PRECOMMISSIONING AND COMMISSIONING PLAN

PROJECT : NPK FERTILIZER PROJECT

OWNER : MALAYSIAN NPK FERTILIZER SDN BHD

LOCATION : GURUN, KEDAH, MALAYSIA

0 FOR APPROVAL 3 March 2004

REV DESCRIPTION DATE PREPARED CHECKED APPROVED

OWNER : Job No :
03-1202

Contract No. :
MALAYSIAN NPK FERTILIZER SDN BHD
MNFSB-01/03-MPP
PMC :
z
Doc No. :

AMEC (MALAYSIA) SDN BHD NPK-C-00-000-PE-024

CONTRACTOR : CONSORTIUM Page No. : REV.

REKAYASA REKMAL 1 of 14 0
PT REKAYASA INDUSTRI REKAYASA INDUSTRI MALAYSIA SDN BHD
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REVISION HISTORICAL SHEET

Rev No Date Description/Reference

DISTRIBUTION ORDER

Internal CONTRACTOR (by DDO): Internal CONTRACTOR (by Transmittal): External CONTRACTOR (by Transmittal):

DDO Attachment
Project Director KPO Copy(s) OWNER
Project Manager With Status for JPO 1 Copy(s)
Procurement Manager For Review SPO 1 Copy(s)
Project Control Manager For Info. H/O 1 Copy(s)
Construction Manager As a “CC”
QA/QC Manager
Engineering Manager SPO Copy(s) PMC
Project Engineer With Status for JPO 3 Copy(s)
Civil Lead Eng. For Review SPO 2 Copy(s)
Electrical Lead Eng. For Info. H/O 2 Copy(s)
Instrument Lead Eng. As a “CC”
Mechanical Lead Eng.
Piping Lead Eng.
Process Lead Eng.
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TABLE OF CONTENT

1. SCOPE

2. ORGANIZATION

3. PRECOMMISSIONING AND COMMISSIONING SCHEDULE

4. RESOURCES PLAN

5. PROCESS LICENSOR AND VENDOR PARTICIPATION

6. COORDINATION TO PFK OPERATION TEAM

APPENDIXES

Appendix-1 Pre-commissioning Organization Chart

Appendix-2 Commissioning Organization Chart
Appendix-3 Sequence Chart For General Pre-commissioning Work
Appendix-4 Raw Material And Utility Schedule
Appendix-5 Pre-commissioning & Commissioning Activities and Schedule
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1. SCOPE

The CONTRACTOR will perform and be responsible for all activities required during Pre-
Commissioning and COMMISSIONING. Procedures, organization, schedule, manpower
plan, tools and equipment, operating manuals, utility and power consumption plan will be
provided in details for the activities later.

Pre-Commissioning activities will be done at the last stage of CONSTRUCTION Phase

before MECHANICAL COMPLETION of the FACILITIES, to enable the FACILITIES to reach
the condition of COMMISSIONING. Pre-Commissioning activities will be performed
according to system priority and process system-wise completion. Based on experience, to
catch up schedule, to reach the best condition for COMMISSIONING, and to maximize
coordination with previous activities such as construction activities and procurement
activities, from priority and system wise completion concept, the activities will be arranged
into four (4) general activities areas. The areas are:

1. Solid Raw Material Area,

2. Utility and Offsite Area including PFK FACILITIES,
3. Product Handling and Storing, and
4. NPK Main Process Plant including Urea Evaporation Section.

COMMISSIONING activities will be performed after getting APPROVAL of Mechanical

Completion. All the required REGULATORY APPROVALS from statutory bodies shall be
taken by the CONTRACTOR before executing COMMISSIONING work. At this stage, each
unit or discrete part of unit in each FACILITIES is ready to operate/start. This means,
individual for mechanical equipment, electrical system, control system and interlocking,
piping system, and laboratory facility have been tested and passed quality control. In
COMMISSIONING phase, setting and tuning for control system will be rectified setting
valve/damper opening will be done, load for mechanical equipment will be evaluate, flow-
pressure-temperature will be set to reach the optimum condition for PERFORMANCE TEST
under supervision of PROCESS LICENSOR.

CONTRACTOR will arrange daily coordination meeting prior to MECHANICAL

COMPLETION with CONTRACTOR’S CONSTRUCTION Manager, COMMISSIONING
Manager, Licensors’ COMMISSIONING representative(s) and OWNER’S Operation
Manager to ensure COMMISSIONING and FACILITIES operation objectives are met.
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2. ORGANIZATION

Pre-commissioning and COMMISSIONING Organization Structure will be planned as per

Appendix-1 and Appendix-2. CONTRACTOR will assign experience Pre-commissioning and
COMMISSIONING personnel with NPK Fertilizer Plant operation.

Pre-Commissioning activities will be performed according to system priority and process

system-wise completion which will be arranged into Solid Raw Material Area, Utility and
Offsite Area including PFK FACILITIES, Product Handling and Storing, and NPK Main
Process Plant including Urea Evaporation Section. Based on CONTRACTOR experience,
combining system priority and process system-wise completion which is commissioning
concept with area wise which is construction concept will give the best result for
COMMISSIONING.

Pre-commissioning team will be led by Pre-commissioning Coordinator who will report to

CONSTRUCTION Manager. Pre-commissioning Coordinator will manage all Pre-
commissioning activities during this period. The Coordinator will assign Pre-commissioning
Engineer/Supervisor for each Area to supervise respective Pre-commissioning activities
which is assisted by experience CONTRACTOR Pre-commissioning crews and OWNER
Operation and Maintenance personnel. Licensors and Vendors activities will be arranged by
Pre-commissioning Coordinator during this period.

Sequence for general Pre-commissioning work will be performed as Appendix-3. Pre-

commissioning Coordinator will formulate activities for each discipline, including vendors
activities, follow the sequence. CONSTRUCTION Manager will arrange close coordination
between CONSTRUCTION Superintendent and Pre-commissioning Coordinator initiated
with regular short-time daily morning meeting to up-date and expedite CONSTRUCTION and
Pre-commissioning activities.

COMMISSIONING team will be led by COMMISSIONING Manager who will report to

PROJECT Manager. All COMMISSIONING activities will be managed by the Manager.
Mainly, the Manager will manage how to, operation and maintenance aspects, PROCESS
LICENSORS participation, laboratory facilities, OWNER operation and maintenance
personnel involvement, tools and equipment, able to work simultaneously and do synergist
each other. To execute COMMISSIONING activities smoothly, CONTRACTOR Pre-
commissioning team which have acquainted all FACILITIES such as flow of activities and
procedure, good communication with OWNER operation and maintenance personnel, and
any regulatory, made them self ready to be COMMISSIONING team by adopting every best
practices in previous phase or activities. The new experience personnel will be provided, if
required.

To create a good communication in COMMISSIONING activities, plant operation parameters

such as operation condition based on DCS and field instrument, equipment condition,
manpower distribution, availability feedstock, utility and raw material, total product, electric
power status, problem solving, maintenance status, and laboratory analysis result will be
recorded in log book by Shift Supervisor and will be transferred to the other shift.
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3. PRECOMMISSIONING AND COMMISSIONING SCHEDULE

Refer to PROJECT Schedule, Pre-commissioning activities is scheduled to be started on

month 14th and will be completed on the end of month 18th, by means MECHANICAL
COMPLETION.

Pre-commissioning activities will be proceeded from Utility and Offsite FACILITIES, including
PFK Plant then Solid Raw Material Handling and Storage Area, Product Handling and
Storage, Main Process NPK Plant including Urea Evaporation Section, in-sequential. Raw
Water and Fire Water System will be the first energize/available FACILITIES. Then LP
Steam and Condensate System, Cooling Water System, HVAC System, and Compressed
Air System. These systems will be the most priority system for the whole Pre-commissioning
and COMMISSIONING activities. Raw Water will be as media for mechanical cleaning,
flushing, chemical cleaning, etc., Fire Water will be important FACILITIES to ensure safety
during Pre-commissioning, Cooling Water will be required for Main Process Equipments,
HVAC will be required for DCS installation and any instrument work in Central Control
Building/Room.

On the other hand, Pre-commissioning activities for Solid Raw Material Handling and
Storage will be executed in a little bit parallel with Utility & Offsite Facilities and Product
Handling and Storage.

The latest priority will be Urea Evaporation Section and Combustion Chamber Package
because the activities will require completion of other predecessor unit/system activity and
will be a little bit overlap with COMMISSIONING activities. Pre-commissioning activities for
the unit will be under supervision of PROCESS LICENSORS or Licensor’s specialist/
representative and their duty shall be extended until INNITIAL ACCEPTANCE.

Major milestone for Pre-commissioning activities will be planned as below:

 Start Pre-commissioning Work (month 14)

 Power Energize 26 May 04 (Month 16)
 HVAC System Energize 31 May 04 (Month 16)
 Raw Water and Fire Water System Energize 7 June 04 (Month 17)
 Cooling Water System Energize 7 June 04 (Month 17)
 Bulk Material Store and Reception Build. Ready to be 2 July 04 (Month 17)
Loaded
 Bagged Material Store Ready to be Loaded/Introd. 2 July 04 (Month 17)
 Product Store Ready to be Loaded 2 July 04 (Month 17)
 Intermediate Store Ready to be Loaded 2 July 04 (Month 17)
 Bulk Material&Bagged Material Ready to be Introduced 3 July 04 (Month 17)
 DCS Completion 30 June 04 (Month 17)
 Fuel Gas Introduced to Combustion Chamber Pack. 2 July 04 (Month 17)
 Compressed Air System Energize 8 July 04 (Month 18)
 LP Steam and Condensate System Energize 8 July 04 (Month 18)
 Ammonia Energize to Refrigeration Unit 11 July 04 (Month 18)
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 Refrigeration System & Bagged Material 11 July 04 (Month 18)

 Packing Bin, Bagging Unit, Palletizing Unit Ready to be 8July 04 (Month 18)
Loaded
 Sulphuric Acid Loading to the Tank & System 8 July 04 (Month 18)
Energized
 LP Condensate Flushing/Washing Introduced 20 July 04 (Month 18)
 Process Condensate Return Ready to be Operated 20 July 04 (Month 18)
 Urea Solution Ready to be Introduced 20 July 04 (Month 18)
 Mechanical Completion 3 Aug. 04 the end month 18

As planned above, MECHANICAL COMPLETION will be are end of month 18th. At this time
Utility & Offsite FACILITIES including PFK FACILITIES, Solid Raw Material Handling and
Storage, Product Handling and Storage, and NPK Main Process Plant including Urea
Evaporation FACILITIES will be ready to operate as per defined design specification.

COMMISSIONING activities will be started from the beginning month 19 th and will be
completed on the end of month 20th. To avoid floating time, preparation for
COMMISSIONING is scheduled to be started from beginning of month 18th.

Preparation work will be started from the time when process water introduced in to
Scrubbing Section and Final Washing Section. Then adjustment for any parameter will be
done as soon as possible after completion of water introducing. In parallel with water
introducing and adjustment, NPK granule will be loaded/introduced in to Granulation Loop,
totally around 40 ton and will circulate in Granulation Loop equipment. Water circulation
and air dust system will be operated while loading and circulation to avoid dust emission to
environment. During water and solid circulation operating, final check for actual interlock
system, start and shutdown sequence, emergency shutdown, and setting some parameters
will be done to ensure COMMISSIONING operation.

On beginning of month 19th, when preparation of COMMISSIONING has been completed,

START-UP of NPK Plant and Urea Evaporation FACILITIES for Formula-1 will be
commenced following START-UP Procedures under supervision of PROCESS
LICENSORS. During this START-UP, Solid and Liquid Material will be introduced, and
Product will be collected. Rectifying and stabilizing operation will be performed for 2 weeks.
Then Demonstration Test will be conducted for seven (7) consecutive days. Then at the
End of month 19th, PERFORMANCE TEST for Formula-1 will be conducted for three (3)
consecutive days.

After ACCEPTANCE of PERFORMANCE TEST of Formula-1 is achieved, following the

same sequence of Formula-1, NPK Plant and Urea Evaporation FACILITIES will be
operated from beginning 1st week of month 20th under supervision of PROCESS
LICENSOR then continue with DEMONSTRATION TEST and complete with
PERFORMANCE TEST for Formula-2at the end of month 20th.

INNITIAL ACCEPTANCE will be expected to be received from OWNER at the end of month
20th.
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4. RESOURCES PLAN

4.1 MANPOWER PLAN

Required skill manpower, suitable tools, proper equipment and any resources will be
provided by Subcontractors as it being included within subcontracting package scopes.
Based on Pre-commissioning Schedule, the anticipated pre-commissioning crews structure
will be as shown in below Table 4.1 Pre-commissioning Manpower Loading Plan of which its
number can be expanded particularly during peak period. This Table 4.1 of crew structure
are excluding CONTRACTOR’s engineers/supervisors.

Table 4.1 Pre-commissioning Manpower Loading Plan

AREA START CREWS PEAK CREWS

Solid Raw Material Area 2 Mechanical Crews 4 Mechanical Crews
1 Instrument Crew 2 Instrument Crew
1 Electrical Crew 2 Electrical Crew
1 Piping Crew
Utility and Offsite Area including PFK 5 Mechanical Crews 7 Mechanical Crews
3 Instrument Crew 4 Instrument Crew
2 Electrical Crew
4 Piping Crew 6 Piping Crew
Product Handling and Store Area 2 Mechanical Crews 5 Mechanical Crews
1 Instrument Crew 2 Instrument Crew
1 Electrical Crew 2 Electrical Crew
1 Piping Crew
NPK Main Process Area including Urea 6 Mechanical Crews 8 Mechanical Crews
Evaporation Section 3 Instrument Crew 4 Instrument Crew
2 Electrical Crew 3 Electrical Crew
5 Piping Crew 6 Piping Crew

CONTRACTOR will source requirement of experienced operators from NPK Plant Gresik,
Indonesia to execute Pre-commissioning activities and to train OWNER’s Operation and
Maintenance personnel. The duty of operators can be extended to cover COMMISSIONING
activities.

Provision of maintenance staff will be introduced during Pre-commissioning period, this will
be arranged by each related CONSTRUCTION Superintendent. The staff will rectify
problems, which appear during Pre-Commissioning.

Manpower for COMMISSIONING activities will be provided directly by CONTRACTOR and

managed by COMMISSIONING Manager. COMMISSIONING activities or operation activities
in all FACILITIES will be executed and supervised by Commissioning Engineers assisted by
experience/skill operators. As a part of job training program, OWNER’s Operators will be
maximum involved in commissioning work under leadership of CONTRACTOR. In order to
keep 24 hour plant operation, CONTRACTOR will arrange 3 (three) shift crew/operators
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including OWNER’s Operator team to assist CONTRACTOR’s COMMISSIONING work.

Each shift will be coordinated by Shift Supervisor.

CONTRACTOR will assign special experience operators from NPK Plant Gresik for
supervising the operation of Granulation Loop Equipment and Laboratory to ensure quality of
NPK granulation and will also serve as instructor/job trainers for OWNER’s Operators.
Manpower loading plan for COMMISSIONING activities will be as shown in Table 4.2 below.

Table 4.2 COMMISSIONING Manpower Loading Plan

Location will be Covered Person Note

Solid Raw Material Handling
Storage
Utility and Offsite Facilities
Product Handling and Storage
3 Plant Operators
3 Loader Operators
3 Plant Operators
1 Plant Operators
1 Bagging Operators
3 Forklift Operators
1 persons each shift,
1 person each shift
1 persons each shift,
1 persons each shift, s
1 person each shift
1 person each shift

NPK Main Process Area 3 Granulation Loop Oprs 1 persons each shift
including Urea Evaporation 3 Scrubbing Section and 1 persons each shift
Section Combustion Chamber Oprs
Laboratory 1 Laboratory Head
1 Laboratory Operators

During COMMISSIONING, CONTRACTOR also will involve maintenance team as provision

staff that will be coordinated by Maintenance Coordinator. The team will rectify any problems
appear during COMMISSIONING up to the FACILITIES INITIAL ACCEPTANCE. OWNER
maintenance personnel will be fully made to involve and join this team in order to have
maximum acquainted with each FACILITIES. Lead Operation will be having a close
coordination to this team in order to keep good/stable operation condition during
COMMISSIONING. Maintenance Coordinator will be assisted by experience supervisors and
crews, from mechanical, piping, instrument, electrical discipline. Each supervisor will be
supported with five (6) persons for mechanical, two (3) persons for electrical, three (3)
persons, three persons (6) for piping.

CONTRACTOR will also assign Safety, Health, and Environment (SHE) Coordinator to
manage and coordinate safety aspect to ensure Pre-commissioning and COMMISSIONING
activities are executed in a safe manner in accordance with PROJECT SHE requirements.
The SHE Coordinator will ensure to timely obtain all required special permits and approvals
from authorities prior to taken any activity within PFK Plan such as hot tapping, instrument
and electrical wiring, flushing and blowing. SHE Coordinator will be assisted by three (3)
SHE officers and three (3) SHE man. The Coordinator will join in daily Pre-commissioning
and COMMISSIONING meeting to know the highlighted time by time Pre-commissioning and
COMMISSIONING activities status. In order to comply with Government Regulations and
SHE Plan and Procedure, the coordinator will conduct, arrange, sign, and announce SHE
aspect to everybody involved in COMMISSIONING work under the coordination with
OWNER’s SHE Coordinator/Manager.
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During COMMISSIONING, CONTRACTOR’s field engineering team such as Process,

Piping, Mechanical, Instrument, Electrical, Civil, together with OWNER’s Engineering/
Maintenance personnel, will be involved to check the authenticity of design & construction as
per process requirements and arranging all kind of technical books and data required for
COMMISSIONING reference. The team will be coordinated by Field Engineer Manager who
has been activity in-charge since ENGINEERING Phase.

4.2. TOOLS AND EQUIPMENT PLAN

Based on Pre-commissioning procedures which have been reviewed by PROCESS

LICENSORS and have been APPROVED by OWNER, CONTRACTOR will provide sufficient
common/special tools and equipment. Common tools will be provided in three (3) sets and
will be stored in reachable area. Tools management will be very important for supporting of
Pre-commissioning and COMMISSIONING. Rough to say, sometimes very critical
COMMISSIONING activities can not be done because of silly tools missing. To ensure
quality of Pre-commissioning and COMMISSIONING work, CONTRACTOR will made
available with special tools such as vibro analyzer, instrument handheld, infra red frequency
meter, and other special tools supplied by related vendor equipment.

During COMMISSIONING, CONTRACTOR will arrange COMMISSIONING equipment that

needed to support the COMMISSIONING activities. Main COMMISSIONING equipment
among others are consist of, front-end loader, forklift, and dump truck. CONTRACTOR will
provide all the necessary assistance and coordination for the movement of the raw material
from unloading point/PFK to the destined FACILITIES.

4.3. OUTLINE OF PRECOMMISSIONING AND COMMISSIONING PROCEDURE

The following are the outlined basic structure of Pre-commissioning and commissioning
procedures and its detailed procedures will be provided by CONTRACTOR six (6) months
prior to commencement of activities.

4.3.1. PRECOMMISSIONING PROCEDURES & MANUALS

a) General Flushing & Blowing Procedure

The procedure covers general requirements for flushing and blowing out for piping as a
part of pre-commissioning stage. The main objective of the work is to clean the lines
and equipment and to remove foreign materials such as debris, grit, welding spatters,
which may enter into or remain inside the pipe and equipment during construction work.

b) Disinfecting Procedure

The procedure covers requirements for disinfecting work for sanitary water system.
This work shall be carried out to make the system sanitary clean and to certify it to be
ready for use and safe for mankind.
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c) Mechanical Test Run Procedure for Rotating Equipment

The procedure covers the mechanical running test for all rotating equipment, i.e.
pumps, fans/blowers, conveyors, screens, elevators, crushers, etc. The main objective
of this work is to make sure that the rotating equipment could operate smoothly
throughout its range and maximum vibration level corresponding with the shaft’s speed
when normal and maximum load test is conducted on the equipment after installation at
site.

d) General Operational Tightness Test Procedure

The procedure describes the operational tightness procedure for all equipment and
connecting line-work. During pressure test and flushing and blowing work, some
connections of lines and equipment are disconnected/dismantled and rotated for
installing temporary spools and some instrumentations and valves is removed for
safety reason. After completion of the pressure tests and flushing and blowing works,
all item of equipment and connecting line-work to be pressurized during operation shall
be tested to check the tightness of the system by using nitrogen, plant air, instrument
air, process air, CO2 or own fluid (service test)

4.3.2. COMMISSIONING PROCEDURES & MANUALS

a) Purging and Venting Procedure

The procedure covers the requirements for purging and venting work for natural gas
lines and ammonia lines system before introducing the fluid. The main objective of this
work is to purge the gas or water remains inside the pipe, which is possible to react or
cause a fire or other dangerous gases or compounds or other side effect, before the
fluid is introduced into piping lines and equipments. The work is carried out after
completion of restoration work.

b) Cooling Down Procedure for Ammonia Service

The procedure covers the requirements for cooling down of ammonia service lines.
This work shall be carried out to make sure the gas or water remains inside the pipe
that may cause or react to other dangerous gases or compounds or other side effect
already removed and to pressurize and cool down the lines with ammonia itself
gradually.

c) Water and Solid Running Procedure

The procedure describes the water and solid running test for each section of the
system in this plant. The plant consists of liquid circulation system and solid handling
system. The main objective of this work is to make sure each section of the system
could start and run separately and/or integrated before start up. All instrumentations
could be operated manually or automatically by Programmable Logic Control (PLC)
and Distributed Control System (DCS) from Central Control Room (CCR). The water
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run of liquid circulation system is carried out by using water and the solid run of solid
handling system by using the NPK product itself. Before water and solid running test all
interlocking systems and rotating equipments shall be already tested completely.

d) Start-up Procedure

This document describe start-up operation procedure for NPK Plant 310,000 MTPY in
NPK Fertilizer Project, including plant preparation and observation, for
PERFORMANCE Guarantee formula. There are 14 step operation for plant start up
operation that consist of 8 step for plant preparation operation and 6 step for plant start
up. Some specification, observing, and controlling work which are described, will be
followed.

4.4. RAW MATERIAL AND UTILITY SCHEDULE

The Pre-commissioning and COMMISSIONING material consumption schedule is estimated as

follows based on Formula 17-20-10 and 16-4-30 :

 Raw Material
o Phosphate Rock, approximately 9565 Tonne
o MOP, approximately 16447 Tonne
o Urea Granules approximately 3216 Tonne
o MAP/DAP 6334 Tonne
o Liquid Ammonia, approximately 634 Tonne
o Urea Solution, approximately 12977 Tonne
o Sulphuric Acid, approximately 1673 Tonne
o Liquid Coating Agent (LCA), approximately 238 Tonne
 Utilities
o Raw Water, approximately 77064 Tonne
o Steam, approximately 16410 Tonne
o Natural Gas, approximately 656 MSm3
o Diesel Fuel, approximately 25600 Lt
o Cooling Water, approximately 842400 Tonne (Circulation)
o LP Condensate Flushing, approximately 2246 Tonne
o Compressed Air, approximately 1044 MS/m3
o Nitrogen, approximately 31 Bottle
o Power, approximately 9389160 kWh
 Chemicals
o Cooling Water Dosing Chem., approximately 215 Lt (Liquid), 6 bottle (Cl)
o Disinfectant Chemicals, approximately 6 kg
 Consumables
o Oxygen, approximately 6 bottles
o Nitrogen, approximately 7 bottles
o Natural Gas, approximately 4 bottles (portable)
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Total consumption is calculated based on three (3) months of Pre-commissioning period and
two (2) months of COMMISSIONING period.

Detail consumption schedule for Utility, Raw Material, and Consumable during Pre-
commissioning and COMMISSIONING are described in Appendix-4

5. PROCESS LICENSOR AND VENDOR PARTICIPATION

During Pre-commissioning and COMMISSIONING, CONSTRUCTION/ COMMISSIONING

manager will arrange vendors serviceman/specialist such as IA/PA System, Refrigeration
System, Cooling Water System, Fire Fighting, HVAC System, Combustion Chamber, Weigh
Feeder and Weigher, Special Solid Material Handling Unit, DCS and Control System,
Electrical Power Systems, Laboratory Equipment and other Special Equipment or Unit, which
will be assisted by experienced operators. In coordination with CONTRACTOR’s
COMMISSIONING team and OWNER operation and maintenance personnel, the vendors
serviceman/specialist will carry out rectification of problems, which may occur during Pre-
Commissioning and COMMISSIONING up to the FACILITIES achieved INITIAL
ACCEPTANCE. Vendors recommendation, guidance and procedure will be followed by
CONTRACTOR.

In coordination with Training Manager, CONSTRUCTION/COMMISSIONING Team jointly

with Vendor servicemen/specialist will arrange training (class room or job training) for
OWNER’s operation and maintenance personnel in detail operation and maintenance
aspects.

PROCESS LICENSORS shall be fully involved right from Pre-commissioning work up to

INITIAL ACCEPTANCE in PFK Plant and Main Process of NPK Plant. Based on
CONTRACTOR experiences in NPK Plant Gresik and Urea K-4 Plant Kaltim, this step is very
useful in ensuring good COMMISSIONING work and eliminating any unpredictable problem
during COMMISSIONING. In Pre-commissioning period PROCESS LICENSORS shall
participate in both internal and external inspection for mechanical equipment, piping
configuration, chute and ducting actual lay-out, operational and maintenance access. The
LICENSOR shall prepare accommodation summary of their inspection activities and will
discuss/clarify item by item of defined recommendations. Based on conclusion of the
discussion/clarification, CONTRACTOR will follow the recommendation, and will identify
them as PROCESS LICENSORS Punch List Item. In COMMISSIONING period, PROCESS
LICENSOR shall supervise in NPK Plant manufacturing such as setting product formulation,
general guidance for NPK Plant and Urea Evaporation operation, evaluate time by time
operation condition, setting load of equipment, prior to PERFORMANCE TEST.

Classroom and job training by PROCESS LICENSORS shall be required to train OWNER’s
Operation and maintenance personnel by highlighting operation and maintenance aspects.
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6. COORDINATION TO PFK OPERATION TEAM

CONTRACTOR will arrange coordination for Tie-in Pre-commissioning and

COMMISSIONING Work in PFK Plant. CONTRACTOR will prepare the required detail
execution schedule, and Raw Materials & Utilities Consumption schedule which shall be
approved by OWNER and PFK prior to its implementation. Daily meeting will be conducted
regularly among CONTRACTOR-OWNER-PFK’s Operation Team to discuss and analyze a
more detail Pre-commissioning and COMMISSIONING activities during this period.
 APPENDIX-1

PRE-COMMISSIONING ORGANIZATION CHART

 APPENDIX-2

COMMISSIONING ORGANIZATION CHART

 APPENDIX-3

SEQUENCE CHART FOR GENERAL PRE-COMMISSIONING WORK

 APPENDIX-4

UTILITY AND RAW MATERIAL SCHEDULE

 APPENDIX-5

PRE-COMMISSIONING, COMMISSIONING ACTIVITIES & SCHEDULE