com .& start-up strategy 120926

7/31/2019 Com .& Start-Up Strategy 120926

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TABLE OF CONTENTS

1

1. Objective

2. Scope of Work

3. Process Configuration

4. Priming Fluids5. Commissioning & Start-up Sequence

6. Schedule

7. Work Definitions & Flow

8. Organization & RR Involvement

9. Areas of Concern


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- Implementation of HSE Plan& Procedures

- Safety Audit- Pre-Startup Safety Review- Safety Training & Emergency Drill- TRA & Risk Assessment

- Qualified & ExperiencedCommissioning Work Force

- Develop Detailed Procedures- Implementation of Training- Faultless Execution ofPre-commissioning /Commissioning Activities

Safe Completion

Good Performance

- Well Planned Preparation- Implementation of CMS- Tight Control of Commissioning

& Start-up Activities/Schedule- Interface Management- Harmonized Communication& Coordination

Schedule On-Time

Safety

QualitySchedule

1. Objective

2

Turnover


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Construction

By UnitBy Subsystem

50 M

Punch A Clear

Commissioning

Start-up &Stabilization

Test Run

2. Scope of work

3

Pre-commissioning

35 M

By Unit /Discipline

48 M

By Subsystem/System

41 M 44 M

Punch B Clear Punch C Clear

Commercial

Production

Pre-Commissioning Team

Construction Team

Commissioning & Start-up Team

COMPANY Operation / Maintenance Team

CONTRACTORs Care, Custody & Control CONTRACTORs Care, Custody & ControlCOMPANYs Assistance

MC Certificate&

Ready ForCommissioning

CommercialProduction

Certificate &Ready For

Test Run Certificate

ProvisionalAcceptanceCertificate &Hand-Over

Nov.2012 May.2013 Aug.2013 Dec.2013 Feb.2014

CommissioningCompletion


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3.

Process Units - EPC #1

Unit No. Unit Name Capacity Licensor / (FEED)

1 1100 Crude Distillation 417.1 KBPSD (Bechtel)

2 1110 Sat. Gas Plant 142.4 KBPSD -

3 1120 Sat. LPG Treating 22.2 KBPSD UOP

4 1130 Sat. LPG Splitter 23.7 KBPSD (Bechtel)

5 1210 SR Heavy Naphtha Hydrotreating 68.9 KBPSD UOP

6 1300 H2 Manufacturing 151.2 kNm3/h Haldor Topsoe (SSW)

7 1400 Kerosene Hydrotreating 107.8 KBPSD UOP

8 1510 LGO Hydrotreating 74.8 KBPSD UOP

9 1520 HGO/LCO Mild Hydrocracking 57.4 KBSPD UOP

10 1530 MHC H2 Recovery 2 t/h (Bechtel)

11 1690 Benzene Reduction 26.9 KBPSD UOP

12 1700 Sour Water Stripping 120 m3/h (Bechtel)

13 1800 MDEA Regeneration 440 m3/h (Bechtel)

14 1810 DEA Regeneration TBA (Bechtel)

15 1900 SRU & TGTU 400 TPSD CB&I

16 1036 Spent Caustic - (Bechtel)

17 1045 Acid Gas Flare - -


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1100CDU

1110SGP

1120/1130LPG Treating

/ Splitter

1210H/N HDT

1400Kero HDT

1510LGOHDT

1520MHC

1300HMU

1690BRU

CrudeOil

AR

LCO/LLCO

Natural Gas

H2

SR Kero

SR LGO

SR HGO

LPG

HDT H/N, S


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1700Sour WaterStripping

Phenolic SW (RFCC)Non-Phenolic SW

(Process Units)

Brine (CDU)

1800MDEA

Regeneration

1810DEA

Regeneration

Rich MDEAUnit 1110/1520/1530

Rich DEAUnit 1600/1220

1900

SRU & TGTU

1045

Acid Gas Flare

Stripped Water to WWTUPhenolic Stripped Water to RFCC

Lean MDEAUnit 1110/1520

1530

Lean DEAUnit 1600/1220

Molten Sulfurto Granulation Plant

1036

Spent CausticTreatment

Acid

Gas

Acid

Gas

Spent CausticUnit 1120

Unit 1610/1620

Oxidized Causticto WWTU

3.

6


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7

UnitPriming

Fluid

Approx. Required Amount (BBls)Expected

DateRequired

Reasons forRequirementTotal EPC1

EPC 3Intercon.

Piping

EPC 4Intercon.

Piping/Tank

11001110

HeavyNaphtha

6,000 6,000 Same line with Unit 1210Heavy Naphtha feed line

26 Jun 2013 - Inventorying for facilitates of Initial S/U- Removing remaining water in LPG serviceline to avoid icing during Initial S/U.

1100LGO

- Flushing Oil26,600 26,600

Same line with Unit 1520LGO line

21 Jun 2013

- Allows flushing of System & checking outof Rotating Machinery.

- For cleaning of filters & strainers duringflushing rather than using Crude Oil.

1110

1120

1130

LPG 1,586 1,500 86 - 25 Jun 2013

- Allows earlier S/U of Unit 1110, 1120 &1130 before feed off-gas introduction fromUnit 1100

- Earlier introduction of main feedstock fromexisting Ruwais Refinery

1210HydrotreatedNaphtha orSR Naphtha

68,219 46,700 134Line: 925Tank: 20,465

15 Jul 2013- Allows the pre-sulfiding of catalystper Licensors requirement.

1400SR Kerosene

- S/U Oil100,400 79,600 327

Line: 308Tank: 20,165

04 Jul 2013- Allows the pre-sulfiding of catalystPer Licensors requirement.

1510LGO

- S/U Oil70,963 50,400 134

Line: 264Tank: 20,165

06 Jul 2013- Allows the pre-sulfiding of catalyst per

Licensors requirement.

1520LGO

- S/U Oil59,195 58,600 86 Line: 509 06 Jul 2013

- Allows the pre-sulfiding of catalyst perLicensors requirement.

- From Unit 1510 LGO Feed Tank

1900Granular

Sulfur6 tons 6 tons - - 12 Jul 2013

- Allows fill-in of Seal Leg & Sultrap to avoidtoxic H2S gas release from SulfurCondenser to Sulfur Degassing Pit

1300 Methanol 14 tons 14 tons - - 24 May 2013- Allows production of recycle H2 for InitialS/U before feed Natural Gas in.

- No need if H2 is available from OSBL


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8* Tank Volume is based on Min. Operating Volume


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UNITS / UTILITY SYSTEM REQUIRED FOR STARTUP BY OTHER EPCS

EPC #1 UNITS Start-up

EPC #2

EPC #3

EPC #4

UNIT 1300

UNIT 1100 UNIT 1110 UNIT 1120 UNIT 1130

UNIT 1530

UNIT 1690

UNIT 1400

UNIT 1045 UNIT 1900

UNIT 1510

UNIT 1520

UNIT 1036

UNIT 1210

UNIT 1800

UNIT 1810

UNIT 1700

UNIT 1600

Utilities Flare FG

CrudeStorageTanks

IntermediateProduct Tanks

Balance &Product Tanks

NG

High Level Unit Interface For Start-up

9

ReformateTanks


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10


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Overall

11


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12

Unit - Typical

7 Work Definitions & Flow


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13

7.Work Definitions & Flow

The System is defined as a major subdivision of an installation, being either

process or non-process, which performs a major operational function of theunit.

Each System is further broken down into a Sub-System, which performs agiven operational function, with no or little interference from other Sub-Systems for the Commissioning execution.

The most efficient way for achieving plant completion in a limited period oftime will be to carry out Pre-commissioning and Commissioning activities bySystems and/or Subsystems according to the predetermined MechanicalCompletion and Commissioning priorities.

The Pre-commissioning & Commissioning Schedules are prepared based on

Sub-Systems.

Each Sub-System will be tied to a database containing all elements of each

Sub-System for tracking & recording the status of Sub-System MechanicalCompletion and Commissioning.

System Approach

7 Work Definitions & Flow (continued )


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The System / Subsystem has been erected in accordance with approved drawings,

specifications and applicable codes.

Activities include non-operating checks, inspections, testing, adjusting andcold alignment, etc. of equipment, piping, instrumentation, electrical to bringthe System / Subsystem to MC and Ready for Commissioning.

- Piping Cleaning : Flushing / Air Blowing / Steam Blowing / Chemical Cleaning- Reinstatement & Box-up- Energize Electrical Network- Rotating direction, Driver Solo-run, Alignment- Instrument & Electrical System / Equipment SIT- Loop Test & Functional Checks- Operational Tightness Test- Purging & Inerting (O2 Free)

Punch List A Clear

Utilities in service

7.Work Definitions & Flow (continued..)

Mechanical Completion incorporating Pre-commissioning



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15

Work Flow for Pre-Commissioning & Mechanical Completion




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Work Volume _ No. of Components

16



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All works, activities and tests associated with preparing the Plant for theintroduction of feedstock for the purpose of starting initial productionof the end products prior to commencement of Test Runs.

- Introduce Fuel Gas- Flares / Hydrocarbon Drains activation- Heater Firing & Drying out / Boil out- Catalyst Loading- Initial filling of Chemicals

- Operational Test

Priming Fluids Introduction

Pre-Sulfiding & Cold Circulation

Punch List B Clear

Company assist with experienced refinery plant operation supervisoryand shift operating personnel to supplement Contractor Commissioning Team.


Commissioning



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18

Work Flow for Commissioning Completion


7. Work Definitions & Flow (continued..)


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Start-up & Commercial Production Operation

19

Feedstock-in

Initial Start-up & Stabilization

The plant will achieve stable, safe, continuous operation

at no less than 80% of guaranteed capacity for a continuous period of 15 daysat guaranteed product quality conditions.

To demonstrate to Company that Units can be operated safely under alloperating conditions in accordance with Contract

- At Design Capacity for 72 hrs

- At Turndown Capacity for 72hrs

Performance Test Run



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Commissioning & Start-Up Organization Chart

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1) Early Involvement of Companys Personnel for Integrated One-Team

- Familiarization with Facilities

- Witness & Supervision- Training

2) Interface between with other Contractors

- On-Time Power Energizing & Introduction of Utilities

3) PSSR (Pre-Startup Safety Review)- Timing of Implementation


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- END -

com .& start-up strategy 120926

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