Pre-Commissioning, Commissioning and

Start-up Procedures for TT,DT Installation

project at shell Shikarpur Terminal.

Document Number: SKP-CSU-001

Date: 19-Jan-2023
Rev: 0

Implementation Contractor:

Engineering Service Provider:

Petrochemical Engineering Consultants

Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

Pre-Commissioning, Commissioning and Start-up

Procedures for TT and DT Installation project at shell
Shikarpur Terminal.
Authors:

Ali Gohar – Site Engineer (Petrochemical Engineering Consultants)

Muhammad Saad – Project Manager (Avanceon Ltd)

Reviewers:
Munir Ahmad – Project Manager (Shell Pakistan Limited)
Mir Hazar – Construction Manager (Shell Pakistan Limited)

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

1. Scope
1.1. Introduction
SPL wanted to resolve the problem related to the Thermal expansion in piping. Hence, this project
tends to resolve the problem regarding thermal relief of the Piping. When piping is exposed to the
temperature, vapours are produced, which tends to raise the pressure inside the pipe. Therefore,
thermal relief valves are used to overcome this pressure-rise due to thermal expansion. ESP has
provided with the detailed study report in this regard. Hence, the extent of this project is the
installation of TT AND DT’s at various locations as depicted in study report for Shikarpur
Installation.
1.2. Scope of Work
The scope of the project includes but is not limited to:
1. Installation of TT and DT at various locations in Shikarpur Installation. The following
describes the works required. This should be read in conjunction with the Bill of Quantities
(BOQs), Specifications and Drawings attached for complete understanding.
1.3. Definitions
In this document, the following definitions apply:

Term Meaning
Contractor Avanceon Limited
Consultant / ESP / Owner’s Engineer Petrochemical Engineering Consultant

Client / Owner / Principal Shell Pakistan Limited

1.4. Acronyms and Abbreviations

In this document, the following Acronyms and Abbreviations apply:

Acronyms / Abbreviation Meaning

ALARP As Low As Reasonably Practical
ASME American Society of Mechanical Engineers
API American Petroleum Institute
ATA Accountable Technical Authority
CSU Commissioning and Start-up Procedures

DEP Design Engineering Practices

DGAME Downstream Global Asset Management Excellence

HSSE Health, Safety, Security and Environment

SKP Shikarpur Terminal

PEFS Process Engineering Flow Scheme

PSSR Pre-Start up Safety Review

RFSU Ready For Start-Up

SoF Statement of Fitness

TA Technical Authority

RTA Responsible Technical Authority

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

1.5. Responsibilities
The following responsibilities apply for all personnel undertaking activities covered by this
document.

Responsibilities Meaning
Project Manager (Shell) Project Manager is accountable for the delivery of the Pipeline Project, overseeing
Munir Ahmad the Execution phase of Construction until SOF / Mechanical Completion and
handover of the Pipelines projects.
Construction Manager (Shell) The Construction Manager is accountable for all site activities up to Mechanical
Completion, including managing the Contractors site activities to ensure a safe
Mir Hazar and quality Mechanical Completion. Construction Manager also support during
commissioning activities

Asset Manager (Shell) The AM supports construction and commissioning activities and is
accountable/responsible for commissioning and start-up of the asset while
Ali Murad Baloch ensuring the asset can be operated safely and successfully.

Contractor Project Manager (Avanceon) Accountable and Responsible for Supply, Construction, Mechanical and Electrical
Completion & Pre-commissioning of the Pipeline Project and handover of the
Muhammad Saad Pipelines projects. Contractor shall also support during commissioning of project
and liaison with Shell accordingly.

1.6. Project Phases

As highlighted in the flowchart below, this document refers in detail to Phases 2 and 4 of the
Pipeline project while Phase 3 is Shell internal process and briefly mentioned in this
document however contractor will be actively involved in Phase 3.

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

Phase 1
Fabrication , Installation , Testing of TT and DT
(Mechanical And Electrical Completion)

Phase 2
Pre-Commissioning and Hydrostatic Testing of Piping

Phase 3
Pre-Startup Safety Review (PSSR) and Statement of
Fitness (SoF)

Phase 4
Commissioning and Startup Acitivites

1.7. CONFLICTING REQUIREMENTS

In the event of conflict, inconsistency or ambiguity between the contract scope of work, this
Specification, National Codes & Standards referenced in this Specification or any other documents,
the Contractor shall refer to the Owner/Engineer whose decision shall prevail.
1.8. Reference Documents
1.8.1. Primary Code
ASME B31.4 : Liquid petroleum transportation piping systems

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

1.8.2. Other Codes & Standards

API RP1110 : Pressure testing of liquid petroleum pipelines
ASME Sect. VIII : Boiler & Pressure Vessel
ASME Sect. V : Non-destructive Examination

1.8.3. Reference Project Document and Drawings

Document Attachments
Contractor HSSE Plan
Emergency Response Plan

Piping Layout map, PIDS & Weld map

3rd Party Certifications

Risk Assessment (Only relevant Sections of

HAZID study)

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

2. System Description
2.1. Overview System Process Engineering Flow Scheme

Figure 1 : REF: PEFS for TT AND DT’s at Shikarpur

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

3. Pre-Commissioning & Commissioning Process

3.1. Phase – 1 - Mechanical Completion
Mechanical completion includes Fabrication and Installation of piping and completion of all
inspection and testing activities as per approved ITP. Construction contractor under
supervision of Shell Construction Manager will carry out mechanical completion. Such
activities will require equipment or systems to be energised, but do not require the
introduction of process fluid. Mechanical completion activities may include following works:

3.1.1. Mechanical
 System Visual inspection for complete and correct installation
 Process verification at site as per PEFS
 Bolt tensioning

3.1.2. Instrument
 Calibration and testing of instruments prior to installation.
 Visual inspection for complete and correct installation.
 Insulation and continuity testing of cables.
 Adjustment of control, alarm and shutdown settings.

3.1.3. Piping
The Mechanical works include, but are not limited to:
1. Procurement in accordance with BOQ after verification from site.
2. Construction documentation.
3. Dismantling of piping (as marked in piping Layout).
4. Re-installation of existing piping along with new gaskets for the fittings.
5. Pre-manufacturing and Installation of pipework spools.
6. Installation of piping fittings. (As mentioned in piping Layout)
7. Tie-ins in accordance with piping layout.
8. Installation Tests (e.g. NDT, Hydrostatic pressure test).
9. Finishing works (e.g. internal cleaning, touch-up paint, labeling and tagging).
10. Start-Up and Pre-commissioning Activities.
11. The Contractor shall issue all the necessary documentation required to undertake and to follow-up
proper procedures for dismantling and installation activities and to record all activities (as built
dossier).

On achievement of mechanical completion, responsibility for the facility will transfer from
those responsible for construction to those responsible for pre-commissioning and
commissioning. Pre-commissioning is also included in Contractor scope of work.

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

Note:

 Checklist for Mechanical Completion are part of ITP.

3.2. Phase – 2 - Pre-Commissioning Process

Pre-commissioning activities undertaken after mechanical completion, but prior to
commissioning, to prove and validate the functioning of equipment as per approved
Inspection Testing Plan/QA/QC Plans.
Pre-Commissioning activities includes:

 Ensure Flushing & Cleaning of piping Spool

 System dry-out
 Reinstatement & Box-Up
 Surface preparation & Paint Touch up
 Torque Tightening
 Close Out of punch list items (P1)

3.3. Phase – 3 – Pre-Start-up Safety Review (PSSR) and Statement of

Fitness (SoF)
3.3.1. Pre-Start-up Safety Review (PSSR)
Prior to Statement of Fitness, several steps of the Pre-Start-up Safety Review (PSSR) are
conducted before the sign-off of the SoF. The PSSR shall be conducted with the asset owner /
operator, and other stakeholders prior to asset start-up.
The PSSR templates shall be used as per SoF guideline document. The PSSR comments and
deficiencies found during the PSSR walkthrough and related mitigation measures are
validated no later than the day of introducing hydrocarbons in the complete system when
Ready For Start-Up (RFSU). The aim of this process is to help drive a smooth handover and
ensure all Process Safety aspects are accomplished. The simplified process is depicted by:

Figure 2 : PSSR and SoF Process

Note:

 In piping case Dry commissioning is referred as Pre-commissioning

3.3.2. Statement of Fitness

The objective of the Statement of Fitness is to uniformly and consistently ensure that the
Asset Integrity Process Safety related activities, deliverables and key operational functions

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

have been verified, assured and completed by competent persons to ensure that hydrocarbons
can be safely introduced, and associated risks effectively managed to ALARP.
The Statement of Fitness is the final sign off by Engineering (incl. Projects) and Asset
managers prior to the introduction of hydrocarbons and confirms that the criteria to safely
introduce hydrocarbons are met. After the handover of the asset, the Asset Manager will have
the sole accountability to facilitate and ensure safe operation of the asset.
Aim of Statement of Fitness document is to confirm that:

 Process Safety Risks have been identified and documented and are managed to ALARP;
 People executing HSSE Critical Activities are competent and fit to work;
 HSSE Critical Equipment meets its Technical Integrity requirements, and Modifications
are complete and have been authorised as specified in the Management of Change
Manual Section;
 The design and construction of New Assets and Modifications to existing Assets meet
design and engineering requirements;
 Process Safety Basic Requirements are met;
 Procedures are in place to operate HSSE Critical Equipment within its Operating Limits.
 All 6 DGAME deliverables (6 pillars) shall be delivered prior to SoF sign off.

3.3.3. Action Items for PSSR/SoF

Outstanding issues/actions are classified in 2 categories:

Pre-Start-up Actions (P-1s):

P-1s are issues and/or actions that require closure prior to SoF sign-off and therefore wet
commissioning to ensure process safety and ALARP issues are addressed.

Post Start-up Actions (P-2s):

P-2s are follow-up closure items that do not present a process or personal safety risk if
completed after Start-up and decided and documented at the P-1 stage. P-2 Due Dates are
commonly set for a maximum of 3 Months.

3.3.4. PCAP Compliance

PCAP compliance shall be required for SoF Sign-off (as recommended by SPL).
Management

Management
Control Name

Construction
HSSE & SP
ORP Phases

Operations
(including
Accronym

Safety)
Project
No

RTA2 RTA3 ATA3

Statement of Fitness
6 E SoF
(New asset) Munir Ahmed Malik Usman Ali Murad Baloch / Muhammad Asim

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

3.4. Phase – 4 - Commissioning & Start-up

These activities are those undertaken after pre-commissioning, PSSR and SoF to dynamically
verify functionality of equipment and to ensure that systems, or facilities forming part of a
system, are in accordance with specified requirements to bring that system into operation by
introducing Hydrocarbon into the system as per CSU Methodology.

3.5. Project Handover

Project handover is a parallel process to the commissioning and start-up activities, which
serves to formalise the transfer of ownership of the new assets from the Projects / Contractor
to the Asset Owner.

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

4. PSSR & SOF Requirements

Once piping & TT and DT has been Installed, Systematic conformity checks should be
carried out on each item of equipment or component to verify visually the condition of the
equipment, the quality of the installation, the compliance with project drawings and
specifications, manufacturer's instructions, safety rules, codes, standards and good
engineering practices. These checks will confirm the following:

 All pipe assemblies and welding have been completed.

 All NDT testing has been carried out successfully.
 Site Restoration performed.

PCAP compliance shall be required for SoF Sign-off (as recommended by SPL). Below
RTA/ATA may change as per availability.

Management
Management
Control Name

Construction
HSSE & SP
ORP Phases

Operations
(including
Accronym

Safety)
Project
No

RTA2 RTA3 ATA3

Statement of Fitness
6 E SoF Abdul Rehman / Khawar
(New asset) Supot Visuthranukul Harinthiren / Malik Usman
Khalid

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

5. Commissioning & Start-up (CSU) Procedures

5.1. Receipt Instructions
Before transfer product through pumps, relevant piping construction to be completed and
tested as per drawings and specification. Pump must not be dry run, measures shall be taken
and should be discussed with prior such as throttling through valves to provide resistance to
pump avoiding tripping, and in order to avoid cavitation air must not be introduced in pump
suction piping.
The first delivery of product must be carried out with great care to avoid the release of large
amounts of vapor through the fill pipe openings of the tank. If possible initial receipt of
product shall be done by gravity. MOGAS tanks to already be filled till low level via TL
receipt to avoid static electricity hazards. [Note: It must be noted that tank inlet valve should
not be throttled as it will increase the tank inlet velocity with empty tank]
1m/s flow rate to be ensured until tank low level is reached for initial product receipt and
open pump discharge valve completely to receive product in tank with design flow rate. Low
level for MoGAS tanks is as below:

The Contractor shall station personnel throughout piping system at high point vents to bleed
air. All flanges and equipment will be periodically inspected for leaks during filling
procedures.
Downstream valves shall be throttled to maintain a packed condition in vessels throughout
initial fill of piping system as described above.

8.1.1 Tank Stripping Requirements

 Tank will be filled initially up until low level through TL receipt to establish slow fill rate
of 1m/s. LOP previously shared.
 Personnel shall be restricted from climbing, gauging or sampling the tank during the tank
filling.
 Plan for safely refloating the tank to be communicated.
 Safely verify Floating Roof is floating and the tank gauge is working – This will be done
using stock reconciliation based on ATG display and established low levels.
 Once the tank has been filled to above the low level, we will revert to normal fill rate with
max allowed 7m/s.
 LEL levels to be confirmed – Once receipt has stopped and the tank is is in operatable
level zone, Use an LEL meter to check the LEL levels at the area right above the IFR.
This will be done using the Gas Tester and its pipe assembly from the top hatch. (LEL
levels at top hatch should be checked and should be less than 10%) . Ideally, after filling
the tank and allowing for natural ventilation and relaxation, it is expected that the tank
vapor space would be below 25% LEL.  Reference (DEP 80.64.10.11 and DSM-250008-
RP-01)

5.2. Product Quality

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

First fill shall be sampled prior to usage. Shell PQ and Operations procedures shall be
followed for testing of products
5.3. Initial Low Point Flush
Perform an initial low point flush operation by flushing each low point drain through a
portable basket strainer for 10 seconds at a system pressure. Repeat flush until basket strainer
collects no additional debris.

5.4. Flushing
The intent of the flushing operation is to remove bulk solids and test leftovers from the
system. Flushing procedures shall precede cleaning procedures. All new pipelines, product
piping, including the transfer line, receipt system piping and supply lines to the storage tanks,
shall be flushed with product. Minimum 4-5 hours product hold time is required.
The flushing of system pipelines shall be accomplished by pumping in bowsers or contractor
can make any other decision after SPL approval. After the main piping system has been
flushed to the satisfaction of SPL, and periodically during the flushing operation, the
Contractor shall flush all high point vents and low point drains.
5.5. Cleaning, Testing & Sampling
Pump product through all new piping sections in the system. Product velocity during all
cleaning operations shall be full pumping capacity. Perform sampling at all system discharge
points, at tanks, and throughout pump house and piping system.
5.6. Commissioning Procedure
Commissioning to be carried out as per given procedure. This includes receipt, flushing,
testing and loading procedure

Figure 3 : CSU for MCH-06 Filling

Attachments

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Pre-Commissioning, Commissioning and Start-up Procedures – TT AND DT At Shikarpur Terminal

6. Safety Measures

 Take measures to ensure that all persons and property are adequately protected from the
consequences of a possible system failure or other causes during the clearing, line filling
and testing operations.
 Avanceon will confirm to SPL that he has instructed all employees engaged on testing
work, or any work associated with testing, or any work in the immediate area (e.g., on
platform) of the possible consequences of a pipeline or test fitting failure under pressure
test conditions.
 Avanceon will comply with any permit-to-work system applicable at any location
influenced by the hydrotest activities.
 Warning notices reading 'KEEP AWAY - PIPELINE UNDER TEST' shall be placed at
appropriate locations such as blanked ends of the test sections, areas where pre-tests or
assembly testing are carried out and test equipment sites.
 Avanceon will obtain the SPL approval in writing of the emergency plan before
commencing pressurization.
 Avanceon team to be present with adequate fitters, mechanics and qualified personnel
during first receipt batch.
 Before any work, including tightening of leaking flanges, is permitted on the test section
under pressure or associated connections, the pressure shall be reduced to a level not
greater than static head plus 1 bar (15 psi). Attached flange management procedure.

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