ARP-HSSE-SWP-037 SIMULTANEOUS OPERATIONS OF PRE-COMMISSIONING ACTVITIES Issue No.

A1

Al-Rushaid Construction Co., Ltd.

Policies and Procedures / Instructions

Document Title:

SIMULTANEOUS OPERATIONS OF PRE-COMMISSIONING ACTIVITIES

Revision History and Highlights
Rev. No. A0 – Approved (19 April 2009)

Highlights of Rev. A1

1.0 Total Revision of the Procedure

Rev. No. A1 – Issued for Approval

APPROVAL

RAMIL V. ESCARMOSA MERCADO T. MAGNO

Corporate HSSE Manager VP & General Manager - Operation
HSE-MS Reviewed By: HGM Labayo
Controlled Copy IMPORTANT:
Uncontrolled Copy No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form, or by means of electronic, mechanical,
Copy Holder: DTS No.: photocopying, recording, or otherwise, without the written permission of Al-
Rushaid Construction Co., Ltd.
Issued By:

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
COMMISSIONING ACTIVITIES
JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 3
2.0 SCOPE 3
3.0 REFERENCES 3
4.0 DEFINITIONS 3
5.0 RESPONSIBILITIES 4
5.1 Project Manager / In-Charge 4
5.2 Pre-commissioning / Commissioning Manager 4
5.3 Project HSSE Manager / Representative 5
6.0 REQUIREMENTS 5
6.1 Planning of Resources 5
6.2 Simultaneous Operation of Pre-commissioning Activities 7
6.3 General Guidelines for Pre-commission Activities 12
7.0 FORM 13

ARCC Page 2 of 13
 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
COMMISSIONING ACTIVITIES
JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

1.0 PURPOSE

This procedure was developed to provide Health, Safety & Environmental (HSE)
instruction for controlling simultaneous pre-commissioning / commissioning activities
during the final stage of construction work on ARCC projects to protect persons working
at site against potential hazards of these activities as well as protecting the environment.

2.0 SCOPE

This procedure covers all preparatory, routine and non-routine commissioning activities
of ARCC without interfering construction work at projects. The main pre-
commissioning activities are divided into different categories depending upon sequential
preparatory activities of various systems and subsystems of a unit. The principle
activities include;

 Inspection of equipments
 Water flushing and cleaning
 Blowing Operations
 Pressure testing
 Tightness testing
 Purge and gas blanketing
 Functional Test of Rotating Equipments
 Instruments checking
 Safety device checking

ARCC shall follow on the Client Pre-commissioning / commissioning procedures.

3.0 REFERENCES

ARCC Health, Safety & Environmental Management System Manual (HSEMSM-01)

4.0 DEFINITIONS

4.1 Pre-commissioning terms

4.1.1 Air Blowing - passing pressurized air through pipeline with full flow.

4.1.2 Air Blasting - pressurization & depressurization of air up to 2kg/cm 2g

pressure.

4.1.3 Battery limit – entry / exit point and isolation valve on any pipeline of a unit
in a process plant.

4.1.4 Hydro test - pressure test carried out using water as pressurizing medium.

4.1.5 Pneumatic test - pressure test conducted using air / nitrogen as pressurizing
medium.

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
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JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

4.1.6 P&ID - Piping and Instrument Drawing.

4.1.7 Punch point list - Punch list contains all mechanical outstanding items at
Pre-commissioning stage to be carried out as per P&IDs and engineering
Drawings.

4.1.8 Pre-commissioning - includes all activities following construction

completion necessary to enable a system to be ready for commissioning and
operation

4.2 Simultaneous Operations - refer to undertaking concurrent construction, Pre-

commissioning, Commissioning and production operations or maintenance
activities at / or adjacent to the same location and time.

5.0 RESPONSIBILITIES

The main responsibility for the pre-commissioning / commissioning activities lies with
the plant operation group. However, the detailed responsibilities are described as;

5.1 Project Manager / In-Charge – shall monitor pre-commissioning

activities simultaneously along with construction and enforce safe operation for pre-
commissioning activities.

5.1.1 To ensure that arrangements are made to carry-out such

preparatory work before start up of the unit in line with safe plant operation
procedures and the equipment manufacturer guidelines.

5.1.2 That all persons involved in pre-commissioning activities

are suitably trained or competent to carry-out pre-commissioning activities.

5.1.3 To ensure that the requirements of this procedure are known

and understood by Dept. / Discipline Manager, Line Supervision and
Subcontractors for construction activities at this phase of project.

5.2 Pre-Commissioning / Commissioning Manager – shall ensure that all

punch points / check points against P&IDs and engineering drawings are
accomplished.

5.2.1 To ensure that the requirements identified during the

development of the method statement and operational procedures are
adequate in terms of detail and are being effectively communicated to
related plant operation personnel.

5.2.2 Ensure that communication between units, control room,

offsite and utilities are complete and in working condition in the unit.

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
COMMISSIONING ACTIVITIES
JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

5.2.3 Plant lighting, electrical connections to all plant machineries

are installed, completed and tested. Electrical supply to all equipments
should be in off position at main electrical substation with proper tag
system.

5.3 Project HSSE Manager / Representative – shall ensure that all pre-
commissioning / commissioning personnel are properly trained to adhere work
permit system, use personnel protective equipments as per plant pre-commissioning
/ commissioning, operation and chemicals hazard.

5.3.1 To provide training to all involved personnel to make fully

conversant with existing Fire fighting system provided in the unit. All of
them should have adequate fire fighting training.

5.3.2 To arrange practice drills for emergency evacuation and

rescue procedures.

6.0 REQUIREMENTS

The Simultaneous operations such as pre-commissioning, commissioning refer to

undertaking concurrent construction. These operations can be started with the proper
planning of the activities to be performed. The general procedure or work-flow is
provided as sequential guidelines.

6.1 Planning of resources

6.1.1 Site personnel and construction activities

The number of persons on the site and construction activities will be

reduced to an absolute minimum prior to start of commencement of pre-
commissioning activities. The operational area is barricaded from the
construction area. The purpose is to keep out construction workers and
traffic to define controlled operating area, which may not be entered without
authorization. Warning notices and security staff will be placed around such
areas.

6.1.2 Area Authorities duties

The Commissioning Manager is the sole responsible for all the pre-
commissioning activities in the area including providing blinds and tie-in as
per the requirement for these activities.

Electrical supply / energization, isolations, electrical work permits and lock

out / tag out will be the responsibility of the Electrical In-charge. Similarly,
Instruments energization, isolations will be enforced after getting clearance
from the Commissioning Manager.

6.1.3 HSE Training

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
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JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

All personnel involved in pre-commissioning / commissioning and

operation shall be trained for working at live areas, testing activities and
related works for pre-commissioning / commissioning works.

Competent ID cards will be issued to trained personnel and only trained

personnel will be allowed to work in controlled areas or ‘live’ locations.

6.1.4 Emergency Evacuation Plan

Due to the changes of activities and / or hazards from construction

operations to the plant become ‘live’, the emergency evacuation plan will be
amended to include all new eventualities. Safe shelters shall be prepared for
the personnel involved in emergency shutdown and controlling the process.

A rescue team shall be organized and communication system for emergency

situation shall be established. All rescue equipment to include but not
limited to;

1) Self contained breathing apparatus

2) Eye washers at strategic locations
3) Safety Showers at strategic locations
4) Basket stretcher for horizontal rescue from height
5) Fire proof suit
6) 100 meter hemp rope for emergency rescue
7) Vertical access tripod for entry / emergency rescue into vessels and
manholes.
8) Gin wheel pulley rope
9) Portable first aid kits
10) Fireman’s axes
11) Resuscitator

6.1.5 Risk Assessment and Permit To Work

Proper planning will be done before commencement of pre-commissioning

activities, all major activities and related hazards listed and each control
measure discussed and enforced to safeguard people, material and
environment. The Commissioning Manager will have sole responsibility for
enforcement of all risk management controls being carried out in the critical
areas. The commissioning team will develop all risk assessment for the
hazardous activities with the assistance from HSSE team members. Copies
of the risk assessment will form part of the permit to the work system and
displayed at the work location.

6.1.6 Environmental Aspect and Impact Analysis

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
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JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

Aspects and impacts that will have a significant effect on the environment
based on the analysis shall be given control measures prior to the execution
of work. The commissioning team shall develop this control measures,
implement, monitor and recommend improvement plans to mitigate impacts
the environment.

6.2 Simultaneous Operations of Pre-commissioning Activities

For pre-commissioning activities, the unit is divided into systems and subsystems
according to equipment like vessels, columns, heaters, Exchangers, pumps,
compressors, piping etc. and associated lines. These activities performed as per the
following:

6.2.1 Inspection of Equipments

The inspection of equipments and associated piping to be carried out with

reference to P&IDs, isometric and other engineering drawings and/or punch
list which indicate the deviations from the design specifications to be made
and distributed to the work supervisor to avoid any mistakes in construction
and corrected at this stage.

1) The general safety precaution during equipment inspection to be

followed as per the checklist given as Table-1 (Attachment A: Table I
Checklist of safety precautions during final inspection of equipments /
vessel).

2) For vessel entry - work permit for Vessel entry / Confined space to be
strictly followed for this activity with proper access and egress, rescue
team, continuous air purging, proper illumination and emergency
evacuation to be provided.

6.2.2 Water flushing and cleaning

The water flushing and cleaning activities using high pressure water is
carried out to clean and flushing of the equipments and associated lines to
remove dirt, scale, welding bits and left out material.

All piping & equipments are isolated and blinded at each opening of the
flanged joints with a thin metallic sheet / blind to prevent dirty water from
entering to connected equipment or piping. Tube lancing, rotating nozzle jet
assemblies are used for inside tube cleaning of exchangers. Shotgun single
jet blasting is also used for surface cleaning of equipments.

1) Safety guidelines for water flushing and cleaning

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
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JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

Proper and correct size of tools should be used for blinding and hose
connection purpose and no adjustable tools having serrated jaws like
slide wrench permitted.

The personnel engaged in this activity must work in crew system with
minimum numbers of two persons in a crew and must follow the
checklist given as Table-II (see Attachment A: Table II Checklist
minimum safety precautions during water flushing and cleaning).

6.2.3 Blowing operations

The safety precautions for blowing operations of air and steam blowing are
described here.

1) Air blowing

All air, gas and vapor lines of the unit are air blown completely from
battery limit with strong flow of pressurized air to clean and dry the
lines including associated drains and vents connections.

2) Steam Blowing

All steam lines (Low, Medium or High pressure) of the unit are steam
blown completely from battery limit to clean the steam network
including associated drains and vents connection with the steam. The
effectiveness of the steam blowing is gauged by providing target plates.
The lines should be repeatedly blown down until virtually unmarked
target plates are obtained.

3) Safety measures for these activities are tabulated in Table – III (see
Attachment A: Table III Checklist minimum safety precautions during
blowing operations).

6.2.4 Pressure testing

This procedure provides guidance for safety in pressure testing of

equipments and piping is carried out to prevent leakage during operation.
The testing medium decided as per the service and operating
conditions of the equipments e.g. air or water.

All the equipments and piping are pressure tested as per service and pressure
profile. The pressure rise to be checked on several pressure gauges and at
least one calibrated pressure gauge must be used in the system coupled with
pressure recorder. For pressure testing of a vessel, the test gauge should be
placed at the bottom of the vessel to account liquid head. Highest vent
must be opened while hydro test to remove any trapped air.

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
COMMISSIONING ACTIVITIES
JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

The equipments designed for vacuum operation to be tested for vacuum as

per designer’s guideline.

At the completion of the hydrostatic test, all water must be removed from
the equipment and if required, flanges may be opened to drain low points
and the equipment air blown to remove as much water as possible before
boxed up.

1) Safety precautions during pressure testing

a. Before hydro test of any vessel, the foundation design must be

checked for its rated load.
b. Before draining any liquid from vessel after hydro test, a vent must
be opened on top of the vessel to prevent a vacuum collapse of the
vessel.
c. During pressure testing of any equipment, particularly in cold
weather, care must be taken that pressure testing not carried out at
temperature levels so low that the metal may becomes brittle.
Temperatures above 17°C (60°F) are considered satisfactory for
testing to eliminate the possibility of cold fracturing of the
equipment. Such temperatures can be attained by warming the
testing medium. (See Attachment A: Table IV Checklist minimum
safety precautions during pressure and tightness testing).

6.2.5 Tightness test

The initial leak tests can be performed using air to check tightness of
flanges, joints, manholes etc. (except pumps and control instruments) in the
unit. The test pressure will be the air pressure or the design pressure and
leaks must be carefully located using soap solution and tightened.

1) Safety precautions during tightness testing

The Checklist provided in Table - IV shall be applicable for tightness

test.

6.2.6 Purge and gas blanketing

The inerting of unit equipments and pipelines is carried out using Nitrogen
under pressure to prevent rusting of the internals from corrosion due to
oxygen in the air which can develop any flammable mixture at initial
charging of hydrocarbons.

1) Safety precautions during inerting

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
COMMISSIONING ACTIVITIES
JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

The general safety precautions must be followed as per the checklist of

Table-V Check list for safety precautions during Inerting.

6.2.7 Functional Test of Rotating Equipments

1) Safety precautions during functional test of Motors / turbines to be

followed as per Table-VI Checklist for safety precautions during
functional test of Motors / turbines.

2) Safety precautions during functional test for Pumps & Compressors

a. All pumps and compressors should be thoroughly checked with

respect to. Instructions as per the Manufacturer’s guidelines
provided.

b. Direction of Non-Return Valve in pump discharge line is proper;

pressure gauges and any special instrumentation are in working
order.

See Attachment A; Table – VII Check list for safety precautions

during functional test of Pumps & Compressors.

6.2.8 Instruments checking

1) General guidelines

All instrument tapings for pressure, level and flow should be clear and
thermowells should not foul with the internals. These should be checked
prior to box up of the equipment with respect to P&IDs.

All the safety control instruments, Interlock(s) and emergency shutdown

system must be checked to control operation, against mal-operation to
fail safe position prevent runaway reactions.

Alarms, field gas detectors and support system relevant set points to be
provided as per safety analysis function evaluation charts to completely
safeguard the unit.

2) Safety precautions during instrument testing are functional test

The safety precautions followed during functional test is as per Table-

VIII Check list for safety precautions during Instruments checking.

6.2.9 Fire fighting safety device checking

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
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JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

All passive and active fire fighting system shall be arranged considering
safety of life, environment and predominant combustible / flammable
materials present, as per NFPA and other international codes &
standards and confirm the design by risk assessment.

Fire protection systems may be checked as per system selected at site. The
general facilities include;

1) The firewater system with pressurized wet

ring main network
2) Firewater hydrants, hose reels and nozzles
3) Automatic wet pipe sprinkler systems

4) Water spray deluge systems

5) Foam systems (particularly for hydrocarbon
storage facilities)
6) Trolley mounted and hands portable fire
extinguishers
7) Local application fire extinguishing
systems
8) Total flood gaseous (CO2) fire
extinguishing systems
9) Aqueous Film Forming Foam (AFFF)
concentrate storage and proportioning systems
10) Firewater / AFFF monitors and nozzles

6.2.10 Specialized process pre-commissioning activities

The specific pre-commissioning activities to be performed as per the

requirement of equipment / system in the unit like heater refractory dry-out
of a furnace / fired heater, Passivation, Chemical cleaning, Catalyst loading,
pigging, etc.

1) Safety precautions for Refractory dry out process

a) Safety instruction provided by the manufacturer must be followed.

b) High-performance infrared (IR) cameras to be used for inspection of
outer hot surfaces. The refractory inspection is carried after natural
cooling and regulated through confined space permit to work.
Leather hand gloves, helmet and face shield safety shoes with steel
toe to be worn.

2) Safety precautions for Chemical cleaning

Chemical cleaning is performed as per process requirements of the

equipment and instructions provided by manufacturer to be strictly
followed. e.g. compressor inlet lines are cleaned with mild acid to
remove dirt and grease to prevent frequent breakdown problems.

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SIMULTANEOUS OPERATIONS OF PRE-
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JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

a) Safety instructions provided by manufacturer must be followed.

b) Safety shower, eye washer and first aid box must be ready.
c) MSDS of cleaning agents / chemicals are referred and risk to be
assessed prior to cleaning.
d) Apron, PVC hand gloves and other necessary PPE’s must be worn.

3) Safety precautions for Passivation

Passivation is the pre-commissioning process in which a spontaneous

hard non-reactive surface film that inhabits further corrosion is formed.
This layer is usually an oxide or sulphide layer having thickness of few
atoms. This passive layer is formed on the inner layer of metallic
surface of the equipment / system to protect from gradual corrosion
during corrosive environment of process condition. General safety
precautions are;

a) Safety instructions provided by manufacturer must be followed.

b) Safety shower, eye washer and first aid box must be ready in the
unit.
c) MSDS of cleaning agents / chemicals are referred and risk to be
assessed prior to cleaning.
d) Apron, PVC hand gloves and other necessary PPE’s must be worn.

4) Safety precautions for catalyst loading

The procedure for catalyst loading are dependent of physical properties

e.g. dusty, coarse granule, hardness etc. of catalyst and geometry of the
reactor. The supplier’s safety instructions must be followed with;

a) The reactor is cleaned and no foreign material should be inside

reactor.
b) Hopper and loading pipe arrangements to be made as per geometry
of reactor to avoid any attrition of catalyst due to loading and
handling impact.
c) Proper approach to be provided for loading purpose.
d) All the necessary safety and personnel protection equipment to be
made available (gloves, dust masks, respirators, safety harness, etc.)
as well as means of communication (walky-talkies).
e) Entering in reactor vessel must be regulated through permit to work
for Confined Space with emergency rescue team, proper illumination
and communication system.

5) Safety precautions for pigging

a) Pigging is performed by especially trained personnel.

b) High standard of housekeeping must be maintained during this
activity.

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 Originator: Approved By:
SIMULTANEOUS OPERATIONS OF PRE-
COMMISSIONING ACTIVITIES
JRC Atienza RVE / MTM
Doc. No. ARP-HSSE-SWP-037 Rev. No. A1 Date: Date:

c) Ball valve must be used in the pipelines which do not cause any
problem of reduction of diameter of the pipeline.
d) Apron, rubber hand gloves, safety shoes with steel toe, respirators
and helmet are the main personnel protective equipments to be worm
whiling handling solid waste disposal.
e) General arrangement for disposal and control of hazardous substance
and waste management to be strictly followed as per policy
requirements and work culture.

6.3 General Guidelines for Pre-Commissioning Activities

6.3.1 Oil, testing water or chemical spills shall be cleaned up. Spill kit shall be
provided at the worksite.

6.3.2 Ensure proper housekeeping on all waste materials, debris lying around and
other potential cause of incidents.

6.3.3 All equipment / piping / rotary machines are grounded and continuity to be
checked and comply with electrical safety requirements.

6.3.4 Hose connection properly secured with chains or whiplash arrestor.

6.3.5 Used water from testing or flushing shall be collected or disposed on

approved disposal facilities.

6.3.6 Ergonomically proper approach to all operating valves and instruments,

panels and equipments shall be observed.

6.3.7 Road / access closure permit shall be applied on areas greatly affected by
simultaneous operations of pre-commissioning activities.

6.3.8 Pre-commissioning activities shall be provided with signs and safely

isolated with barricades.

7.0 FORM

HSSE-SWP-F037A – Checklist and Guides for Testing / Pre-commissioning Works

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