Doc. No.

: 26071-100-530-GSH-00001

Job No. : 26071 Rev.001

Hyundai Pre-commissioning &

Commissioning Management (HPCM)
Setup Procedure

PROJECT : Engineering, Procurement and Construction (EPC) Inside

Battery Limits (ISBL) and Outside Battery Limits (OSBL) for
the Refinery Development Master Plan (RDMP) Project
X
RU V Balikpapan
LOCATION : Refinery Unit V Balikpapan, East Kalimantan,Indonesia
OWNER : PT PERTAMINA (Persero)

001 15 NOV 19 ISSUED FOR CONSTRUCTION Y.N.CHOI C.Y.KIM Y.D.KIM

000 05 AUG 19 ISSUED FOR CONSTRUCTION H.L.LEE C.Y.KIM Y.D.KIM

00A 30 MAY 19 ISSUED FOR REVIEW H.L.LEE C.Y.KIM Y.D.KIM

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

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REVISION LOG

REV. NO. DATE PAGE DESCRIPTION

00A 30 MAY 19 - ISSUED FOR REVIEW

6,8,11,12,15,16,
000 05 AUG 19 ISSUED FOR CONSTRUCTION
17,18
001 15 NOV 19 11,14,16,17 REVISED AS PER COMMENT

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HOLD LIST

NO. Paragraph HOLD Content

NO HOLD

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TABLE OF CONTENTS

1. PURPOSE ............................................................................................................................... 5

2. SCOPE .................................................................................................................................... 5

3. DEFINITIONS ........................................................................................................................ 5

4. REFERENCE ........................................................................................................................... 6

5. HPCM (HYUNDAI PRE-COMMISSIONING AND COMMISSIONING

MANAGEMENT) .......................................................................................................................... 6

5.1 HPCM’s Characteristic ............................................................................................................................... 6

5.2 HPCM’s Work Flow.................................................................................................................................... 8

5.3 Commissioning Progress of HPCM ........................................................................................................ 9

5.4 HPCM’s Organization Chart ................................................................................................................... 10

5.5 Transfer of HCQM data into HPCM ..................................................................................................... 12

5.6 Overall flow chart to set-up HPCM’s Database ................................................................................. 13

6. PROJECT BREAKDOWN....................................................................................................14

6.1 System........................................................................................................................................................ 14

6.2 Sub-system................................................................................................................................................ 14

6.3 Benefit of System / Subsystem approach .......................................................................................... 15

7. CLASSIFICATION OF COMPLETION DATABASE ..........................................................15

8. VERIFICATION OF MECHANICAL COMPLETION (MC) ..............................................15

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1. PURPOSE
The purpose of this procedure is to describe the function of HPCM (Hyundai Pre-
commissioning and Commissioning Management), electronic management system to
manage, store and control data which reflects Pre-commissioning/Commissioning activities
for the Refinery Development Master Plan (RDMP) Project RU V Balikpapan (hereinafter
referred to as PROJECT).

2. SCOPE
This procedure covers the general description and workflow, system breakdown,
classification of completion database, verification of system completion of the HPCM

3. DEFINITIONS

Terms Definition

CONTRACTOR RDMP Balikpapan JO

HCQM Hyundai Construction & QC Management Program

Hyundai Pre-commissioning & Commissioning Management

HPCM
Program

Integrated Project Management Team consists of a

combination of OWNER Personnel and select third-party

IPMT personnel.(PMC)

Communication between OWNER and CONTRACTOR to be

executed through IPMT as representative of OWNER

JO Joint Operation, CONTRACTOR's Joint Operation (JO) Body

OWNER PT. Pertamina (Persero)

PMC Worley

Engineering, Procurement and Construction (EPC) Inside

Battery Limits (ISBL) and Outside Battery Limit (OSBL) for
PROJECT
The Refinery Development Master Plan (RDMP) Project RU
V Balikpapan

SUB-SYSTEM Subdivision of a System

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Major subdivision of the plant, being either process or utility,

SYSTEM including all the equipment required for that System to
operate.

4. REFERENCE

DOC. No. Title

26071-100-500-GST-00001 Pre-commissioning, Commissioning / Start-up and

Performance test Plan

26071-100-500-GST-00002 Pre-Commissioning & Commissioning Procedure

26071-100-GQI-GAQ-00017 HCQM Procedure

5. HPCM (HYUNDAI PRE-COMMISSIONING AND COMMISSIONING MANAGEMENT)

Hyundai Pre-commissioning & Commissioning Management Program (hereafter “HPCM”) is
the electronic system to carry out efficient & systematic pre-commissioning and
commissioning management and to check status on the system/sub-system basis during
Pre-commissioning/Commissioning stage.
The main purpose of using HPCM is:

 To provide exact information on Pre-commissioning/Commissioning activities

 To provide real time status in order to minimize outstanding work

 To ensure effective management of Pre-commissioning/Commissioning

documentation for further handover process
5.1 HPCM’s Characteristic
HPCM has the following characteristics:

 Pre-commissioning & Commissioning Status Monitoring: HPCM can easily monitor

Pre-commissioning & Commissioning Status by inputting completion date of
inspection with scan file of check sheet. The status is automatically reflected in
HPCM.

 Report exporting: HPCM can easily export pre-commissioning and commissioning

status data in various report format(excel, pdf) on system or sub-system basis.

 Punch Management Function: HPCM can manage commissioning punch

systematically by registering punches which were created.

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 Monitoring and reporting on all aspects of Pre-commissioning and Commissioning

Activities. IPMT also can access HPCM and monitor Pre-commissioning and
Commissioning status in real time. ID with ''read permission'' will be given to IPMT
for HPCM Access

 Calculations of Pre-commissioning and Commissioning progress for planning

interface

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5.2 HPCM’s Work Flow

HPCM has the following work flow.

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5.3 Commissioning Progress of HPCM

HPCM and Primavera P6 have a different calculation method for making Commissioning
progress.
Progress calculation method of each program is as following:

HPCM can provide ‘Plan / Actual / Behind’ status of Pre-commissioning and

Commissioning task. But weight that reflects progress is not considered.
Therefore, in order to check the weight reflected progress, Primavera P6 should be
referred.

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5.4 HPCM’s Organization Chart

For HPCM operation on-site, collaboration with Construction team & QC team is very
essential. In order to ensure the availability or work front for starting the Commissioning
work, Pre-commissioning status and construction status must be checked.

<HPCM's Organization Chart>

Site Manager

Construction System Completion

QA/QC Manager
Manager Manager

Construction HPCM HCQM

Engineer Administrator Administrator
(Each Discipline)

Construction
Supervisor HPCM Operator HCQM Operator
(Each Discipline)

The ‘HCQM’ (Hyundai Construction & QC Management Program) is used in the

construction team and QC team to manage the items and test PKG by Area or Unit in
the beginning of Project. When construction is around 60% completed, Construction
team will also manage the items and test PKG by System/Sub-system. Subsystem
information will be given to HCQM Administrator. Therefore, seamless information
sharing is required between HPCM Administrator and HCQM Administrator in the final
stage of construction.

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IPMT

Commissioning
Team

HPCM

Construction QA/QC
Team
HCQM Team

IPMT

The responsibilities of personnels are as follows:

 System Completion Manager (Commissioning Manager)
He is responsible to manage and monitor the accomplishment of the
Commissioning work procedure on site.
 HPCM Administrator
He is responsible to setup and manage the HPCM. He also cordinates with
Construction team and QA/QC team.
 HPCM Operator
He is responsible to input data to HPCM and export report. He also handles
the commissioning dossier.
 Construction Engineer
He is responsible to follow and accomplish the construction procedure on site.
 Construction Supervisor
He is responsible to follow all instruction in accordance to the approved
procedure & plan and fulfill all inspections and construction works required on
site.

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 HCQM Administrator
He is responsible to setup and manage the HCQM. He also cordinates with
Construction team and Commissionning team.
 HPCM Operator
He is responsible to input data to HCQM and export report. He also handle
the construction and QA/QC dossier.
5.5 Transfer of HCQM data into HPCM
After systemization is done, essential Construction data from HCQM should be linked
with HPCM in order to ensure that relevant system is ready for Pre-commissioning. (Ex.
Hydro test which belongs to construction activities should be done prior to flushing
activities.)
Contractor’s Commissioning team will select essential Construction data and move it
into HPCM. Below picture is sample from other Project showing that construction data
has been transferred into HPCM.

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5.6 Overall flow chart to set-up HPCM’s Database

Below flow chart is overall flow chart to set-up HPCM’s database. Close cooperation
among Engineering, Quality and Construction team must be taken for smooth set-up of
HPCM database.

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6. PROJECT BREAKDOWN
Contractor shall convert schedule monitoring from ‘area base’ to ‘system completion base’
when the construction progress is achieved around sixty percent (60%). The plant will be
controlled by subsystem basis. In order to optimize resources and Pre-commissioning &
Commissioning period, Plant will divided into further subdivision such as system,
subsystem.
6.1 System
A System is a major subdivision of an installation, being either process or utility, which
performs a major operational function of the plant.
6.2 Sub-system
A Sub-system is a further subdivision of a system, which performs a given operational
function, with no or little interference from the other subsystems for the commissioning
execution.
Most of the preparation and execution activities are performed within a subsystem
boundary.
The subsystem list must be compatible with the plant initial start-up sequence.
Equipment which have different steps of the start-up sequence must not belong to the
same subsystem.
Below is System/Sub-system sample for Diesel Hydrotreating Unit (Unit 054/083)

Unit No. Unit Description System No. System Description Subsystem No. Subsystem Description

DHT (Diesel Hydrotreating

054 / 083 000 DHT Common 000 DHT Common
Unit)
100 Feed System 000 Feed System
100 Feed Coalescer Package
200 Feed Surge Drums and Feed Pumps
300 Feed filter and back wash
400 Chemical Injection packages
200 Reaction System 000 Reaction System
100 Combined Feed Heater
200 Reactor
300 Separation System 000 Separation System
100 HP Separators
200 Washing Water System
300 HP Amine Abosorber and Amine Drums
400 Recycle and Makeup Compressor 000 Recycle and Makeup Compressor
100 Recycle Gas Compressor
500 Stripper System 000 Stripper System
100 Stripper and Stripper Reflux Drum
200 Corrosion Inhibitor Agent Package
600 Fractionator Section 000 Fractionator Section
100 Feed Heater
200 Fractionator and Reflux Drum
300 Kerosene Stripper and Rundown
700 Product Rundown 000 Product Rundown
100 Diesel Product Pumps and Coolers
200 Diesel Product Coalescer Package
300 Lubricity Improver Injection Package

System/Sub-system list are detailed in “System / Sub-system Definition & List

(26071-100-530-GSH-00002)”

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6.3 Benefit of System / Subsystem approach

 Efficient for planning of Pre-commissioning and Commissioning execution

 Optimize the resources and construction period

 Bring the plant on line in the shortest period

 Hand over the plant to the OWNER in full confidence with the required safety

7. CLASSIFICATION OF COMPLETION DATABASE

Following table shows “job class” for the Project. Job class means tasks and activities in
Pre-commissioning and Commissioning. Task and activities are divided into Pre-
commissioning, Commissioning.
Phase Job Class
Line Cleaning (Air blowing / Water Flushing)
Steam Blowing
Chemical Cleaning
Lube Oil Flushing
Pre-Commissioning Instrument Loop Test
Motor Solo Run
Vessel Internal Inspection
Completion
Site Acceptance Test (Electrical & Control System)
Database
Catalyst / Absorbent Loading (If possible)
in HPCM
Logic & Function Test
System Leak Test
Purging(Inerting)
Commissioning Refractory Dry Out
Catalyst / Absorbent Loading
Chemical Loading
Mechanical Running Test

8. VERIFICATION OF MECHANICAL COMPLETION (MC)

System Mechanical Completion is achieved when all Pre-commissioning activities and A
Punches in the system are completed. Mechanical Completion is awarded when all SMCs
are achieved.
Below schematic describes flow to achieve SMC and MC.

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MC

Subsystem A‐01 SMC

Utility System A
Subsystem A‐02

Subsystem B‐01
SMC
Process System B
Subsystem B‐02

Pre‐commissioning

System Mechanical Mechanical

SMC MC
Completion Completion

Punch status will be extracted from HCQM and will be transfered to HPCM. SMC and MC
are easily verified by using status monitoring in HPCM. As shown below pictures, Punches
(A, B and C) and Pre-commissioning activities can be managed on subsystem basis in
HPCM.

Sequence Level 3 Sub System Sub System Description Punch Punch A Punch B Punch C

Total 2 2 3
MC2 41-P-01 MC2_Feed Section Cleared 2 1 1
Outstanding 1 2
Total 3 3 2
MC2 41-P-04 MC2_Recycle Gas Compressor Cleared 3 2 1
Outstanding 1 1
Total 2 4 5
MC2 41-P-05 MC2_Make-up Gas Compressor Cleared 2 3 2
Outstanding 1 3

There is no outstanding punch A meaning that good to

go for further activities (Commissioning) if the all Pre‐
commissioning activities are done.

< Punch status monitoring >

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PRE-COMMISSIONING
Sequence Level 3 Sub System Sub System Description Task CI COMM EL ME
SubTotal Prog(%)
LOOP SCLN LEAK LBOF CMCL SOLO MECK
Total Task 2 2 2 6
MC2 41-P-01 MC2_Feed Section Total Done 2 2 2 6 100
Remaining 0
Total 3 1 1 2 7
MC2 41-P-04 MC2_Recycle Gas Compressor Cleared 3 1 1 5 71.4
Outstanding 2 2
Total 1 2 2 5
MC2 41-P-05 MC2_Make-up Gas Compressor Cleared 1 2 2 5 100
Outstanding 0
Note
‐ Discipline : CI (Instrument), COMM(Commissioning), EL(Electrical), ME(Mechanical)
‐ Task Class : LOOP (Loop Test), SCLN (Flushing & Blowing), LEAK (Leak Test), LBOF ( Lube Oil Flushing)
CMCL (Chemical Cleaning), SOLO (Motor Solo Run), MECK (Vessel Final Box Up)

All Pre‐commissioning activities can be captured on subsystem basis.

< Pre-commissioning status monitoring >

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