Operations Philosophy is complied with;
• Asset Integrity is verified and can be demonstrated;
• Operations staff are sufficiently trained and competent to start-up and operate;

• Asset Management Deliverables are available and uploaded into the SHELL Maintenance
Management System, ready for operations;
• Vendor deliverables are available on WORKSITE;
• Emergency response preparedness is demonstrated and complete;
• Audit and review actions, site queries, technical queries and non-conformances have been closed
out
• HSE-MS is in place;
• Commissioning and operational spares and special tools are available on worksite
• Flawless Start-Up and Operations Readiness Pre-requisites have been satisfied.
• The pre-start up audit will cover a wider spectrum than the previous audits, and will, next to
HSE, concentrate on the facilities, systems and operations readiness.
MORPOL shall be responsible for:
•Providing all technical information, drawings and documents required for the audits, e.g. design
drawings, documents and change control register, audit close-out reports, operations management
system and readiness documents, commissioning execution strategy, plan and manual, start-up
procedures and organization, test pack dossiers, handover strategy, commissioning HSE Plan,
emergency procedures, communications procedure, etc.
•Providing the engineers’ clarifications to the audit team
• Implementing and closeout of all audit recommendations that affect the WORK.
17.0 TECHNICAL DOCUMENTATION
All technical documentation generated during commissioning to record and/or measure, and to
verify the facilities mechanical completion, pre-commissioning, commissioning and start up status
shall be accepted/witness subject to the project’s nomination, and be used as part of the handover
suite of documentation to be submitted to SHELL.
The importance of recording and correlating the Pre-commissioning / Commissioning

documentation is essential. This will be backbone of handover process and therefore will
demonstrate the following:
• Demonstrate construction has been completed in accordance with design:
• Demonstrate the extent of testing undertaken.

• Demonstrate system operability to SHELL Asset Owner at the time of handover to them:
• Provide the SHELL Asset Owner with the technical information required to allow safe operation
of the systems and their components.
• The commissioning documentation for each system will be compiled to form a commissioning
test pack dossier. In some circumstances it may be appropriate to breakdown a system into sub
systems and create a commissioning dossier for each sub system. The dossier will be a part of the
overall handover package to SHELL Asset Owner.
Below follows content of K2S Commissioning Dossier. CONTENTS
1) SYSTEM DESCRIPTION AND LIMITS, ASSOCIATED SYSTEMS, OBJECTIVE
2) SAFETY
3) CONSTRUCTION/PRE-COMMISSIONING DOCUMENTATION
4) VENDOR SUPPORT
5) PRESERVATION
6) COMMISSIONING SPARES AND CONSUMABLES
7) TEST EQUIPMENT AND TEMPORARY SUPPLIES
8) COMMISSIONING PROCEDURE
9) COMMISSIONING TEST RECORDS AND REPORTS
10) DRAWINGS AND VENDOR DATA
11) HANDOVER DOCUMENTATION
12) NOTES AND CORRESPONDENCE
And to facilitate a smooth transition throughout the Pre-Commissioning / Commissioning

process MORPOL will prepare the following:
• Commissioning Plan.
• Project Phase Definitions.
• High Level Logic.


• Commissioning Organization / Resources.
• Commissioning Definitions.
• Scope Delineation (MORPOL vs. Project / SHELL Operations).
• Job Descriptions and Tasks and Targets.
• Safety and Training Plans.
• Commissioning Deliverable Development Plan.
• Suite of Commissioning and Start Up Management and Control Procedures.
• Systems Limit Drawings.
• Systems Coding.
• CMS System.
• Check Sheets and Check Sheet Norms.
• Level 2 and 3 Commissioning Plans.
• Level 4 Working Plans. E.g.N2 Testing,
• FAT Attendance / Acceptance Schedule.
• Systems Mechanical Completion Hand over Schedule / S Curve.
• Commissioned Systems Hand Over Schedule / S Curve.
• Execution Resource Histogram.
• Systems Statement of Intent.
• Commissioning Procedures.
• Integrity Testing Procedures.
• Commissioning Interfaces.
• Commissioning Temporaries.

• Commissioning Spares.
• Preservation Routines.
• First Fill Schedule.
• Commissioning tools, consumable and test equipment.
• Lubrication Schedule.
• Mobilization Plans.
• Start Up Time Line.
• Start Up Flaring Projection and Approvals.
• Up-time Forecast.
• Permit to Work.
• Start Up Procedures.
• Verification Scheme.
• Critical Success Factors.
• Project Learning.
17.1 As Built Drawings
Red Line ‘As Built’ drawings will be maintained by MORPOL as part of the commissioning
documentation and updated to reflect commissioning changes as commissioning activities proceed.
Back drafting of all required ‘As Built’ will be completed by MORPOL immediately after
commissioning and will form part of the final handover documentation to SHELL
17.2 Punch Lists
Punch list records will also be included as part of the systems handover documentation. Systems
punch lists will incorporate any items outstanding on vendor equipment carried over at the time of
release of the equipment from the vendor’s premises. MORPOL will be responsible, via the vendor
for closing out such items. All punch list items will be closed out before COMPLETION of the
WORKS associated with each system.

A punch list is defined as an item list that does not correspond to the design documentation or is
accepted as a design or construction errors found during FAT and Commissioning Team plant
inspection.
Punch list items will be categorized and completed as follows:
Category A: This is a safety or operability related item that shall be completed/remedied prior to
Mechanical Completion and Handover to the Commissioning Team.
Category B: This is a design or construction item that is considered non- safety related and can be
completed prior to initial Start-up (introduction of hydrocarbons)
Category C: This is minor item, which can be completed during Initial

Operations but must be completed prior to Final Acceptance.
Punch list from the FAT will be used as a baseline and will be added on during site checks if
necessary. All equipment, that has previous been checked, shall be re-examined in case of possible
shipping damage / losses and remedied factory punch list items.
The following check list is intended to assist in PEFS and systems checking. However, it is not
necessarily limited to this list.
Individuals must use their own judgment and experience as the check is carried out. Vital
information may be overlooked if the checklist is simply followed.
When carrying out the checks, it is essential that the latest revisions of the
PEFS and other relevant documentations are used.
It is important that items on the checklist are clearly defined and the item numbers entered on the
PEFS or other relevant documentations are correct, as this ensures most efficiency and accuracy.
In the event of uncertainty during checks, reference to Senior Management/Engineering is to be

sought. Such action will eliminate the costly time waste and ensure best time allowance for
resolution and procurement if required.
PEFS / DOCUMENT CHECK METHOD

REMARKS
All punch listing will be referenced to appropriate PEFS, electrical drawing etc. These will be
highlight marked as the punch listing progresses to map progress, ensure completeness of checks and
for audit reference. Faulty items are given a check number, this number is marked on the
PEFS/drawing and corresponding number entered on the check list with a description of the fault.
Two copies of the PEFS/drawing and punch list will be made with the checklists attached to the
drawing in each case.

One copy of checklist and PEFS/drawing is used as the Punch list work copy. The other copy will
be used as Master copy for the final sign-off and records. The work copy will remain on site at all
times until completion of the procedure. The Master copy must remain with designated person
responsible for document control.
The work copy is used for rechecking purposes and entering the findings into the master copy.
Regular meetings with relevant parties (Commissioning Team, SHELL Project Engineering, and
Punch List Team) will take place to discuss and resolve issues.
When the work is complete, MORPOL shall mark the items as appropriate and inform
SHELL/operator.
Punch list team shall recheck the items to ascertain whether or not they have been corrected. If not,
a note is made in the checklist recheck space and SHELL informed.
Above steps are repeated until all items are eliminated.
18.0 COMPLETION AUDIT
Prior to issue of a COMPLETION CERTIFICATE, a Completion Audit shall be performed by

SHELL. This is to confirm that: -
• Sustainable steady state operating conditions are met
• Performance acceptance criteria are met
• Availability profile has been met
• Ramp up profile has been met
• All Punch list items and technical queries have been closed out
• Commissioning report has been issued
• The Asset Management System is working
• Final documentation deliverables have been submitted to SHELL
• Project close out report has been reviewed and accepted by SHELL
Any items considered incomplete by SHELL shall be completed prior to the issue of the
COMPLETION CERTIFICATE.
For spare equipment, any individual item shall be placed on ‘standby' for only one week at a time.
This shall ensure that each item is in operation and tested for a significant part of the ninety (90)

days period. The reliability of each item shall be recorded separately. All change-overs shall be
recorded (logged).
During this period, should MORPOL require shutdown of units or systems to perform work to
optimize the performance of the facilities or correct faults, MORPOL shall submit to SHELL a
written request for the shutdown. Such requests will be considered by SHELL on a case-by-case
basis in relation to SHELL’s integrated activity plan. SHELL will, at its sole discretion, decide
upon the timing of the shutdown.
If a unit or system is shut down for maintenance or correction of a fault, MORPOL will immediately
effect such maintenance or correction and advise SHELL when the unit or system is reinstated and
ready for operation.
The ninety (90) day reliability run will be accepted provided that the availability percentages
indicated below are achieved during the specified periods.

K2S-CW230907-KOLS1-BA5711-00002 - A01 - Commissioning Plan

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K2S-CW230907-KOLS1-BA5711-00002 - A01 - Commissioning Plan

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Originating Company MORPOL ENGINEERING SERVICES LIMITED

Project Installation of Back-up

Document Number K2S-CW230907-KOLS1-BA5711-00002

Revision Date Description Originator Checker Approver

K2S-CW230907-KOLS1-BA5711-00002 K2S COMMISSIONING PLAN Page 1 of 1

This document is controlled electronically and uncontrolled when printed

Revision No. Date of Reason for change

K2S-CW230907-KOLS1-BA5711-00002 K2S COMMISSIONING PLAN Page 2 of 2

This document is controlled electronically and uncontrolled when printed

4.0 DEFINITIONS AND ABBREVIATIONS

6.0 COMMISSIONING ORGANISATION AND RESPONSIBILITY

7.0 COMMISSIONING STRATEGY

8.0 COMMISSIONING MANAGEMENT SYSTEM (CMS)

9.0 COMMISSSIONING PREPARATION ACTIVITIES

13.0 VENDOR SPECIALIST SERVICES

14.0 COMMISSIONING MATERIAL/TOOL

15.0 COMMISSIONING HSES MANUAL

16.0 PRE-START-UP AUDIT

17.0 TECHNICAL DOCUMENTATION

18.0 COMPLETION AUDIT

K2S-CW230907-KOLS1-BA5711-00002 K2S COMMISSIONING PLAN Page 3 of 3

This document is controlled electronically and uncontrolled when printed

4.0 ABBREVIATIONS AND DEFINITIONS

4.1 K2S- Kolo creek to Soku

4.2 CTQ – Construction/Commissioning Technical Queries.

4.3 DCC – Document Control Center

4.4 SPDC – Shell Petroleum Development Company

This document is controlled electronically and uncontrolled when printed

4.6 F&G – Fire and Gas

4.7 FAR- Field auxiliary room

4.8 PTW- Permit to work.

4.9 ISO – ISOMETRIC

4.10 QC – Quality Control

4.11 PPE – Personnel Protection Equipment

4.12 HVAC – Heating, Ventilation and Air Conditioning

4.13 PEFS – Process Engineering Flow Scheme

4.14 OSD – Operation Shut Down

4.15 ESD – Emergency Shut Down

4.16 DEP- Design and Engineering Practice

4.17 KCPS –Kolo creek Power Station

4.18 MMscfd- Million standard cubic feet per day

4.19 ITP- Inspection test plan

4.20 RFSU- Ready for start-up

4.21 SAC – System Application Products

4.22 SER – Sequence of Events Recorder

4, 23 SIT – System Integrated Test

4.24 TEG – Tri-Ethylene Glycol

4.25 UCP – Unit Control Panel

4.26 UPS – Uninterruptible Supply

This document is controlled electronically and uncontrolled when printed

4.28 PAS – Plant Automation System

4.29 HVAC – Heating, Ventilation and Air Conditioning

4.30 IC&A – Instrument Control and Automation

4.31 MAC – Main Automation Contractor

4.32 NAG – Non-Associated Gas

4.33 FAT – Factory Acceptance Test

4.34 FOC – Fibre Optic Cable

4.35 HAZOP – Hazard and Operability