Pre Commissioning Commissioning Execution Plan

CONTRACTOR ID CODE
PRE COMMISSIONING & COMMISSIONING 080036-DZ-PQ-001

EXECUTION PLAN ACVC ID CODE
080036-DZ-PQ-001
ARABIAN CHLOR VINYL PROJECT AL-JUBAIL K.S.A Sheet 1 of 45 Issue 3
Pre-Commissioning &
Commissioning Execution Plan
EPC CONTRACTOR:
3 For Construction K.S.K Y.T.Y D.G.S C.W.Y 18-Jan-2012
2 For Construction K.S.K Y.T.Y D.G.S C.W.Y 05-Dec-2011
1 For Construction K.S.K Y.T.Y D.G.S C.W.Y 18-Nov-2011
0 For Construction K.S.K Y.T.Y D.G.S C.W.Y 30-Sep-2011
A For Approval K.S.K Y.T.Y D.G.S C.W.Y 03-Aug-2011
Issue DESCRIPTION PREP’D CHK’D APPR’D APPR’D Date
This Document is the property of ACV and is lent without consideration other than the Borrower’s agreement that it shall not reproduced, copied, lent, or dispos
ed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by pate
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Table of Contents
1. General ............................................................................................................................................ 6
1.1. Introduction ............................................................................................................................ 6
1.2. Objectives .............................................................................................................................. 6
1.3. Pre-commissioning & Commissioning activities ..................................................................... 6
1.4. Units of measurement/language ............................................................................................ 7
1.5. Standards and specifications ................................................................................................. 7
1.6. Key project documents .......................................................................................................... 8
2. Plant overview................................................................................................................................. 8
2.1. CA plant ................................................................................................................................. 9
2.2 EDC plant ............................................................................................................................. 13
2.3 Utilities ................................................................................................................................. 14
3 System definition .......................................................................................................................... 17
4 Organization. ................................................................................................................................. 17
4.1 Introduction .......................................................................................................................... 17
4.2 Preparation step (documentation step) ................................................................................ 18
4.3 Pre-commissioning step. ...................................................................................................... 20
4.4 Commissioning and start up step ........................................................................................ 21
5 Construction & pre-commissioning............................................................................................ 23
6 Mechanical completion ................................................................................................................ 25
7 Commissioning ............................................................................................................................. 26
7.1 Introduction .......................................................................................................................... 26
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7.2 Schedule .............................................................................................................................. 28
7.3 Work permit control .............................................................................................................. 28
7.4 Lock-out and tag-out ............................................................................................................ 28
7.5 Vendor commissioning activities .......................................................................................... 28
7.6 Spare parts, temporary equipment and consumables ......................................................... 29
7.7 Tightness test....................................................................................................................... 29
7.8 Drying out / inerting of lines and equipments ....................................................................... 31
7.9 System by system commissioning ....................................................................................... 32
7.10 Plant initial start up(electrolyzer energizing) ........................................................................ 36
8 Ready For Start Up (RFSU) .......................................................................................................... 38
9 Start up .......................................................................................................................................... 39
10 Testing ........................................................................................................................................... 39
10.1 Introduction .......................................................................................................................... 39
10.2 Number of tests .................................................................................................................... 39
10.3 Performance test.................................................................................................................. 40
10.4 Reliability Test ...................................................................................................................... 42
11 Hand-over ...................................................................................................................................... 43
12 Punch and Punch Control............................................................................................................ 43
13 Vendor’s training at site ............................................................................................................... 44
13.1 Vendor’s technology support. .............................................................................................. 44
13.2 Vendor’s training at site ....................................................................................................... 44
14 Communication............................................................................................................................. 44
14.1 Radio-communication .......................................................................................................... 44
14.2 Mobile phone ....................................................................................................................... 44
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15 Reporting ....................................................................................................................................... 44
16 HSE management ......................................................................................................................... 45
Attachments .......................................................................................................................................... 45
Attachment 1: Pre-commissioning / commissioning & start up schedule

Attachment 2: Pre-commissioning / commissioning process and activities
Attachment 3: Organisation for preparation phase
Attachment 4: Organisation for pre-commissioning phase
Attachment 5: Organisation for commissioning phase
Attachment 6: Completion process flow chart
Attachment 7: Start up flow chart
Attachment 8: EDC Plant Drying & Start-Up Plan
Attachment 9: List of Preparation Plan of Pre-commissioning &Commissioning Documents and Activities
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Revision Index
Rev Date Description
3 18-Jan-12 Revision as per SAMAPCO comments(TR-OH-DH-5406, dated on 09-Jan-12)
2 05-Dec-11 Revision as per SAMAPCO comments(TR-OH-DH-6088, dated on 04-Dec-11)
1 18-Nov-11 Revision as per SAMAPCO comments(TR-OH-DH-4884, dated on 27-Oct-11)
0 30-Sep-11 Revision as per SAMAPCO comments(TR-OH-DH-4531, dated on 12-Sep-11)
A 03-Aug-11 Issue for Approval
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1. General
1.1. Introduction
The Arabian Chlor Vinyl Plant in the Kingdom of Saudi Arabia, comprising a plant and associated
facilities at Jubail Industrial City including a caustic soda and ethylene dichloride plant and associated
infrastructure, along with utilities and off-sites, with the capacity to process 250,000 MTPA(100%con.
Basis) of caustic soda and 300,000 MTPA of ethylene dichloride.
This pre-commissioning and commissioning execution plan covers overall pre-commissioning and
commissioning execution works and provides basic information to SAMAPCO. It will be used as
guidance for the further development of the functional work.
This commissioning execution plan describes the organization, philosophy and plans for pre-
commissioning, commissioning, ready for initial start up (electrolyzer energizing), RFSU, start up,
testing, and handover. This plan is to be read together with other plans and procedures which are
written for the project.
This plan is a “live” document and will be subject to further periodic review by SAMAPCO and a
commissioning works to reflect project requirement changes or situations.
1.2. Objectives
The objectives of this project are to design, construct and commission the facilities and reach steady
state operation within the agreed project schedule and budget, and deliver CA/EDC facilities to
SAMAPCO that are mechanically complete and operationally proven within the project specifications.
Contractual target dates are;
Plant Initial Acceptance date : 02 Dec. 2012
Taking-Over date : 02 Jan. 2013
For this purpose, the commissioning organization will carry out the following activities.
1.3. Pre-commissioning & Commissioning activities
(1) Preparation of documentation - This includes management documents and procedures, check
lists and system definitions.
(2) Pre-commissioning of the facilities – before Mechanical Completion (MC), pre-commissioning will
be performed by each system as per approved procedures.
(3) Commissioning of the utility - Each utility will be commissioned and energized according to the
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approved commissioning procedures. Completion of commissioning and energizing of utilities

shall be done before MC date.
(4) Once utilities are energized and process systems have been dried and inerted with nitrogen,
commissioning team will carry out the following.
 Pre start up safety review (PSSR)
 Ready for initial start up and operation which allows energizing of the electrolyzer.
 Ready for start up, which means the design rate operation of the process systems in which
dynamic tuning of controllers is performed and system functions checks are completed.
 Start up – this phase includes initial operation and carrying out of the performance guarantee
test by Contractor to demonstrate the performance characteristics. The plant have been
achieved in accordance with the procedure outlined in contract, reliability operation test of the
plant and all its components are assessed and analyzed.
 Reliability test - this will follow after performance guarantee test.
(5) Once all basic functions of a sub-system have been functionally tested and all relevant pre-start
up activities for that sub-system are completed, the sub-system will be subject to an operational
test wherever applicable. This operational test brings the equipment into operation under
condition as close as possible to normal. The purpose of operational test is therefore to prove
that the major equipment is mechanically sound, and that each sub-system, as a whole, is ready
for normal operation. ESD tests will be performed. The operating test procedure will be developed
during commissioning preparation phase and submitted to SAMAPCO for approval.
(6) The Contractor will conduct performance testing in accordance with the contents of the contract.
The performance test procedures will be developed by the Contractor and submitted to
SAMAPCO for approval prior to conducting the tests.
(7) Repair and/or corrective measures, both planned, as per agreed project schedules, and
unplanned break down will be performed.
1.4. Units of measurement/language
Metric system shall be used as the unit of measurement and English language will be used on all
official project documents.
1.5. Standards and specifications
In general, the pre-commissioning and commissioning works will be carried out in accordance with;
 Arabian law
 Royal Commission Environmental Regulations (RCER-2004)
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 ASTM / ASME /API / TEMA (Tubular Exchanger Manufacturer's Association)

 AD-2000 Standard / EN/DIN Standard / UBC 1997 / SMACNA
 SAMAPCO project standards (SPCC-M-001-01, SPCC-G-006-02, SPCC-M-004/005/006,
SPCC-A-003/004/0056)
 International Electrotechnical Commission (IEC)
 SPCC-E-001/E-001-04
 National Fire Protection Association (NFPA)
 Contractor’s codes and working standards
1.6. Key project documents
Key project documents to be used in conjunction with this pre-commissioning and commissioning
execution plan are shown below.
 Contract
 Engineering procedure
 SAMAPCO Specification
 Construction execution plan
 Project quality plan
 Work permit approval system procedure
 Document/equipment numbering system
 Project HSE plan
 Construction HSE plan
 Coordination procedure
2. Plant overview
The Arabian Chlor Vinyl Project is to produce CA/EDC product in the Kingdom of Saudi Arabia,
comprising a plant and associated facilities at Jubail Industrial City including a caustic soda and
ethylene dichloride plant and associated infrastructure, along with utilities and offsite ,with capacity to
process 250,000 MTPA (100% con. basis) of caustic soda and 300,000 MTPA of ethylene dichloride.
The CA/EDC plant is designed to make chlorine and caustic soda from salt electrolysis process and
EDC by react chlorine with ethylene.
The plant consists of salt handling, brine treatment, electrolyzer, chlorine cooling, drying, compression,
EDC reaction, EDC purification, H2 boiler system, demineralized water system, product storage tank,
package items and others.
In addition to these facilities, equipment for electric power, cooling water system, process water,
instrument air, nitrogen storage and vaporization, sewage and waste water treatment, fire water supply
are also provided.
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2.1. CA plant
2.1.1. Salt storage and handling

Raw salt will be received at site by trucks. Salt will be unloaded into the salt unloading hoppers. Salt
from unloading hoppers will be transferred to salt storage through belt conveyor. Salt is fed to
saturation pit where salt is dissolved using lean brine having a concentration of app. 205 gpl.
2.1.2. Primary brine system

The CA Plant has a total cell-room production capacity of 768.8 MTPD NaOH 100% as 32% solution.
The primary brine system is designed to produce polished brine containing less than 0.5 ppm of
suspended solids.
For satisfactory operation of membrane cell electrolyzer, ultra pure brine is a must. The primary brine
system comprise of the following system: brine saturation, brine precipitation and Na2CO3 preparation,
brine clarification, brine filtration (anthracite media), brine polishing
2.1.3. Secondary brine purification

In order to warrant trouble-free operation of the membrane cells and a long service life of the
membranes, the cells must be supplied with extremely pure brine. The calcium and magnesium
content in the brine is not allow to exceed a maximum level, which is less than 20 ppb, as the
deposition of these ions in the membrane affects its function and leads to an increased power
consumption. Such low contents can be achieved in a proven technology by using ion exchange
columns.
The columns are filled with a cation exchange resin, with a very high selectivity for calcium,
magnesium and strontium cations. The ion exchange resin absorbs calcium and magnesium ions
present in the brine. Ion exchange nozzles ensure the resin remain in the columns.
2.1.4. Brine dechlorination

The considerable amount of chlorine remaining dissolved in the anolyte, which requires dechloination
unit before the lean brine can be recycled to the saturator. The dechlorination is carried out in two
process steps. The first step is a Cl2 desorption under vacuum. In the second step the remaining free
chlorine in the brine is chemically destroyed by means of sodium bisulphite(NaHSO3).
Bisulphite solution is added in slight excess to ensure that no Cl2 escapes.
2.1.5. Chlorate Decomposition

Electrochemical side reactions in the cell generate the chlorates. As the electrolyte recirculates, a
chlorate decomposition unit is required to prevent the accumulation of NaClO3. This unit forms mainly
chlorine from the chlorate and hydrochloric acid reaction.
2.1.6. Sulphate removal

Amount of sulphates in brine keeps on accumulating and if not reduced then exceeds the maximum
limit for the safe operation of the membrane plant. So part stream from the lean brine pump is sent to
lean brine cooler where lean brine entering cools down and lean brine leaving the Nano filtration unit
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gets heated from lean brine cooler.

Brine enters a series of filter for removal of suspended particles. First filter is activated carbon filter and
second one is lean brine filter. After filtration brine goes to the filter feed tank from where brine goes to
sulphate removal system. The reject stream from the unit is then sent to gypsum precipitation tank
where sulphate is converted into gypsum by addition of calcium chloride from CaCl2 tank. The gypsum
thus formed is transferred to gypsum filter by gypsum filter pump. The filtered gypsum is transferred to
B.L.
The permeate lean brine from the sulphate removal system and filtrate from gypsum unit is sent back
to brine saturators.
2.1.7. Cell room and electrolysis

The cell room is designed to produce 768.8 MTPD NaOH 100% as 32% solution and chlorine using 8
electrolyzers containing 171 bipolar cell elements each +21 spare each,.
The electrolyzers normally operate at a load of 16.32KA or 6kA/m2 to produce 768.8 MTPD NaOH
100% as 32% solution. The bipolar cells are capable of very fast load changes, which are only limited
by maintaining a stable chlorine and hydrogen pressure.
Pure brine having a concentration of 300-310gpl flows into the electrolyzer cells
Each electrolyzer cells have two chambers. The anode chamber and cathode chambers of the cell are
isolated from each other by the membrane. Cl2 is liberated at the anode surface and flow to the
anolyte header with depleted brine.
H2 is liberated at the cathode surface and flow to catholyte header with 32% NAOH
2.1.8. Chlorine treatment

In order to improve the heat balance of the electrolysis process, the energy of chlorine from
electrolyzers is recovered first against the brine system, then cooling water and finally chilled water.
Chlorine leaving the cells is about 88℃ and about 200mbar and is saturated with water vapor.
The chlorine gas is passed through chlorine recuperator(E12103) where it exchanges heat with
polished brine.
Chlorine is cooled down whereas polished brine is heated. Chlorine gas at about 65℃ then passes
through Chlorine cooler I(E12104) where it is cooled to 45℃ using cooling water.
The gas leaving cooler I is further cooled to 15℃ in chlorine cooler II (E12105) using chilled water.
Protection of membranes against too low chlorine pressure is achieved by under pressure safety
vessel (D12101), which is connected to chlorine waste air header.
The control valve relieving the excess chlorine pressure to waste gas dechlorination is located
between coolers I and II.
Temperature controller on the outlet of CL2 gas stream from chlorine cooler II controls the chilling
water flow to the cooler.
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The gas leaving the cooler II is then passed through the wet chlorine filter (F12101) to remove the
entrained brine aerosol.
Demineralized water is continuously added to the inlet stream to flush away any salt crystals that may
have deposited on the surface of the filter candles and may increase pressure drop.
Part of the stream emerging from wet chlorine filter is withdrawn and sent to HCL synthesis unit as per
requirement.
The moist chlorine gas coming from the wet chlorine filter is dried in chlorine drying tower by means of
98% sulphuric acid to meet final moisture content of about 10ppm wt%. The chlorine leaving the drying
tower flows to the chlorine compressor via a dry chlorine filter to remove entrained H2SO4 droplets.
2.1.9. Chlorine compression

Dry Cl2 gas from dry chlorine filter enters suction side of Cl2 compressor at around 1.02bar(a) and
15℃ and is compressed to about 5 bar(a) and 45℃ in a three stage chlorine compression unit.
After every compression stage, the compressed chlorine is cooled to prevent excessive outlet gas
temperature by chilled water. The compressed chlorine is transferred to EDC plant.
2.1.10. Waste gas dechlorination

The waste gas dechlorination unit serves as a safety system and removes chlorine and traces of HCl
from the waste gases drawn from various parts of the plant. All chlorine bearing waste streams from
the plant are led to the waste gas dechlorination system, where it is rendered free of chlorine in three
stages by absorbing the chlorine in caustic soda solution. The absorption leads to the formation of
sodium hypochlorite (NaOCl).
The first two stages are designed with an ejector each whereas the third stage consists of a final
absorber.
The bleaching lye produced by the waste gas unit is collected in the bleaching lye tanks.
It is then pumped to anolyte system by bleaching lye pumps.Here, NaOCL can be decomposed with
HCL to NaCL and Chlorine. Chlorine will be recovered back into the chlorine system.
2.1.11. Cell work shop

A cell work shop meets the requirements to assemble and dissemble the cell elements and for all
manipulations necessary in the cell room
2.1.12. Rectifier transformer system

Required amount of electricity at required voltage is supplied to the electrolyzers through transformer-
rectifier.
Each electrolyzer is connected to one rectifier. Two rectifiers are connected to one transformer.
Switches are provided for isolation of each electrolyzer.
Thus there are 8 rectifiers and 4 transformers.
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2.1.13 Polarization Rectifier

Each electrolyzer is supplied with a polarization rectifier, connected to the bus bars between switches.
The polarization rectifier feeds a small amount of current to the electrolyzer to prevent damage to
cathode coating in presence of chlorine.
Such situation arises especially in case of shutdown. A diode prevents reverse current flow into the
rectifier when the main rectifier is running.
2.1.14 Caustic concentration/ Storage tank

The caustic concentration unit is designed to handle 768.8 MTPD NaOH100% as 32% solution
production from electrolyzer.
32% caustic leaves the electrolyzer through an overflow pipe into the Catholyte Header along with
hydrogen.
Separation of H2 and Catholyte takes place in the Catholyte Header
The Catholyte (32% NaOH) flows under gravity at approx. 88°C to the Catholyte Tank and transferred
to the caustic concentration unit
32% caustic soda is concentrated to 50% in the caustic evaporation package unit by steam produced
in the H2 boiler system.
This unit is based on an optimization of investment and operation costs considering the following
aspects;
•Using heat recuperation of vapour, product and steam condensate to lower the steam consumtion.
•Capacity of quick capacity changes.
•Using special materials to increase corrosion resistance of those parts in contact with caustic soda.
The caustic soda at 50% by wt. of concentration is received from the concentration unit and stored in
the NaOH 50% day tank (TK13301 A/B) with a volume of 1100m3 each.
The tank is located within a dike, designed to hold the content of the tank.
Safety interlocks are provided to stop the feed into tank upon high liquid level and to stop transfer
pumps on low level signal.
From TK 13301A/B, 50% caustic is pumped to the NaOH bulk storage tank (TK35001) with a volume
of 19000m3.
2.1.15 Hydrogen treatment

The hydrogen cooling system is designed to handle a hydrogen load corresponding to 768 MTPD
caustic soda (100%) production from electrolyzer.
The system consists of the treatment section, where cooling and filtering of the gas is done, a
condensate collection system and the hydrogen stack. Hydrogen gas leaving the cells is at a pressure
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of about 220 mbarg and a temperature of about 88℃. The gas is saturated with water vapors at these
condition and is cooled to around 45℃ by cooling water in the hydrogen cooler, where most of water
vapor condenses. The cooled gas is passed through hydrogen filter to remove mist and NaOH
aerosols. Most of hydrogen gas feed to the boiler system as a fuel and a part of the gas to the HCl
synthesis unit as per requirement.
2.1.16 HCl synthesis and storage

This unit is designed for the production of 86MTPD of HCl 100% as 32% solution. The HCl synthesis
system consists of HCl synthesis unit with scrubber column and two HCl storage tanks with transfer
pumps.
2.1.17 Waste water treatment (neutralization)

Waste water from process buildings are collected in pits / sumps in various process areas and pumped
via pit pumps or routed via trenches to the waste water pits for chemical treatment.
The waste water unit is designed to treat process effluents from the plant and to send them after PH
adjustment and free chlorine removal to outside for disposal.
2.2 EDC plant
The process plant consists of 3 units.

 Direct chlorination unit,
 EDC purification,
 EDC drying and waste water stripping.
2.2.1 Direct chlorination
Chlorine reacts with ethylene directly to make ethylene dichloride.
The reaction is carried out in a recycle reactor which consists of the U-shaped reaction loop and the
EDC vapors drum which is installed on top of the reaction loop.
Reaction takes places in the upper part of the loop’s riser.
In this process the required chlorine is drawn into the reactor with the ejector J21001 which is operated
with a driving stream of circulation EDC. The ejector is designed in a way to ensure that the required
chlorine flow is brought into the system at partial load conditions that means with reduced driving
stream.
Ethylene is dissolved physically in EDC in the lower part of the riser section of the reaction loop
R21001. Even at partial load conditions the difference in density between the riser and the down
comer section of the reaction loop ensures a constant flow of the reaction medium.
2.2.2 EDC distillation

In order to achieve sales grade EDC quality, reduction of byproducts formed by side reactions in the
direct chlorination process is required. To remove these components, which mainly consist of high
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boiling compounds 1.1.2-trichloroethane or 1-bromo-2-chloro-ethane, EDC is purified with two

distillation columns:
 EDC column system
 Vacuum column system
2.2.3 EDC drying, waste water stripping and incineration

This unit serves the following three purposes:
 Drying of EDC (operation mode 1)
 Waste water stripping (operation mode 2)
 Disposal of process waste gas and waste liquid
Dry EDC is required for the initial filling of equipment like vessels, filters and columns of the EDC Plant
before start up of the plant. Additionally, dry EDC is required for removing moisture inside of the plant.
The second application for the stripper column T27001 is the removal of EDC from contaminated
surface water. This water is collected in several pits located inside the plant area
The waste water enters the waste water stripper, where EDC and other steam volatile organic
components are stripped off from water by heat input through reboiler.
The unit is operated only discontinuously. It can be brought into service whenever it is necessary.
Furthermore, the incineration package unit PK27001 is assigned. The incineration system is used for
the disposal of all continuous process waste gases and non-continuous waste gases (e. g. from
collecting drums system, equipment shutdown, maintenance) containing chlorinated hydrocarbons, as
well as liquid chlorinated waste by-products.
2.2.4 Flare
One low-pressure flare system is installed. The flare is the ignitable vent type. During normal operation,
small operational intermittent releases will be vented through the flare stack. During emergency
condition, the flare will self ignite to properly dispose any emergency releases.
2.2.5 Truck loading

The plant includes a truck loading facilities for send-out 50% NAOH, 32% HCL and 78% H2SO4.
Each loading bay is fitted with an articulated liquid loading arm.
2.3 Utilities
2.3.1 Steam & condensate system

Steam will be generated as MP steam at steam boiler package to match the overall demand of both
MP and LP steam users. A portion of the MP steam will be letdown and desuperheated to LP steam to
balance the LP steam system demand. LP steam is also produced from MP condensate and blow
down. All steam condensate recovered back and recycled.
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2.3.2 Cooling water system

The closed cooling water circuit provides cooling water to the various users in the CA/EDC plant and
associated utilities, and returns warm cooling water from the users to the cooling water exchanger
(E4302A~H) which is installed at the outside of the plant via a set of cooling water circulation pumps
in ISBL.
The warm cooling water is cooled through the exchanger by sea water that is cooed by the cooling
tower in the neighbor ALWAHA plant.
2.3.3 Chilled water system

The chilled water circuit provides chilled water to the various users in the CA/EDC plant, and is also
used to provide cooling to the safety shower water. Return water from users is chilled against
refrigerant from the refrigeration unit. The circuit comprises of chilled water supply and return headers,
chilled water supply (TK43501) and return tank (TK43502), circulation pumps (P43501A/B), water
chiller (E43501) and chemical dosing package (PK43501).
2.3.4 Drinking water system

Potable water from off-plot is treated to produce drinking quality water to supply drinking water
fountains, safety showers and eye wash stations. Water is continuously circulated from the safety
shower buffer tank (TK41201) through a drinking water treatment package (PK41101) around a ring
main and back into the tank.
2.3.5 Process water system

The process water distribution system will be supplied with potable water received from Royal
Commission (RC). The water is subsequently distributed to produce demineralised water and to
provide water for various process users and utility stations throughout the plant.
2.3.6 Demineralised water system

The demineralised water plant will be designed to produce water of a high enough quality, which is
distributed to deaerator for production of boiler feed water, the CA and EDC process units and
auxiliary plants.
2.3.7 Fire water system

The process water from OSBL will be used as firewater to fill the storage tank (TK49601). A looped
underground firewater distribution system shall be provided for all areas of the plant.
The plant will maintain a minimum quantity of fire water on site sufficiently to supply the maximum fire
water demand for a specified period according to the basis of design safety philosophy.
Above ground fire water piping is constructed of carbon steel. The fire water main ring is to be buried
in order to minimize risk of damage from collision or explosion. 3 fire water pump P-49602A/B/C (1
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electrical and 2 diesel) and 2 fire water jockey pump P-49601A/B were installed.
2.3.8 Boiler feed water system

To provide BFW to steam boiler (PK41801AB), incinerator (PK27001) and desuperheater (E41807),
BFW is prepared in deaerator (D14804) with demineralised water which is preheated by condensate.
2.3.9 Instrument air system

Compressed air is dried in desiccant dryer package (PK46002), to meet instrument air quality.
Instrument air from PK46002 is distributed to users via the instrument air receiver (D46004).
2.3.10 Plant air system

Compressed air (plant air) is generated by 2 air compressor units in the package (PK46001A/B), which
operates in a duty and a standby arrangement. Compressed air is distributed to users via air receiver
(D46002).
Emergency air receiver (D46005) is dedicated to provide plant air to the emergency caustic tank
(D12604) under upset conditions.
2.3.11 Nitrogen system

A supply of gaseous nitrogen (LP nitrogen) is available at the OSBL plant battery limit via a pipeline
from an external supplier. Nitrogen is supplied between 6.0 and 10.0 Bar from OSBL and is distributed
to various users across the CA/EDC plant and associated utilities. Pressure may be letdown locally
according to requirements of the individual users. If it is not available from external supplier,
emergency nitrogen can be supplied by the liquid nitrogen package unit (PK44002), composed of a
standard vertical storage drum, loaded from road tankers, associated with ambient air vaporizers.
2.3.12 Refrigeration system

The refrigerant is used to cool the overhead vapor stream from the EDC column in the EDC column
chiller in order to recover EDC, and to provide the cooling duty required by the chilled water system.
Refrigerant is also used in the EDC vent condenser, where liquid EDC is recovered from tank vents
and returned to storage. The remaining chilled vapor is routed to incineration system.
2.3.13 Fuel gas system

Fuel gas is supplied to the OSBL boundary from the neighboring PP plant via a fuel gas header. Fuel
gas is mainly required by the EDC incinerator located in the ISBL. It is used at start up and to meet
heat input requirements during normal operation. Fuel gas shall first pass through knock-out drum
(D41501) to remove any slugs of particles from the fuel gas supply. A cyclone separator (S41501) and
filters (F41501A/B) are provided for removal of fine particles from the fuel gas supply.
2.3.14 Electric power system
The Plant receives power from the PEA substation.

Battery limit is the bus bar connection to the existing Sahara 230kV GIS Bay.
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Supply system is incoming: 230 kV, 3 phases, 3wire, 60 Hz, and 63 kA for 1 second.
Two feeders from the existing Sahara 230kV GIS Bay feed power to the two (2)-230/34.5kV
transformers via underground cables.
The two transformers which shall have on-load tap changing capability will transform the 230kV
voltage to 34.5 kV to supply power to the double -ended, indoor, air insulated 34.5kV switchgear
located in the main substation
The 34.5 kV switchgear is to feed power to the two (2)-34.5/4.16kV transformers which will transform
the 34.5kV voltage to 4.16kV to supply power to all distribution transformers which will step down
voltage to the utilization levels of 4.16kv and 0.48kv.
The 34.5 kV switchgear is also to feed power to the four (4) -34.5kV/544.4V rectifier transformers
which will transform 34.5kV voltage to 544.4V voltage to supply power to the eight (8) rectifiers which
will convert AC voltage to DC voltage.
An emergency diesel generator is provided to start automatically and supply electric power to certain
critical equipment in the event of failure of the power supplies from PEA Substation. An uninterruptible
power supply (UPS) will be provided to safety critical systems.
3 System definition
Designation for separate system/sub-system shall be given in order to increase the accuracy and
expedition of the commissioning of each step and be marked up on P&ID.
The purpose of this designation is to define the systems that will be used for the Project. These
systems will be used as the basis to facilitate progressive completion of construction, pre-
commissioning, Mechanical Completion, commissioning and RFSU of the Contract Plant.
Designation for separate system/sub-system shall be completed by the commissioning team

(responsible for executing pre-commissioning and commissioning).
These system definitions will be detailed in a separate procedure.

 System definition (080036-MZ-SD-001)
4 Organization.
4.1 Introduction
The Contractor shall approach step by step with careful preparations by expert on each step because
this plant is a newly built CA, EDC plant which is composed of facilities which are extremely toxic and
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explosive.
The Contractor will select key personnel who have experience on commissioning and operation of CA,
EDC facilities with minimum five years and others who will assist the key personnel shall be trained by
the key personnel.
In addition, key personnel such as commissioning manager and discipline leaders shall participate in
the project from the preparation step, whereby the continuity of tasks shall be secured and each step
shall be transferred smoothly to next step.
During the pre-commissioning, commissioning, start up and testing of the plant, an integrated
commissioning team will be organized with SAMAPCO personnel if required. During commissioning,
SAMAPCO’s operators shall work under Contractor supervision, but maintenance staff will only
witness during Contractor’s worker do the job.
Punch control team shall be organized for the control of the punch. That team shall be managed under
site manager’s direction and supported by commissioning team.
The timing of the joining of SAMAPCO’s personnel to the commissioning team will be based upon the
staffing plan and the organization chart which will be jointly developed by the SAMAPCO and the
Contractor.
The operation of the Plant up to achievement of Initial Acceptance as per Contract shall be carried out
by Contractor under his sole responsibility and at his expense.
After reliability test operation, systems shall be completed and turned over to SAMAPCO under project
manager’s direction.
For the execution of the project, the organization shall be divided into three steps. Commissioning will
be performed with suitable organization and manpower for each step.
 Preparation (documentation)
 Pre-commissioning
 Commissioning and start up
4.2 Preparation step (documentation step)
This phase where a series of preparatory jobs will be executed includes;

 Establishment of the commissioning team and set-up of master schedule with respect to the
overall process
 Employment and development of the organization for the commissioning project
 Self-training for the commissioning staff related to process design concept and equipment
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 Development of manuals and procedures for pre-commissioning, commissioning, start up,

performance test, initial operation.
 System definitions, including marked up drawings. All equipment, tags, cables etc. should be
allocated to a system or sub-system.
 Development of system work packs for both construction and commissioning activities.
 Development of specific discipline based on pre-commissioning check sheets.
Key personnel will be assigned with appropriate duties according to their specialties (operation,
maintenance and training). They will prepare the documentation of their own respective disciplines and
provide guidance to the development of relevant procedures and documentation requiring multi
discipline interface involvement. Most documentation will be prepared in home office Korea, but many
technical procedures will be completed at sites by on site team members.
The major duties of key personnel in the preparation step are as follows;
(1) Commissioning manager

 Manage the project pre-commissioning and commissioning
 Control the overall pre-commissioning and commissioning schedule of the project
 Preparation for pre-commissioning dossier and hand over
 Integrate commissioning schedule / activities into master schedule
(2) Commissioning coordinator

 Coordinate commissioning activities with the construction team and the SAMAPCO
 Coordinate commissioning schedule with the construction team
(3) Discipline engineer

 Develop the commissioning schedule
 Develop and manage all check sheets, procedures and manuals
 Develop the system definition list and marked-up drawings
 Develop the Vendor schedule
 Develop Vendor training schedule for operations and maintenance
 Prepare staff mobilization
 Perform general services for commissioning control
(4) Commissioning HSE engineer

 Establishes commissioning HSE management plan/permit to work system and prepare
relevant procedures/pre-start up audit check list.
 Ensures that all established plan and procedures are implemented in commissioning
activities
 Provides information and inputs as required into the SAMAPCO's report on protective
measures for operational safety
 Performs training to ensure that all relevant personnel, specifically commissioning personnel
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fully understand the commissioning plan and procedures
(5) Environmental specialist

 Produces and complies with an environmental monitoring and mitigation report
 Prepares and implements the environmental control procedures for site
 Monitors the implementation of mitigation measures during construction and commissioning
period
 Ensures that all environmental aspects and impacts are identified, mitigation measures are
determined properly.
 Manages environmental monitoring program
 Manages environmental compliance inspection
 Monitors the implementation of the plans for water quality protection, air quality
4.3 Pre-commissioning step.
The major duties of key personnel in the Pre-commissioning step are as follows.

 Manage the project pre-commissioning activities
 Control the pre-commissioning schedule
 Manage safety and direction of the team of specialist, Vendors and the related construction
work.
 Coordinate pre-commissioning activities with the construction team and SAMAPCO

 Coordinate pre-commissioning schedule with the construction team and SAMAPCO
(3) Discipline engineer

 Supply consumables necessary for pre-commissioning work.
 Develop the pre-commissioning schedule
 Maintain records of the pre-commissioning activities
(4) Operation supervisor

 Supervise pre-commissioning activities
 Supervise control room activities
 Arrange documentation related to pre-commissioning
(5) Commissioning supervisor

 Perform the pre-commissioning activities
 Support Vendor test runs
 Perform pre-commissioning check
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(6) QA/QC manager

 Plan, monitor and perform all field quality verification and inspection activities
 Prepare QA-QC records
 Supervise subContractors QA-QC program
 Monitor adherence of work to the drawings and specifications / material control procedures
 Manage the documents
 Reviews generated punch list
(7) Turnover coordinator

 Manage the punch
 Prepare turnover documents
4.4 Commissioning and start up step
The major duties of key personnel in the commissioning and start up steps are as follows.

 Manage the project commissioning and start up
 Control the commissioning schedule
 Manage safety and direction of the team of specialist, Vendors and the construction team
 Manage operation test and performance tests
 Manage the initial operation.
 Manage the acceptance test and reliable test operation.

 Coordinate commissioning activities with the construction team and the SAMAPCO
 Coordinate commissioning schedule with the construction team and the SAMAPCO
 Manage the training schedule.
 Coordinate and support vendor specialists' site works in link with each relevant
commissioning activities.
(3) Commissioning Engineer

 Supply consumables necessary for commissioning, operation test and performance tests
 Develop the commissioning, operation test and performance test schedules
 Input records of the commissioning, operation test and performance tests
 Coordinate on-the-job training
 Arrange documentation related to commissioning
(4) Operation supervisor

 Supervise commissioning and start up
 Supervise control room activities
 Perform the safe induction of hydrocarbons into the facilities to start up
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 Execute the operation test and performance test of equipment

 Responsible for operation test and performance test on each item of equipment and facilities
of each system and the plant.
(5) Commissioning supervisor

 Support Vendor test runs
 Perform commissioning and start up check
 Perform preventive inspection and maintenance of the plant
 Support the operation
 Input records of maintenance
 Support operation test and performance tests on each item of equipment and facilities
(6) QA-QC manager

 Plan, monitor, and perform all field quality verification and inspection activities
 Prepare QA-QC records
 Supervise subcontractor’s QA-QC program
 Monitor adherence of work to the drawings and specifications / material control procedures
 Manage the documents
(7) Turnover coordinator

 Manage the punch
 Prepare turnover documents
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5 Construction & pre-commissioning
Construction & pre-commissioning include all those activities, as indicated in the tables of general
requirements for quality checks, (3.0 division of responsibilities-project standard specification
No.SPCC-G-008-02), required to achieve the mechanical completion milestone.
Construction & pre-commissioning also include those activities required to execute the functional tests
and performance tests (as per Annex K, part 5 Para 21, of the Contract, related to utility package units,
where feasible), for the SAMAPCO to issue a test result statement in relation to the same.
At or near construction completion of each system/subsystem (including process and utilities

systems/subsystems), Daelim will submit official notice to the OWNER that the system/subsystem is
ready for punching. OWNER’s punch team(s), including all applicable disciplines, will punch each
system/subsystem, compile a master punch list, and establish the priority categories (A, B, C, etc) for
each punch item and submit the list to Daelim. Daelim will then begin closing out the punch items and
all “A” punch items must be closed out before pre-commissioning of the system/subsystem.
All Punch Items should be defined as three Categories (“A”, “B” and “C”) and it should be included in
Punch Control Procedure.
Within the context of this project, pre-commissioning for the process is the term used to encompass
the activities before mechanical completion.
In case of utilities, pre-commissioning is the term used to encompass the activities includes start up.
All categories “A” punch items shall be corrected and closed out before pre-commissioning of the
system/subsystem begins
At the end of construction following activities should be completed:

 Contract Plant or any section of the Contract Plant should be mechanically and structurally
completed in accordance with the Contract including all drawings specifications, and applicable
laws, codes and standards by Contractor.
Pre-commissioning activities include:
 The non-operating adjustments and cold alignment checks.

It means all checks, cleaning, drying, and testing of any portion of the Contract Plant which can
be implemented without introducing raw material and/or auxiliary fluids as well as permanently
energizing said parts. These activities verify the completeness of the installed equipment
/components.
 All activities associated with preparing or operating the utilities or part thereof with auxiliary fluids,
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prior to initial start up (electrolyzer energizing).

During this phase, electrical equipment will be finally energized, and equipment / circuits will be
pressurized and tested to check as far as possible their performance. During this period all utilities
shall be ready with quantities and qualities. All plant safety system shall be in service.
Main activities of pre-commissioning are as follows and marked up in the subsequent tables.
For process;
 Pipe line flushing and blowing
 Reinstatement
 Cold alignment(final alignment and coupling of rotating equipment)
For utility;
 All plant safety system , fire water and protection system etc, shall be in service
 Pipe line flushing and blowing
 Reinstatement
 Cold alignment(final alignment and coupling of rotating equipment)
 Tightness test
 Testing and check-out of fire and gas detection facilities
 Function testing of control systems (instruments and electrical)
 Energizing and testing of switchboard
 Installation of temporary strainers and permanent gaskets after reinstatement
 Loading of packed bed.
 Dry-out and inerting
 Start up and operation before Mechanical Completion
(N2, process water, drinking water, instrument air, plant air CTW, boiler, demineralized water,
fire water, refrigerator, chiller, fuel gas, etc.)
Detailed descriptions of each pre-commissioning activity will be prepared separately for each
operational system.
Necessary documentation
Effective pre-commissioning requires a variety of technical documentation, which must be up-to-date

and available for the commissioning group, before pre-commissioning activities commencement.
The following list is indicative of what is required.

 Process flow diagrams (PFD)
 Piping and instrument diagrams (P&ID)
 System dry-out and inerting procedures
 Vendor installation, operating and maintenance manuals
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 Instrument function testing procedures

 Equipment list
 Electrical distribution drawings
 Functional logic diagrams
 Trip and alarm summary
 Detailed equipment manufacturers drawings
 Detailed vessel internals drawings
 Lubrication list and schedule
 Material safety data sheets
 Instrument tag list and piping list
• Tightness test procedure
6 Mechanical completion
Mechanical completion occurs when the Contract Plant or any section of the Contract Plant has
finished:
 All activities listed in SPCC-G-008-2-quality checks required to achieve the MC milestone.
 General requirements for quality checks during pre-commissioning (including functional tests)
and Mechanical Completion.
 All deficiencies that could prevent safe and orderly commissioning activities and determinable
without the use of feedstock have been corrected by Contractor.
It is recognized that minor painting, insulation (not affecting plant safety and operations) as part of the
project scope must be finished by Contractor until the issuance of a taking over certificate under the
Contract.
It is also possible that sections of the total Contract Plant can be mechanically complete before the
entire Contract Pant is declared mechanically complete.
Certificate of Mechanical Completion (MC)
Certificate of Mechanical Completion will be issued by SAMAPCO for each system or sub-system once
the following activities have been completed;
 Constructed in accordance with project design drawings
 Mechanical Completion activities have been completed.
 All necessary check sheet, documents and drawings are duly filled and signed by Contractor and
SAMAPCO.
 All safety devices such as pressure safety valves (PSV) are tested, witnessed and certified by the
representative of the Contractor and SAMAPCO.
 System is punch listed and confirmed complete (punch “A”).
• Completely documented and inputted into commissioning management system by the
construction group or administrator
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At the end of the Mechanical Completion the Contractor shall submit a request to SAMAPCO for an
issue of certificate.
Along with it the Contractor will enclose all system definition, tag list, mark-up P&ID, calibration
documents, check sheets, cleaning /flushing documents and test results documents (such as
hydrostatic testing and pneumatic testing documents) duly filed and signed.
Also a master blind and record of set pressure of all PSV's should be provided.
These documents shall be completed by the Contractor system wise and a copy of the same shall be
submitted to SAMAPCO.
Once satisfied that Mechanical Completion is successfully completed, the SAMAPCO shall issue a test
result statement in accordance with the Contract.
If Mechanical Completion is not successfully completed, The SAMAPCO shall notify Contractor of any
deficiencies.
In the event of such deficiency Contractor shall promptly rectify the deficiency and the provisions of
sub-clause 9.3A of the Contract shall apply.
Minor works mutually agreed between the parties and listed on the punch lists, which will not hinder
the start of commissioning activities, will not prevent the release of the Mechanical Completion
Certificate.
At plant Mechanical Completion, Contractor shall hand over as-built documentation for the Contract
Plant as described in Contract appendix 215, in section C part 2.
7 Commissioning
7.1 Introduction
Commissioning encompasses all the required checks, tests and proving of a system that can be
implemented for the introduction of process fluids or the permanent energizing or pressurizing of a
system.
Within the context of this project, commissioning is the term used to encompass the activities from
Mechanical Completion to ready for start up (RFSU).
Detailed descriptions of commissioning activity will be prepared separately for each operational system.
The commissioning team is responsible for all aspects of pre-commissioning and, therefore, for
preparing the plant systems and / or sub-systems for commissioning.
Commissioning team will also direct the sub- Contractors (mechanical, electrical and instrument) and
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Vendor representatives involved in their activities required during the commissioning phase.
Prior to commence commissioning, the commissioning team, especially turnover coordinator, will
ensure that the relevant QC checks have been carried out by the construction group sufficiently to
enable commissioning to commence.
To enable this process works effectively there are specific documents and checks required to be
confirmed which will include documentation such as Mechanical Completion check sheet, QC check
sheet, discipline acceptance certificate, relevant site queries, relevant engineering queries and agreed
outstanding punch list.
Commissioning will follow the approved commissioning procedures together with the completion of the
relevant commissioning check sheets and recording sheets.
Commissioning will commence by system as follows

 Issuance of Mechanical Completion certificate.
 All fuels, lubricants, chemicals, preservatives, and any other consumables necessary for the
operation of the entire system have been installed.
 Completion of any punch “A” raised in MC stage.
 All necessary documentation and permits in place
“Commissioning” means all activities associated with :

Preparing the Contract Plant to receive salt and 32 % NaOH for chlor-alkali plant and
hydrocarbon for EDC plant such as:
 drying out of lines and equipment;
 tightness tests of lines and equipment at operating pressure;
 Steam out and/or purging of lines and equipment with nitrogen.
 Introduce process feed into the Contract Plant.
 Operating the Contract Plant or part thereof with raw material /hydrocarbons charge from
reduced up to design rate.
 During this phase all instrumentations shall be “tuned up “for proper functioning.
 The Commissioning phase terminates when the Contract Plant starts to operate at design
capacity producing products (i.e. as mentioned in technology documents) matching with process
specifications and the SAMAPCO issues a Test Result Statement to this effect in accordance
with sub-clause 9.3B of the Contract.
 At the end of commissioning phase the Contractor will notify the SAMAPCO that the Contract
Plant “is ready for start up”.
 During the commissioning phase the SAMAPCO will put at disposal of Contractor sufficient and
qualified personnel for section and/or Contract Plant operation and maintenance.
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7.2 Schedule
Both the pre-commissioning and commissioning schedules have been integrated into the overall
project schedule and attached in this plan.
The commissioning team shall keep commissioning progress according to the commissioning
schedule.
To minimize any loss in time, the commissioning team shall submit a detailed schedule to the
SAMAPCO for review.
If any modification of schedule and procedure is needed due to an unexpected impact, the
commissioning team shall discuss it with the SAMAPCO.
Level 1 overall project schedule and level 3 detailed pre-commissioning/commissioning schedules
have been developed. These schedules will be updated and submitted to reflect the actual progress of
pre-commissioning/commissioning activities.
7.3 Work permit control
As construction progresses the emphasis changes from completion by area to completion by system.
Construction will arrive at a state of completion which will commence permit activities.
At this point the system or area is barricaded and sign-posted to indicate the area is designated an
"operational" area and a strict entry control is exercised.
At this stage of project the system will be transferred to commissioning team with its responsibility for
the system. As such the work permit control comes into effect.
Work permit approval system procedure (080036-xx-xx-xxx) will be used during commissioning. This
system will be controlled by the HSE manager and commissioning team.
7.4 Lock-out and tag-out
Lock-out and tag-out procedure shall be used to de-energize or render inoperable any valves,
switches, equipment, and/or process for the purposes of pre-commissioning, commissioning, repair,
maintenance, or operation. The procedure also prevents the unplanned/unscheduled start up or
operation of de-energized machinery, equipment or processes.
Lock-out and tag-out procedure shall be submitted to SAMAPCO for approval. This Lock-out and tag-
out will be detailed in a separate procedure.
Lock-out and tag-out procedure (080036-xx-xx-xxx).
7.5 Vendor commissioning activities
Commissioning expertise will be required from a number of equipment Vendors. The commissioning
manager will coordinate with procurement group; the requirement, timing, and duration of various
Vendor representatives to the plant. These will include, but not necessarily limited to, representatives
for the following equipment.
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 Flare stack
 Electrolyzer
 Chlorine compressor package
 Demiwater package
 Sulfuric acid concentration package
 Sulphate removal system.
 HCl synthesis unit
 Boiler package unit
 Air compressor and dryer
 Nitrogen storage and vaporization unit
 Emergency power generation package.
 Brine polishing filter package
 Ion exchange package
 Anthracite filter package
 Fire water pump package
 Incinerator package.
 Gypsum filter
 Sludge filter
 Refrigeration compressor
 Hydrogen compressor
 Caustic concentration unit
 Others
　
Vendor representatives’ schedule (include Vendor training schedule for operations and maintenance)
shall be submitted to SAMAPCO for review.
7.6 Spare parts, temporary equipment and consumables
Each specialist, as part of his duties in the preparation phase, will confirm the quantities of
consumables required for the pre-commissioning, commissioning, start up, operation test,
performance test and testing of various facilities as well as the initial operation phase.
All spare parts, temporary equipment, measuring equipment and consumables list of oil, diesel,
propylene, chemicals, etc. including the first fill of the facilities, will be prepared before commencing
the pre-commissioning and commissioning.
SAMAPCO will review commissioning spare parts and confirm received spare parts.
7.7 Tightness test
After cleaning, the plant units may be subjected to leakage tests performed to detect and eliminate
leaks. For this purpose the units are pressurized to working pressure with a suitable agent. However,
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this leak test does neither replace the pressure test stipulated by the technical supervision authorities
nor the pressure test to be performed during erection.
A leak test shall be performed always after the system has been dismantled on hydrostatic pressure
test (e.g. removal of blinds, installation of safety valves or opening of machines for inspection) and is
part of the commissioning.
The leakage test can only be performed in a completely erected unit (with installed electrical
equipment and instrumentation).
Before putting into service the chlorine system should finally be tested in order to guarantee perfect
leak tightness.
The following general instruction should be followed:

 The unit to be tested is to be isolated from other units. However, for this purpose it is not sufficient
just to close the shutoff valves. The equipment is slightly pressurized to detect major leaks up to
max. Pressure of 0.5 bar g for gaseous media and normal operating pressure for liquid media.
 All flange connections (e.g. connections between pipes and equipment, instrumentation) are
covered with a suitable leak detection solution.
 In the first step the system to be checked is brought to a pressure of approx. 0.5 bar g by means of
nitrogen.
 Leakage can be detected by formation of bubbles in the leak detection solution (soap or special
spray) and must be eliminated.
 If the stuffing boxes of valves are leaky, care shall be taken to ensure that the valves may be
operated easily even after tightening the stuffing boxes.
 If no further leaks are detected, the unit remains pressurized over several hours. The pressure
drop is recorded taking into account possible temperature differences.
 Before bolts at the graphite equipment are tightened see the instructions of the manufacturer and
use a torque wrench.
 If liquid is used for leak testing, in the second step, the pressure is slowly increased up to the
operating pressure of the system to be checked and all connections are checked for leakage.
 When pressurising with gaseous agents leaks can be detected by application of a leak detection
solution
 During pressurising and depressurising it must be ensured that no damages occur to internals.
 The gas velocity must not exceed that of normal operation inside of packing materials.
 After completion of tests, no vacuum (e.g. heat exchanger) is allowed to occur.
Sufficient breathing has to be ensured.
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7.8 Drying out / inerting of lines and equipments
All process systems shall be dried in accordance with the project specification dew point. The activity
will be done by systems and by the individual equipment items. Dry-out will be done using dry air
supplied by 100% oil free air compressors and dryer packages.
All process systems shall be purged in accordance with the project specification. The activity will be
done by systems and by individual equipment items. Inerting will be done by using the project nitrogen
system or temporary nitrogen system to comprise a liquid nitrogen tank, nitrogen vaporizers and
heating equipment capable of producing gaseous nitrogen heated to the required temperature.
To assure proper dry-out and inerting, all ball, globe and gate valves shall be manipulated to
open/closed position several times to displace any free water. Butterfly valves shall be thoroughly
dried while being left in full open position.
All bypass line shall be dried and purged. To assure bypass line dried out,block valves in main line
should first be blocked or throttled to allow flows through the bypass line. When the bypasses are dried
and purged, the block valves in the main line should be opened wide.
Also all safety relief valve line, branch line and tubing for instrument shall be dried and purged. The
dry-out and inerting procedure will be carefully planned and sequenced so that a minimum amount of
air and nitrogen will be required to dry and inerting the overall piping and equipment effectively the
procedures, marked-up drawings and work schedules for dry-out and purge shall be subject to the
SAMAPCO’s approval.
Dry-out and purge/inerting works shall be performed prior to introduction of the hydrocarbon product,
and the dried and purged condition should be maintained thereafter. Dry-out and inerting for pipelines,
equipment and facilities shall be executed by dry air and nitrogen gas until reaching the target dew
point and oxygen limit.
Once the facilities are dried out and purged, the facilities shall remain in a condition such that positive
pressure of nitrogen is supplied to inhibit the entrance of foreign matter into previously purged systems.
Pressures on these completed systems should be monitored on a regular schedule to assure that a
positive inert pressure is being maintained.
The chlorine system downstream of the drying tower must be thoroughly dried. To dry the system the
chlorine compressors are started alternately and input air/ nitrogen is sucked through the drying tower
and blown through the entire system purging the air out at the EDC plant.
Special care is to be taken that all dead spaces and dead pipe sections are likewise dried. If this
cannot be accomplished dry instrument air should be fed in.
If there is a risk of water having accumulated in dead spaces of valves, fittings and other items of
equipment of the dry chlorine section, the latter are to be opened, dismantled as far as necessary and
then dried. Dry compressed air or nitrogen should be used for drying larger equipment.
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In the EDC Plant all systems in contact with fluids containing traces of HCl have to be dried out before
the initial start up or after any shutdown in which there is a chance that the equipment has become wet,
all equipment must be thoroughly dried out because the simultaneous presence of water and HCl will
cause rapid corrosion.
The water content in the system has to be lowered to a value < 20 ppm wt. to avoid any corrosion.
 The first step in drying out the equipment is to drain all equipment and lines at the lowest point and
blow out all the vessels and lines with plant air to eliminate pools of water.
 The second step is to replace possible air in the system by nitrogen and the oxygen content has to
be checked.
 The oxygen content must be below 0.5 % by vol. before EDC can be introduced.
For drying EDC resistant hoses must be available.
7.9 System by system commissioning
7.9.1 Utility
The commissioning of the utility system shall be prioritized during the latter construction stages to
which they are required to be commissioned for their utilization in the Mechanical Completion and
commissioning of process facilities and dry-out and inerting of the piping.
The commissioning sequence of utility system is as follows;
(1) Energizing of electric power receiving and distribution systems

The power receiving system and distribution systems shall be energized and commissioned
before Mechanical Completion of the other systems.
(2) Air supply system

As soon as electric power is available, air compressors and drying facilities for instrument air shall
be promptly commissioned. Impurities in the pipeline for supplying instrument air will be removed,
dried and pressurized. In addition, temporary air compressors and air dryers for cleaning and
drying of the equipment and piping shall be prepared.
(3) Nitrogen supply system

As early as possible, nitrogen shall be brought in and commissioned in order to be used in drying
and inerting of process facilities. Besides, in view of the necessary nitrogen unavailable, for drying,
temporary nitrogen vaporizers and liquid nitrogen tanks shall be prepared.
(4) Water and seawater intake system

When power systems have been energized, utility systems such as utility pumps, effluent
treatment systems, seawater pumps and fire water pumps shall be commissioned.
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CONTRACTOR ID CODE
080036-DZ-PQ-001
(5) Potable and Service water

Potable and service water tanks shall be cleaned and filled with fresh water. After pumps are
commissioned, the distribution system of the pump outlet shall be cleaned.
(6) Seawater
Seawater intake and header shall be cleaned and filled with seawater. After seawater pumps
are commissioned, seawater filtration and chlorination systems are commissioned.
(7) Diesel oil supply system

Diesel oil for fire engine pump and emergency generator shall be brought in and diesel oil storage
tanks and related facilities shall be commissioned.
(8) Expected consumption schedule of utilities

A utilities and raw material consumption schedule for commissioning shall be prepared by the
Contractor and submitted for the SAMAPCO’s approval.
(9) Commissioning of boiler system

Steam blowing for the steam line is necessary in the pre commissioning activities. Brine and
process fluid is needed to heat up to meet pre start up condition.
So boiler system shall be commissioned prior to process system commissioning.
Fuel gas shall be supplied from near plant via pipe line for the commissioning and start up in
accordance with manufacturer’s recommendation.
(10) Demineralized water system commissioning
Demineralized water is used in the process for multi-purpose.

So demineralized water should be available before boiler commissioning.
Start up shall be carried out in accordance with Vendor’s instruction.
7.9.2 Process commissioning
(1) Brine system

 Complete brine circuit as mentioned below is running at 70℃-75℃
Saturator
Buffer vessel
Raw brine pump
Precipitation tanks
Clarifier/clarifier brine pump
Anthracite filters
Filtered brine tank
Filtered brine pump
Polishing filters
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CONTRACTOR ID CODE
080036-DZ-PQ-001
Polished brine pump

Chlorine recuperator
Ion exchanger
Pure brine
Brine heat exchanger
Head tank
Cell header bypass
Anolyte tank
Dechlorination
 All controllers will be working in auto mode.

 Anthracite filter sequence is streamlined.
 Exchanger is ready for operation; with ion exchange resin filled in and duly regenerated.
 Required laboratory analysis procedures for salt / brine are established along with the
laboratory equipment/instrument.
 Regular analysis is to be carried out at various sampling points.
 Start up with salt: start charging salt into the brine saturator whichever is in operation.
(2) Anolyte dechlorination and chlorate destruction.

Following prerequisites are to be ensured before start up of anolyte system and chlorate
destruction unit:
 Pure brine is available
 Temperature of pure brine is maintained at 70℃ - 75°C.
 NaCI concentration in pure brine is greater than 270 gpl.
 18% HCI is available.
 Sodium bisulphite (NaHSO3) is available
 18% caustic soda is available
 All controllers in auto mode.
(2) Chlorine cooling & drying

Prior to start up of the chlorine cooling section, following prerequisites must be fulfilled.
Following systems should be in operation:

 Cooling water circulation
 Chilled water circulation
 Demineralised water system
 Instrument air
 Waste gas dechlorination unit
 All controllers in 'auto' mode
 Process air sparging in 78% sulphuric acid day tank
 H2SO4 drying tower
 Dry chlorine compressor by N2
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CONTRACTOR ID CODE
080036-DZ-PQ-001
Following systems should be ready for operation:

 Rectifiers / electrolyzers
 Chlorine downstream system like HCI synthesis unit.
 Brine & catholyte cycle
(4) Caustic system (catholyte)

Following pre-requisites are to be ensured before start up of catholyte system.
 Instrument air, nitrogen, demineralized water and low pressure steam should be in operation
 Rectifier, electrolyzers should be ready for operation
 All controllers are in auto-mode
 Confirm the purity of demineralised water and caustic 32%.
(5) Hydrogen system

Prior to start up of the hydrogen cooling section, following prerequisites must be fulfilled:
 Demineralized water
 Cooling water
 Nitrogen and instrument air
 LP steam
 All controllers in "auto mode"
Following systems should be ready for operation

 Rectifier / Electrolyzer
 HCI synthesis unit
(6) Waste gas dechlorination

Following preparations are indispensable to ensure safe and trouble free start up of the unit.
 Filling of heat exchangers
 Chilled water side of the heat exchangers must be filled with chilled water. Take care that
exchanger is vented via vent valve.
 Filling of suction tank and final absorber sumps and caustic safety tank, and emergency
caustic tank with 18%NaOH.
Prior to start the waste gas dechlorination system, following systems must be operating:
 Chilled water cycle/chilled water unit
 Instrument and plant air.
 NaOH dilution system and inventory of 18% NaOH in 18% caustic safety tank.
(7) Incinerator
Incinerator should be in operation prior to introduction of EDC to EDC process system.
7.9.3 Fire fighting systems commissioning
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CONTRACTOR ID CODE
080036-DZ-PQ-001
Fire fighting systems shall be proven and operational prior to introduction of fuel gas or H.C. The fire
water system shall be flushed and all pumps, hydrants, monitors and sprinkler facilities shall be
commissioned and certified by the authorities.
Also, fire detection systems shall have been tested to satisfy local code requirements.
7.9.4 Commissioning of flare stack

The flare system directs the fuel gas and process H.C to the flare stack for safe disposal. The excess
gas is ignited by the flare pilots and burned at a safe distance from the plant. So, the flare stack shall
be commissioned prior to the introduction of fuel gas or H.C.
Ignition of the flare stack pilot shall be carried out and operated before the plant start up.
7.9.5 ESD test

The Contractor shall test all of the control function tests and emergency shutdown (ESD) system. The
tank high level alarms and emergency shutdown (ESD) systems will be tested during pre-
commissioning, commissioning or operation with caustic and EDC in the system.
The high level alarm of each tank shall be tested during the actual operation.
ESD shutdown for the port system shall be initiated during send out operation to ensure that this
system is shutdown safely and in proper sequence.
7.10 Plant initial start up(electrolyzer energizing)
7.10.1 Pre start up safety review (PSSR)

As a condition of achieving initial start up(electrolyzer energizing) and prior to the introduction of any
H.C into the plant, the Contractor and the SAMAPCO shall jointly conduct a pre start up safety review
(PSSR) to ensure system / plant is ready for the safe introduction of chlorine and/or hydrocarbons and
everyone involved in the start up of the plant is trained to understand the entire plant design,
operational procedures, HSE requirements and compliance, emergency response procedures, team
roles and responsibilities during start up of plant.
PSSR shall be done for overall systems related to introduction of hydrocarbon and energizing of
electrolyzer.
The plant is ready for initial start up (electrolyzer energizing) provided that all of the following
conditions have been met and checked:
 Development of all procedures plans, schedules, arrangement of personnel are made and these
have been approved.
 All Mechanical Completion activities have been completed including all relevant testing.
 All commissioning activities defined in the commissioning procedures have been completed.
 All punch list items have been completed to satisfaction; with the exception of agreed items.
 Construction equipment and scaffolding removed, the plot cleared of all surplus materials and
properly cleaned.
 Temporary connections have been removed as appropriate.
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CONTRACTOR ID CODE
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 Safety inspection carried out with satisfactory result

 Buildings, equipment and/or furniture have been installed and the buildings are ready for
occupation.
 Ancillary systems ready for connection to a live system where appropriate.
 Utility systems are in operation.
 All safety valves (pressure safety valves, thermal safety valves, vacuum breakers) shall have
been checked out, be operational and be in service prior to starting the start up activity.
 All construction, Mechanical Completion and commissioning dossiers have been accepted.
 Fire fighting system and fire detection system has been completely commissioned and operated.
7.10.2 Notification of initial start up(electrolyzer energizing)

When the plant has fully commissioned all systems (completion of operational testing for all
equipment) and the entire plant such that the process system is ready for electrolyzer energizing, the
Contractor shall notify to the SAMAPCO for the initial start up (electrolyzer energizing).
Notifying : (a) the plant has achieved ready for initial start up (electrolyzer energizing), (b) all priority
“A” and “B” punch items related to the plant have been completed or corrected, and (c) the plant has
satisfied all requirements for achievement of ready for initial start up (electrolyzer energizing).
Contractor shall include any additional documentation requested by SAMAPCO or necessary to

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

SAMAPCO shall review all documents of ready for initial start up (electrolyzer energizing) submitted by
Contractor.
If the SAMAPCO does not agree that the plant has achieved ready for initial start up (electrolyzer
energizing), SAMAPCO shall notify the Contractor of the reasons that the plant has not achieved ready
for initial start up (electrolyzer energizing), and Contractor shall remedy, complete or correct the
relevant works as necessary to achieve ready for initial start up (electrolyzer energizing) and re-notify
the ready for initial start up (electrolyzer energizing) to SAMAPCO.
If SAMAPCO agrees that the plant has achieved ready for initial start up(electrolyzer energizing),
either initially or upon resubmission by Contractor, then the SAMAPCO shall accept the ready for initial
start up(electrolyzer energizing).
7.10.4 Initial start up (electrolyzer energizing)

Once SAMAPCO accept the ready for initial start up, the Contract Plant is ready for electrolyzer
energizing.
Initial start up (electrolyzer energizing) shall be carried out by Contractor according to the
commissioning procedure with assistance from appropriate Vendor representatives as required.
Technology provider's specialists shall attend at Contract Plant start up as well.
The Contractor shall develop procedures for the start up of the plant which will be provided to the
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CONTRACTOR ID CODE
080036-DZ-PQ-001
SAMAPCO for review and approval.
Initial start up (electrolyzer energizing) activities include

 All testing activities, including the running tests of the each equipment.
 Electrolyzer energizing
 Introduce process feed such as brine for CA plant and chlorine/ethylene for EDC plant.
 Operating the plant or part thereof with hydrocarbon charge from reduced up to design rate.
 All instrument tuned up for proper functioning.
During initial start up (electrolyzer energizing), the operation, maintenance, safety and security of the
plant will remain under the full responsibility of Contractor.
Clearance of certain punch list Items may be achieved during Initial start up (electrolyzer energizing),
subject to the agreement of the SAMAPCO.
The commissioning manager is responsible for establishing the project organization and job
assignment in accordance with commissioning procedure.
During this phase it will acquire any permission required for operation of plant prior to the hydrocarbon
introduction to the system and electrolyzer energizing.
7.10.5 Operating test

Operating test shall be conducted within a period of system commissioning to figure out the features
and capacity. Operating test shall be carried out in accordance with commissioning procedure and
acceptance criteria. The Contractor shall maintain the best condition for the test..
7.10.6 Tuning and stabilization of process

Tuning shall be executed between the completion of load test and the beginning of preliminary
demonstration for performance test. To achieve tuning conditions, operation mode must be set at 'auto
mode' and pressure or flow rate should not be changed. In particular, equipment which may cause
hunting or trip must be stopped before tuning. When all works are completed, all set values should be
restored to their initial status. In addition, all features and details of tunings should be sent to operators
with a printed report produced during tuning. In this step, equipment shall be operated in an automatic
mode. When load changes, equipment has to be stabilized for a required period of time which shall be
recorded. If load tests are completed, operators shall implement tuning. All test data must be recorded
and compiled.
8 Ready For Start Up (RFSU)
Ready For Start Up of any section and /or Contract Plant is the event that occurs when all
commissioning activities have been successfully performed by Contractor to allow commencement of
the production operation and assessed /certified by SAMAPCO.
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CONTRACTOR ID CODE
080036-DZ-PQ-001
The plant is fed with process feed to design rate and products, complying with the project specification,
are sent to storage.
At the end of the commissioning phase the Contractor will notify the SAMAPCO that the plant is ready
for start- up (RSFU).
Immediately after establishing that any section and/or the Contract Plant is ready for start up,
SAMAPCO will issue the test result statement to Contractor.
A test result statement stating that commissioning has been successfully completed and RFSU has
been achieved is signed by SAMAPCO and submitted to the Contractor in accordance with sub-clause
9.3B of the Contract.
9 Start up
After RFSU, the start up phase includes initial operation and carrying out of the performance test by
Contractor to demonstrate the performance characteristics of the plant have been achieved in
accordance with the procedures outlined in Annex-K.
Start up is deemed to have been completed on the calendar day on which 100% of daily production is
achieved in the Contract Plant, all performance tests have been successfully completed, and the
SAMAPCO has issued a test result statement in accordance with sub-clause 9.3C of the Contract.
This means Initial acceptance date is hit.
10 Testing
10.1 Introduction
The Contract Plant shall be tested in accordance with the standards adopted for the works as
established in the approved specifications and testing procedures. No later than [three (3)] months
prior to the Mechanical Completion date, the Contractor shall submit a testing protocol (an inspection
and testing procedure) for the plant for review and written approval by the SAMAPCO.
For situations where physical tests are not possible at the time of performance test, a proposed
methodology to demonstrate the performance guarantees shall be proposed in such testing protocol.
10.2 Number of tests
The Contractor may perform any number of tests simultaneously provided that test conditions and
safety requirements of each test are satisfied and observed by both the SAMAPCO and the Contractor.
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CONTRACTOR ID CODE
080036-DZ-PQ-001
10.3 Performance test
10.3.1 General
(1) The performance Guarantees shall be proven in a Performance Test run of seventy-two (72)
hours to be performed by the Contractor under SAMAPCO’s supervision and the Technology
Provider’s assistance, consecutively and without interruption, producing the guaranteed
quality of the products at the rated capacity with the consumption figures as detailed in the Annex
K of the Early Works Agreement
(2) The result of each Performance Test shall be recorded in a protocol and signed by both parties
immediately after the Performance Test.
10.3.2 Interruptions
(1) If there is an interruption during the Performance Test which is equal to or less than six (6)
hours, the duration of the Performance Test shall be extended by the actual duration of the
interruption period and the calculation of the result of the Performance Test shall be made on the
basis of the seventy-two (72) hours period during which the conditions of operation have been
normal .
(2) If the period of the interruption during the Performance Tests lasts more than six (6) hours
and the CA Plant and/or EDC plant (as the case may be) has been operating for less than forty
eight (48) hours, the Performance Test shall be repeated by the Contractor
10.3.3 Failure to achieve Performance Guarantees

In the event any Performance Guarantees cannot be reached during the Performance Test, the terms
of Sub-Clause 9.3C [Result of Performance Tests and Retesting] and Sub-Clause 9.4 [Failure of
Performance Tests or Reliability Test] of the Contract shall be applied.
10.3.4 Preparation for the performance guarantee test run

(1) Pre-test activities
After the start up of the overall units, the Contractor shall carry out the necessary fine tuning and
calibrations. All facilities to be tested shall be in steady operation mode for 3 days before the
performance guarantee test run commences.
(2) Feed stock definition

The SAMAPCO shall furnish salt at the quality defined in the Contract and in quantity sufficient to
enable the required test flow rates to be met during the performance guarantee test run period.
Contractor shall submit notice test date before 90 days prior to test as minimum. In the event that
the actual feed stock quality, as determined from laboratory analysis, differs substantially from the
design feed stock, then the Contractor shall request the SAMAPCO to review the situation before
commencing performance guarantee test run.
(3) Utilities
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CONTRACTOR ID CODE
080036-DZ-PQ-001
All required utilities shall have been made available, as required for the performance guarantee
test run period. Contractor will be responsible for ensuring the required volume and quality except
if utilities have already been handed over to SAMAPCO. These utilities including fire water,
nitrogen, instrument air, plant air, drinking water, process water, fuel gas, electric power,
demin.water, chilled water, steam, etc.
(4) Chemicals
The Contractor shall make available all the chemicals required for the performance guarantee test
period except if facilities have already been handed over to SAMAPCO.
(5) Laboratory services

Sufficient staff and sampling equipment shall be made available by SAMAPCO throughout the
performance guarantee test run for the handling and rapid analysis of gas/ liquid samples as
required during the tests.
Suitable sample bombs shall be provided by SAMAPCO.
Auxiliaries shall be designed and supported by Contractor.
Calibration and verification of laboratory equipment to be used in sample analysis will be

performed jointly between SAMAPCO and Contractor prior to start up of the performance
guarantee test run.
Analysis will be performed in the new laboratory building.
The analysis should be signed off by SAMAPCO laboratory staff and included in the performance
guarantee test run report.
10.3.5 Performance guarantee test run organization

An integrated performance guarantee test team will be formed with SAMAPCO personnel and the
Contractor/ other parties such as UHDE etc.
Contractor shall be responsible for acting as a leader of the integrated test team so as to perform the
test operation.
The SAMAPCO will supervise the performance test until successfully completed.
The commissioning team must liaise closely with the SAMAPCO to ensure that mutual objectives are
met.
10.3.6 Performance guarantee test run procedure and schedule

The performance tests procedures and schedule shall be developed by the Contractor and submitted
to the SAMAPCO for approval prior to conducting the performance tests.
10.3.7 Measuring and sampling method of data

All instruments that will be used for demonstration of the performance of the Contract Plant will be
checked prior to start the performance guarantee test run period.
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CONTRACTOR ID CODE
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Data during the testing period will be recorded at two hour intervals using the plant data historian or
can be manually recorded in log sheet prepared by Contractor.
DCS trend log will be provided specifically to record the performance guarantee test data.
These log sheets will be retrieved from the system with SAMAPCO representative.
10.3.8 Data conversion

Gas and liquid flow readings from flow meters during the performance test shall be corrected for
temperature, pressure, and molecular weight wherever necessary. And general correction equation
and method shall be described on performance test procedure.
10.3.9 Performance guarantee test run report

After the successful completion of the performance guarantee test run, Contractor will prepare the
performance guarantee test run report with all results and conclusions, which demonstrate that the
performance guarantee has been fulfilled.
Contractor will submit this report to SAMAPCO for approval. SAMAPCO shall communicate to the
Contractor, within seven (7) days after the receipt of the report, its acceptance or its rejection and in
the latter case SAMAPCO shall state its reasons in writing.
In the event that the installations do not perform or fail to operate in accordance with the Contract,
Contractor shall carry out appropriate remedial design and construction work and provide the
necessary replacement materials in accordance with the Contract. Upon completion of such remedial
works the performance guarantee test run will be repeated.
10.4 Reliability Test
10.4.1 Tests
The Reliability Guarantees specified in paragraphs 20.2 and 20.3 of the Annex K shall be proven in a
Reliability Test run of [thirty (30) days] to be performed by the Contractor consecutively without
interruption.
The result of Reliability Test shall be recorded in a protocol to be agreed between the Parties and
signed both Parties immediately after the Reliability Test.
10.4.2 Reliability Guarantees for CA Plant

The reliability guarantees shall be as follows;
(a) [95]% of the Performance Guarantees set out in paragraph 3.1; and
(b) the Minimum Performance Standards set out in paragraph 9.1.of the Contract
10.4.3 Reliability Guarantees for EDC Plant

The reliability guarantees shall be as follows
(a) [95]% of the Performance Guarantees set out in paragraph 15.1; and
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CONTRACTOR ID CODE
080036-DZ-PQ-001
(b) the Minimum Performance Standards set out in paragraph 18.1.of the Contract
10.4.4 Reliability Performance LDs

In the event that the CA Plant and/or the EDC Plant (as the case may be) fail to meet any of the
Reliability Guarantee during the Reliability Test, then ANNEX K, paragraph 20.4 of the Contract shall
be applied..
11 Hand-over
Following satisfactory completion of the initial operation and performance tests, SAMAPCO shall agree
to a formal hand-over of the facilities. The commissioning team shall compile a systematic hand-over
package, which will include SAMAPCO approved reports demonstrating successful completion,
commissioning, and acceptance of the performance and reliability tests.
Hand-over is the formal transfer of the asset to SAMAPCO.

This hand-over will be detailed in a separate procedure.
Hand-over procedure (080036-xx-xx-xxx)
12 Punch and Punch Control
Punch-out of each of the systems/subsystems by SAMAPCO or in conjunction with SAMAPCO is

critical.
It should be made clear in the plan and schedule when SAMAPCO perform this critical operation.
SAMAPCO shall have final decision concerning punch item categories (A, B, etc) and shall have final
decision as to whether or not the punch item has been corrected and closed out.
A formal “punch-out” of each system and associated sub-system will be performed by the Contractor.
Owner will also perform an independent punch-out as described in sect 5, paragraph 3.
All defective or incomplete items will be recorded on a punch list for the respective discipline system
and associated sub-systems. Where applicable, the equipment tag number and associated drawings
will be used as the prime means of identifying the defect or incompletion. Punch list items will be
registered and tracked electronically by means of an electronic certification management system or
database.
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CONTRACTOR ID CODE
080036-DZ-PQ-001
13 Vendor’s training at site
13.1 Vendor’s technology support.
Vendor’s personnel will be required to support pre-commissioning and commissioning activities, and
Contractor will be responsible for scheduling the presence of these specialists on site at appropriate
time.
Contractor shall submit Vendor’s schedule for specialist Vendor support for SAMAPCO approval for all
phases.
Vendor support for package equipment items containing multi-discipline equipment shall include
multiple visits by different disciplines, as advised by the Vendor.
13.2 Vendor’s training at site
The Vendor’s training and required related exercises will be conducted in the designated training
facility and at the site respectively; they will be scheduled at the most appropriate time.
The training officer will coordinate to establish course attendees and schedules to ensure that courses
are arranged to meet attendees’ availability.
This training schedule shall be detailed and submitted to SAMAPCO.
14 Communication
14.1 Radio-communication
The Contractor shall provide adequate explosion proof radios for all pre-commissioning,
commissioning and start up activities.
Contractor shall ensure that enough radios, and channels, are available to support simultaneous pre-
commissioning, commissioning and start up, and are also available for Vendor representative.
14.2 Mobile phone
Contractor shall be responsible for prohibiting use of non-intrinsically safe equipment in areas where
flammable fluids exist prior to initial start up. This equipment includes mobiles phones, cameras, spark
producing tools, electric drills etc. Use of essential tools shall be controlled by appropriate permit to
work procedures.
Mobile phones shall not be permitted under any circumstances after initial start up.
15 Reporting
A site meeting will be held for daily and/or weekly reporting once critical activities commence.
The commissioning team will provide a weekly progress report. The progress report will be submitted
in a format agreed among the parties involved in this report.
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CONTRACTOR ID CODE
080036-DZ-PQ-001
16 HSE management
The Contractor generates and develops the HSE management plan for the commissioning including
evacuation plans and procedures.
A permit to work (PTW) system will be set up by commissioning HSE engineer and submitted to the
SAMAPCO for review and approval one month before the date electrolyzer energizing.
Training on PTW system, emergency shutdown, safety philosophy and safety procedures etc. will be
carried out for all personnel involved in commissioning.
The commissioning HSE engineer will prepare and submit commissioning HSE management plan
including all HSE procedures and pre-start up safety review (PSSR) procedure to the SAMAPCO two
months prior to the start of commissioning.
Attachments
Attachment 1: Pre-commissioning / commissioning & start up schedule

Attachment 2: Pre-commissioning / commissioning process and activities
Attachment 3: Organisation for preparation phase
Attachment 4: Organisation for pre-commissioning phase
Attachment 5: Organisation for commissioning phase
Attachment 6: Completion process flow chart
Attachment 7: Start up flow chart
Attachment 8: EDC Plant Drying & Start-Up Plan
Attachment 9: List of Preparation Plan of Pre-commissioning &Commissioning Documents and
Activities
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Attachment 1
Pre-Commissioning / Commissioning & Start Up Schedule
Sep/30/2011
Arabian Chlor Vinyl Project Based on System Definition rev.A
2011 2012 2013
Start Finish Dura
No Activity 12 Dec 1 Jan 2 Feb 3 Mar 4 Apr 5 May 6 Jun 7 Jul 8 Aug 9 Sep 10 Oct 11 Nov 12 Dec 1 Jan 2 Feb
(mm/dd) (mm/dd) tion 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21
Mile Stone . 1/31 Power 3/ 1 Pre-Comm. Start 5/1 Boiler 7/31 MC 10/1 Electro. 11/2 RFSU 12/2 Initial 1/2 Reliability Test Ach.
Energ. 2/29 DCS SAT Start Up Comp. of Comm. Utility Energiz. Accept. Taking Over Certi
1 Utility 02/16/2012 10/07/2012 235

2 U03 Process Water System 02/16/2012 03/01/2012 15
3 Pre-Commissioning 02/16/2012 02/21/2012 6
4 Commissioning 02/22/2012 02/26/2012 5
5 PSSR 02/27/2012 02/29/2012 3
6 Start Up 03/01/2012 03/01/2012 1
7 U10 Sea Water 02/20/2012 03/09/2012 19
9 Commissioning 02/28/2012 03/05/2012 7
10 PSSR 03/06/2012 03/08/2012 3
11 Start Up 03/09/2012 03/09/2012 1
12 U11 Cooling Water 02/25/2012 03/14/2012 19
14 Commissioning
g 03/04/2012 03/10/2012 7
15 PSSR 03/11/2012 03/13/2012 3
16 Start Up 03/14/2012 03/14/2012 1
17 U15 PA and IA System 02/22/2012 03/20/2012 28
19 Commissioning 03/03/2012 03/16/2012 14
20 PSSR 03/17/2012 03/19/2012 3
21 Start Up 03/20/2012 03/20/2012 1
22 U17 Fire Water Pump and Distribution 03/02/2012 03/27/2012 26
24 Commissioning 03/11/2012 03/23/2012 13
25 PSSR 03/24/2012 03/26/2012 3
26 Start Up 03/27/2012 03/27/2012 1
27 U05 Drinking & Safety Shower Water 03/19/2012 04/04/2012 17
29 Commissioning 03/26/2012 03/31/2012 6
30 PSSR 04/01/2012 04/03/2012 3
31 Start Up 04/04/2012 04/04/2012 1
32 U16 Waste Water 03/19/2012 04/03/2012 16
34 Commissioning 03/24/2012 03/30/2012 7
35 PSSR 03/31/2012 04/02/2012 3
36 Start Up 04/03/2012 04/03/2012 1
37 U04 Demin. Water 03/24/2012 04/10/2012 18
39 Commissioning 03/31/2012 04/06/2012 7
40 PSSR 04/07/2012 04/09/2012 3
41 Start Up 04/10/2012 04/10/2012 1
SAMAPCO CA/EDC Project page-1 of 7

Attachment 1
Sep/30/2011
2011 2012 2013
Start Finish Dura
(mm/dd) (mm/dd) tion 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21
42 U14 Nitrogen 03/30/2012 04/17/2012 19

44 Commissioning 04/07/2012 04/13/2012 7
45 PSSR 04/14/2012 04/16/2012 3
46 Start Up 04/17/2012 04/17/2012 1
47 U06 Fuel Gas 04/11/2012 04/24/2012 14
49 Commissioning 04/16/2012 04/20/2012 5
50 PSSR 04/21/2012 04/23/2012 3
51 Start Up 04/24/2012 04/24/2012 1
52 U02 Hot Relief and Flare System 04/05/2012 05/01/2012 27
54 Commissioning 04/15/2012 04/24/2012 10
55 PSSR 04/25/2012 04/27/2012 3
56 Pre-Start Up with Air 04/28/2012 04/30/2012 3
57 Start Up with Fuel Gas 05/01/2012 05/01/2012 1
58 U07 Boiler system 04/10/2012 10/07/2012 23
60 Commissioning 04/18/2012 04/27/2012 10
61 PSSR 04/28/2012 04/30/2012 3
62 Pre-Start Up with Fuel Gas 05/01/2012 05/01/2012 1
63 Start Up with H2 10/07/2012 10/07/2012 1
64 U08 Steam Distribution 04/18/2012 05/01/2012 14
66 Commissioning 04/25/2012 04/27/2012 3
67 PSSR 04/28/2012 04/30/2012 3
68 Start Up 05/01/2012 05/01/2012 1
69 U09 Condensate and Collection Tank 04/19/2012 05/02/2012 14
71 Commissioning 04/25/2012 04/28/2012 4
72 PSSR 04/29/2012 05/01/2012 3
73 Start Up 05/02/2012 05/02/2012 1
74 U12 Refrigeration Unit 06/27/2012 07/11/2012 15
76 Commissioning 06/30/2012 07/07/2012 8
77 PSSR 07/08/2012 07/10/2012 3
78 Start Up 07/11/2012 07/11/2012 1
79 U13 Chilled Water 07/05/2012 07/21/2012 17
81 Commissioning 07/12/2012 07/17/2012 6
82 PSSR 07/18/2012 07/20/2012 3

Attachment 1
Sep/30/2011
2011 2012 2013
Start Finish Dura
(mm/dd) (mm/dd) tion 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21
83 Start Up 07/21/2012 07/21/2012 1

84 U01 EDC Relief and Vent System 07/10/2012 08/05/2012 11
86 Commissioning 07/28/2012 08/01/2012 5
87 PSSR 08/02/2012 08/04/2012 3
88 Start Up 08/05/2012 08/05/2012 1
89 Logistic 03/14/2012 10/01/2012 202
90 L05 Hydrochloric Acid Storage 03/18/2012 04/07/2012 21
92 Commissioning 03/25/2012 04/03/2012 10
93 PSSR 04/04/2012 04/06/2012 3
94 Pre-Start Up 04/07/2012 04/07/2012 1
95 L04 Caustic Soda Storage 03/14/2012 04/03/2012 21
96 Pre-Commissioning
g 03/14/2012 03/20/2012 7
97 Commissioning 03/21/2012 03/30/2012 10
98 PSSR 03/31/2012 04/02/2012 3
99 Pre-Start Up 04/03/2012 04/03/2012 1
100 L02 Propylene Distribution 06/25/2012 07/08/2012 14
102 Commissioning 06/30/2012 07/04/2012 5
103 PSSR 07/05/2012 07/07/2012 3
104 Pre-Start Up 07/08/2012 07/08/2012 1
105 L03 Sulfuric Acid Storage 07/12/2012 09/20/2012 19
107 Commissioning 09/07/2012 09/16/2012 10
108 PSSR 09/17/2012 09/19/2012 3
109 Pre-Start Up 09/20/2012 09/20/2012 1
110 L06 EDC Storage 07/17/2012 08/10/2012 19
112 Commissioning 07/28/2012 08/06/2012 10
113 PSSR 08/07/2012 08/09/2012 3
114 Pre-Start Up 08/10/2012 08/10/2012 1
115 L01 Ethylene Distribution 07/22/2012 10/01/2012 19
117 Commissioning 09/18/2012 09/27/2012 10
118 PSSR 09/28/2012 09/30/2012 3
119 Pre-Start Up 10/01/2012 10/01/2012 1
120 EDC Plant 06/29/2012 10/01/2012 95
121 E06 Incinerator 06/29/2012 08/10/2012 25
123 Commissioning 07/27/2012 08/05/2012 10

Attachment 1
Sep/30/2011
2011 2012 2013
Start Finish Dura
(mm/dd) (mm/dd) tion 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21
124 PSSR 08/06/2012 08/08/2012 3

125 Pre-Start Up with Fuel Gas 08/09/2012 08/09/2012 1
126 Start Up 08/10/2012 08/10/2012 1
127 E05 Waste Water Collection 07/10/2012 09/16/2012 11
129 Commissioning 09/09/2012 09/12/2012 4
130 PSSR 09/13/2012 09/15/2012 3
131 Start Up 09/16/2012 09/16/2012 1
132 E01 Direct Chorination Reactor 07/02/2012 10/01/2012 55
134 Commissioning 08/23/2012 09/06/2012 15
135 PSSR 09/07/2012 09/09/2012 3
136 Dehydration (Dry with EDC) 09/10/2012 09/23/2012 14
137 Pre-Start Up
p with EDC(EDC
( Fill Up)
p) 09/24/2012 09/30/2012 7
138 Start Up with Cl2 & Ehtylene 10/01/2012 10/01/2012 1
139 E02 EDC Distillation Column 07/11/2012 10/01/2012 59
141 Commissioning 08/14/2012 08/23/2012 10
142 PSSR 08/24/2012 08/26/2012 3
144 Pre-Start Up with EDC 09/03/2012 09/30/2012 28
145 Start Up with EDC product 10/01/2012 10/01/2012 1
146 E03 Vacuum Column 07/15/2012 10/01/2012 52
148 Commissioning 08/21/2012 08/30/2012 10
149 PSSR 08/31/2012 09/02/2012 3
153 E04 EDC Drying & Stripping System 07/22/2012 10/01/2012 63
155 Commissioning 08/07/2012 08/16/2012 10
156 PSSR 08/17/2012 08/19/2012 3
160 CA Plant 06/27/2012 10/21/2012 117
161 C15 Waste Water Treatment 06/27/2012 09/01/2012 19
163 Commissioning 08/19/2012 08/28/2012 10
164 PSSR 08/29/2012 08/31/2012 3

Attachment 1
Sep/30/2011
2011 2012 2013
Start Finish Dura
(mm/dd) (mm/dd) tion 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21
165 Start Up 09/01/2012 09/01/2012 1

166 C01 Salt Handling 07/03/2012 09/04/2012 15
168 Commissioning 08/24/2012 08/31/2012 8
169 PSSR 09/01/2012 09/03/2012 3
170 Start Up 09/04/2012 09/04/2012 1
171 C02 Brine Saturation 07/05/2012 09/09/2012 26
173 Commissioning 08/20/2012 08/29/2012 10
174 PSSR 08/30/2012 09/01/2012 3
175 Pre-Start Up with Water & Demin-Water 09/02/2012 09/08/2012 7
176 Start Up with Brine 09/09/2012 09/09/2012 1
177 C03 Primary Brine Treatment 07/09/2012 09/14/2012 31
178 Pre-Commissioning
g 07/09/2012 07/13/2012 5
179 Commissioning 08/20/2012 08/26/2012 7
180 PSSR 08/27/2012 08/29/2012 3
181 Pre-Start Up with Water & Demin Water 08/30/2012 09/13/2012 15
183 C04 Secondary Brine Treatment 07/13/2012 09/19/2012 31
185 Commissioning 08/25/2012 08/31/2012 7
186 PSSR 09/01/2012 09/03/2012 3
189 C05 Anolyte Dechlor.& Chlorate Decom. 07/17/2012 10/01/2012 21
191 Commissioning 09/08/2012 09/14/2012 7
192 PSSR 09/15/2012 09/17/2012 3
194 Start Up with Anolyte 10/01/2012 10/01/2012 1
195 C11 Catholyte Circulation 07/21/2012 10/01/2012 21
197 Commissioning 09/11/2012 09/17/2012 7
198 PSSR 09/18/2012 09/20/2012 3
200 Start Up with Catholyte 10/01/2012 10/01/2012 1
201 C10 Waste gas Dechlorination 07/25/2012 10/01/2012 19
203 Commissioning 09/16/2012 09/22/2012 7
204 PSSR 09/23/2012 09/25/2012 3

Attachment 1
Sep/30/2011
2011 2012 2013
Start Finish Dura
(mm/dd) (mm/dd) tion 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21
206 Start Up with Waste Gas 10/01/2012 10/01/2012 1

207 C07 Electrolyser 07/22/2012 10/01/2012 35
209 Commissioning 09/04/2012 09/18/2012 15
210 PSSR 09/19/2012 09/25/2012 7
211 Anolyte / Catholyte Fill Up 09/26/2012 09/30/2012 5
212 Energizing 10/01/2012 10/01/2012 1
213 C08 Chlorine Cooling Drying and Comp. 06/27/2012 10/02/2012 28
215 Commissioning 09/10/2012 09/19/2012 10
216 PSSR 09/20/2012 09/22/2012 3
217 Pre-Start Up with Air / N2 / H2SO4 09/23/2012 09/29/2012 7
218 Start Up with recycle H2SO4 10/02/2012 10/02/2012 1
219 C12 Caustic Conc. and Distribution 07/02/2012 10/03/2012 31
221 Commissioning 09/01/2012 09/10/2012 10
222 PSSR 09/11/2012 09/13/2012 3
223 Pre-Start Up with Water / Caustic 09/14/2012 09/23/2012 10
224 Start Up with Caustic Product (32%) 10/03/2012 10/03/2012 1
225 C14 HCl Synthesis and Distribution 07/07/2012 10/04/2012 28
227 Commissioning 09/06/2012 09/15/2012 10
228 PSSR 09/16/2012 09/18/2012 3
229 Pre-Start Up with Water 09/19/2012 09/25/2012 7
230 Start Up with H2 & Cl2 Product 10/04/2012 10/04/2012 1
231 C09 H2SO4 Concentration 07/12/2012 10/04/2012 28
233 Commissioning 09/08/2012 09/14/2012 7
234 PSSR 09/15/2012 09/17/2012 3
235 Pre-Start Up with Water / H2SO4 09/18/2012 09/27/2012 10
236 Start Up with recycle H2SO4 10/04/2012 10/04/2012 1
237 C13 H2 Cooling and Compression 07/17/2012 10/06/2012 26
239 Commissioning 09/12/2012 09/21/2012 10
240 PSSR 09/22/2012 09/24/2012 3
241 Pre-Start Up with Air / N2 09/25/2012 09/29/2012 5
242 Start Up with H2 Product 10/06/2012 10/06/2012 1
243 C06 Sulfate Removal and Gyp.Filtration 07/22/2012 10/21/2012 31
245 Commissioning 09/28/2012 10/07/2012 10
246 PSSR 10/08/2012 10/10/2012 3

Attachment 1
Sep/30/2011
2011 2012 2013
Start Finish Dura
(mm/dd) (mm/dd) tion 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21 1 11 21
247 Pre-Start Up with Water 10/11/2012 10/20/2012 10

248 Start Up with Lean Brine 10/21/2012 10/21/2012 1
249 Initial Start Up / Tunning 10/01/2012 11/01/2012 32
250 RFSU 11/02/2012 11/02/2012 1
251 Performance Test 11/02/2012 12/01/2012 30
252 Initial Acceptance Test 12/02/2012 12/02/2012 1
253 Reliability Test 12/03/2012 01/01/2013 30

Attachment 2 : rev. 2 Dec/5/2011
Pre-Commissioning / Commissioning Process and Activities
Utility Mechanical Initial Reliability

RFSU
Pre-Comm. Start Completion Acceptance Test Achieved
2012. 2013.
3/1 7/31 11/2 12/2 1/2
Start Up/ Reliability

Construction Pre-Comm. Comm.
Operation Operation
▪ Loop Check OVERALL SYSTEM ▪ "B" Punch Cleared ▪ Plant design rate ▪ Reliability test
▪ Hydro Test of Piping ▪ "A" Punch Cleared ▪ PSSR Operation
▪ Power Energizing ▪ Pipe Cleaning ▪ Tightness Test (at
▪ DCS SAT ▪ Reinstatement Operating Pressure) ▪ Hand Over
▪ PSV Popping Test ▪ Leak Test ▪ System Drying Out / ▪ Complete Punch - Special Tools
▪ Functional Test Inerting (including "C") - Spart Parts
▪ Equip. Final
(Interlock check for ▪ Catalyst Loading - Final Data Books
Inspection
▪ Vessel/Tank Closing Process, F&G ) ▪ Initial Chemical
Fill-up ▪ Operational Test
▪ Cold Align. Check
UTILITY SYSTEM only ▪ Refractory Dyr Out
▪ Install. of Instrument
▪ "A"&"B" Punch Clear (for Incinerator)
▪ Motor Solo Run ▪ Performance Test
▪ PSSR ▪ MRT
▪ OWNER disciplines
▪ Tightness Test (at ▪ Load Test
to punch all systems Operating Pressure) (Compressor)
/subsystems,
▪ Steam Boiler ▪ Brine System
compile master
Refractory Dty-out (CA Plant)-Start Up
punch list, and
decide punch ▪ Chemical Preparation & Operation
item categories. and Chemical ▪ Electrolyzer-Start Up
in Service & Operation
for Steam Boilers ▪ Introduce Chlorine /
▪ DIC shall submit ▪ Start Up & All Utility Ethylene Feed for
pre-comm./Comm. System in Service EDC Plant
procedure 6 months ▪ Hot Alignment ▪ Control System
prior to precomm. ▪ Performance Test Tunning
OJT Traning
Attachment 3 rev. A Aug/2/2011
Organization for Preparation Phase

Korean ACVC TCN
Staff Grade
DIC Project ACVC Number of Staff
Manager Management Nationality
K 1 K : Korean / T : TCN / A : ACVC
S : Supervisor / L : Leader
W : Worker
Comm.
Construction Engineering Total
Manager
K 1 S Korean
TCN
Comm. Procurement
Coordinator
K S
CA Plant EDC Plant Utility /

Lab
Off Site
Process Process Process Lab

Engineer Engineer Engineer Engineer
K 1 S K 1 S K 1 S K S
Operation Operation Operation

Supervisor Supervisor Supervisor
K 3 S K 2 S K 2 S
Attachment 4 rev. 0 Jan/17/2012
Organization for Pre-Commissioning Phase

Korean SAMAPCO TCN
Staff Grade
DIC SAMAPCO Number of Staff
Site Manager Management Nationality
K 1 S
K : Korean S : Supervisor
T : TCN L : Leader
A : SAMAPCO W: Worker
Comm.
Construction Punch Team Safety S/V
Manager Total
K 1 S K 1 S Korean
TCN
Comm. Comm. Turnover Safety

QA/QC
Engineer Coordinator Coordinator Engineer
K 1 S K 1 S K 1 S K 1 S K 1 S
SAMAPCO Operation S/V SAMAPCO

Comm. S/V
Operation S/V (Utility) Maint. S/V
A 1 S K 1 S K 1 S A 1 S
Operation
Shift A
A Operation Operation Lab. Control Mechanical
Mechanical Electrical Instrument
(Day) (Night) (Day) System Engineer
Operation
Shift B K 1 S K 1 S K 1 S K 1 S A
Operation
Shift C Control Electrical
Operator Operator Analyst Mechanical Electrical Instrument
A System Engineer
K 1 S K 1 S K 1 S T 2 L T 1 L T 2 L T 2 L A
Operation
Shift D
A
Operation Instrument
Shift E Engineer
A T 3 W T 3 W T 2 W T 8 W T 3 W T 8 W A
Attachment 5 rev. 0 Jan/17/2012
Organization for Commissioning Phase

Korean SAMAPCO TCN
Staff Grade
DIC SAMAPCO Number of Staff
Site Manager Management Nationality
K 1 S S : Supervisor
K : Korean
T : TCN L : Leader
A : SAMAPCO W: Worker
Comm.
Construction Punch Team Safety S/V
Manager Total
K 1 S K 1 S Korean
TCN
Comm. Comm. Turnover Safety

QA/QC
Engineer Coordinator Coordinator Engineer
K 1 S K 1 S K 1 S K 1 S K 1 S
SAMAPCO SAMAPCO
Operation S/V Comm. S/V
Operation S/V Maint. S/V
A 1 S K 1 S K 1 S A 1 S
Operation
Shift A
A Operation Operation Lab. Control Mechanical
Mechanical Electrical Instrument
(Day) (Night) (Day) System Engineer
Operation
Shift B T 1 S K 1 S K 2 S K 1 S A
Operation
Shift C Control Electrical
A System Engineer
K 8 S K 6 S K 2 S T 2 L T 1 L T 2 L T 2 L A
Operation
Shift D
A
Operation Instrument
Shift E Engineer
A T W T W T W T 8 W T 3 W T 8 W A
Attachment 6 Completion Process Flow Chart
rev.A Aug/2/2011
QC Procedure for
Prepare Prepare Pre- Comm.
Check Cleaning, Leak Test
QC Dossier / Comm. Dossier
Sheet Drying, Function, etc.
NDT
Records Prepare Start Up, Comm.,
Review by
& Performence Test
ACVC
Material Dossier
Identification
Shop
Inspection ACVC
Report Approval
System Certified
as Mechanically Final Issue
Complete
Construction
Completion
Pipe Cleaning,
Multi Disciplinary Pre-Comm.
Function Test
Punch List Activities
Utility Start Up, etc.
Punch A Witness /
Cleared Sign Off
Punch A should be
MECHANICAL
cleared before
COMPLETION
M/C sign off.
Construction
Finalize QC Commissioning Tightness Test
Completion Check
Dossier Activities Drying, etc.
List, Site Reports
Summary of
Prepare Witness
Testing &
QC Data Sign Off
Inspection
System Comple.
Dossier
Submit
Multi Disciplinary
Sys. Dossier to
Punch List
ACVC
Punch
ACVC
A/B
Approval
Cleared
PSSR
Ready fo Start Up
Initial Start Up Energizing
for Cl2 / EDC
Comm. Procedure Electrolyser
Down Stream
Comm. Acitivies Inst. Tunning

Completion RFSU Load Up to
Product to Storage Design Rate
100% Daily
Production START UP
Operation Manual
Special Toos
Performance Performance Test
Spare Parts
Test Procedure
Hand Over
ACVC
Approval
Submit
Final Data Book
Performance
Acceptance
ACVC Punch C
Approval Cleared
Initial
Acceptance
Reliability Test
Taking Over
Certificate
Issued by ACVC
FINAL
ACCEPTANCE
Attachment 7
Start Up Flow Chart Sep/30/2011
Preparation for Commissioning Dmin. Water Sys. H2SO4 Con. Sys.

Start Up Pre-Start Up
PC&C ▪ Prepare the precom,comm,start up procedure
▪ Prepare the performance test procedure
Team ▪ Prepare the vendor engineer schedule Boiler Cl2 Compressor
▪ Ready for tools,consumable,test equipment Pre-Start Up Pre-Start Up
Mobilization (Fuel Gas)
▪ Ready for temp.equipment and piping installation
▪ Ready for consumable utility items Salt
Cl2 Emergency
Scrubber S/U
Salt Handling Sys.
Start Up
Control & SWGR Bld. HAVC Incinerator

▪ Punch and physical checks Anthracite Filter Sys Pre-Start Up
▪ Balance Start Up
▪ Energize & running test
EDC Reactor
EDC Filling Up
Polishing Filyer Sys.
230KV Power Incomming Start Up
▪ Punch and physical checks EDC Plant Drying
with EDC
▪ Cable isolation check
▪ E power available
Sulfate Rem
Removal
oval Ion Ex. Resin Sys EDC Purification
Pre-Start U
Upp Start Up Pre-Start Up
34.5KV Switch Gear

▪ Punch and physical checks
▪ E-bus isolation procedure
▪ E power available Electrolyser
Rectifier Power
Catholyte / Anolyte
Ready for ON
Filling
MV/LV (4.16/0.48KV) NaOH

Switch Gear
▪ Punch and physical checks NaOH Evaporation INITIAL START UP
▪ E-bus isolation procedure Pre-STart Up (Energizing)
▪ E power available NaOH
H2
Control System (F&G) Cl2
▪ Punch Cooling / Drying /
NaOH Evaporation H2 Compressor
▪ Energize for F&G system AC/DC UPS System Compressing
Start Up Start Up
▪ Loop test ▪ Punch and physical checks Start Up
▪ Cause and effect test ▪ Charge batteries Cl2
▪ Discharge/Recharge tests
Boiler
EDC Reactor Sys. Start Up (H2)
Control System (SIS) NaOH Storage
Start Up
▪ Punch Control System (DCS)
▪ Energize ESD system ▪ Punch
▪ Loop test ▪ Energize all system EDC Purification HCl Synthesis Sys.
▪ Cause & effect test ▪ Energize checks/soft ware Start Up Start Up
▪ Checks / Function checks
Incinerator Sys.
▪ OPC checks Start Up
Instrument Air ▪ Communcation check
HCl Storage
▪ Punch list Instrument Tuning
▪ Compressor runs 100% Production
▪ Line blowing EDC
▪ Air available EDC Storage
All System Pre-Com
▪ Loop check/Sequence test
▪ Valve stroke test RFSU
▪ MCC auto function test
▪ C&E test/Utility start up/run
Ready for N2
Performance Test
▪ N2 system service
Commisssioning
▪ Tightness test
Performance
▪ Drying/Inerting
Acceptance
▪ Functional Test
Initial
PRE START UP SAFETY Acceptance
REVIEW (PSSR)
Reliability
Test
Taking Over
Certificate
Attachment 8
EDC PLANT DRYING & START-UP PLAN

M/C
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Ͳ14 Ͳ13 Ͳ12 Ͳ11 Ͳ10 Ͳ9 Ͳ8 Ͳ7 Ͳ6 Ͳ5 Ͳ4 Ͳ3 Ͳ2 Ͳ1 0

06/18 06/25 07/02 07/09 07/16 07/23 08/06 08/13 08/20 08/27 09/03 09/10 09/17 09/24 10/01
M/C
Attachment 9
List of Preparation Plan of Pre-commissioning &Commissioning Documents and Activities
1. Preparation of pre-commissioning and commissioning documents as per Plant Completion of Project Standard
Specification (SPCC - G - 008)
Items Preparation Plan

1.1 Section definition (System Definition) Preparaed and issued to Owner
(Document No. 080036-MZ-SD-001)
1.2 Detailed pre-commissioning (including
FUNCTION TESTS) procedure
1.2.1 Box-up procedure Will be prepared by 29th Feb. 2012
1.2.2 Loop test procedure Will be prepared by 29th Feb. 2012
1.2.3 Electrical pre-commissioning procedure Will be prepared by 29th Feb. 2012
1.2.4 Motor solo run procedure Will be prepared by 29th Feb. 2012
1.2.5 Pipe cleaning procedure
1) Air blowing procedure
Preparaed and issued to Owner
2) Water flushing procedure (Document No. 080036-DZ-MP-002)
3) Steam blowing procedure
4) Chemical cleaning procedure
1.2.6 Tightness test procedure with marked-up P&ID Preparaed and issued to Owner
(Document No. 080036-DZ-PQ-011)
1.2.7 Functional test procedure Will be prepared by 29th Feb. 2012
1.2.8 Drying & Inerting Procedure Preparaed and issued to Owner
1.2.9 MRT procedure Preparaed and issued to Owner
1.2.10 Reliability Test procedure Preparaed and issued to Owner
(Document No. 080036-DZ-MP-003)
1.3 Detailed pre-commissioning planning by section Will be prepared by 31th Mar. 2012
and discipline
1.4 Detailed commissioning / ready for start-up Will be prepared by 31th May 2012
procedures
1.5 Detailed commissioning planning by section and Will be prepared by 30th June 2012
discipline
1.6 Pre-commissioning and commissioning technical 1) Pre-commissioning : will be prepared by 31st Mar. 2012
database 2) Commissioning : will be prepared by 30 June 2012
1.7 Pre-commissioning and commissioning check & 1) Pre-commissioning : will be prepared by 31st Mar. 2012
test sheets 2) Commissioning : will be prepared by 30 June 2012
1.8 Detailed pre-ready - for start-up activities Will be prepared by 30th Sep. 2012
procedure
1.11 Performance test procedure Will be prepared by 31st Oct. 2012
1.13 Operation manual Preparaed and issued to Owner
(Document No. 080036-VZ-MP-01 / 080036-VZ-MP-002 /
080036-VZ-MP-003 / 080036-VZ-MP-OO4 / 080036-VZ-
MP-005)
1.14 Maintenance manual Will be prepared by 30th April 2012
1/2
Items Preparation Plan
1.15 Turnover procedure Will be prepared by28th Feb. 2012

1.16 List of consumable to use during pre- Will be prepared by 31st March 2012
commissioning and commissioning activities
1.17 Pre-commissioning and commissioning schedule Schedule have preparaed and issued to Owner, updated
schedule will be issued by 30th Apr. 2012
1.18 Start-up schedule Schedule have preparaed and issued to Owner, updated
schedule will be issued by 30th June. 2012
2. Pre-commissioning and commissioning site activities List
2.1 Schedule for site attendance of vendor specialists
2.2 Optimize detailed pre-commissioning and commissioning procedures
2.3 Manage and execute pre-commissioning and commissioning activities in field as per detailed procedure
2.4 Coordinate vendor specialists and the TECHNOLOGY PROVIDER's site attendance during plat pre-
commissioning, mechanical completion, commissioning and ready for start up phases.
2.5 Coordinate and execute plant start up, initial operation and performance tests with OWNER and
TECHNOLOGY PROVIDER's respective personnel
2.6 Training on the job to OWNER personnel in accordance with CONTRACT.
2.7 Taking-over of the PLANT by the OWNER after successful performance test and reliability tests.
2/2

Pre Commissioning Commissioning Execution Plan

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CONTRACTOR ID CODE

PRE COMMISSIONING & COMMISSIONING 080036-DZ-PQ-001

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Rev Date Description

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

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

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

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

A 03-Aug-11 Issue for Approval

Contractual target dates are;

Plant Initial Acceptance date : 02 Dec. 2012

Taking-Over date : 02 Jan. 2013

1.3. Pre-commissioning & Commissioning activities

approved commissioning procedures. Completion of commissioning and energizing of utilities

1.4. Units of measurement/language

1.5. Standards and specifications

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

1.6. Key project documents

2.1.1. Salt storage and handling

2.1.2. Primary brine system