AMMONIUM NITRATE PROJECT

75,000 MTPY AMMONIUM NITRATE

60,000 MTPY NITRIC ACID
PT. KALTIM AMONIUM NITRAT

PRECOMMISSIONING & COMMISSIONING PLAN

FOR APPROVAL
DATE 28-10-2020

王军亭
2020.10.28
08:36:08 +08'00'

A0 19-Oct-20 Issued for Approval NF IND HD WJT

WIKA SEDIN
REV DATE DESCRIPTION PRE CHK
APP’D

TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN WITHOUT PRIOR WRITTEN
AUTHORIZATION OF KAN

AMMONIUM NITRATE PROJECT

Contract Number : 001/KAN/EPC-CONTRACT Revision

Document No. : A0
AMNIT-CU-100-LST-1001-A0
AMMONIUM NITRATE PROJECT 75,000 MTPY AMMONIUM NITRATE & 60,000 MTPY NITRIC ACID
PT. KALTIM AMONIUM NITRAT

PRECOMMISSIONING & COMMISSIONING PLAN

OWNER : PT. KALTIM AMONIUM NITRAT

CONTRACTOR : PT. WIJAYA KARYA (PERSERO) TBK –
SEDIN ENGINEERING CO., LTD
PROJECT NAME : AMMONIUM NITRATE PROJECT
LOCATION : BONTANG – KALIMANTAN TIMUR
CONTRACT NUMBER : 001/KAN/EPC-CONTRACT

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REVISION SHEET DESCRIPTION

NO PAGE SUBJECT DESCRIPTION OF CHANGE REV.

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PRECOMMISSIONING & COMMISSIONING PLAN

TABLE OF CONTENT

Contents
1. OBJECTIVE ..................................................................................................................... 5

2. TERMINOLOGY & ABBREVIATIONS ............................................................................. 5

3. REFERENCES ................................................................................................................ 7

4. SCOPE OF WORK .......................................................................................................... 7

5. COMMISSIONING REQUIREMENTS ............................................................................. 8

6. PREPARATION BEFORE COMMISSIONING ................................................................. 9

7. PRECOMMISSIONING, COMMISSIONING, START UP & PERFORMANCE TEST .... 11

8. ATTACHMENT............................................................................................................... 13

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PRECOMMISSIONING & COMMISSIONING PLAN

1. OBJECTIVE
This document provides guidance for execution of precommissioning and commissioning
works in AMMONIUM NITRATE PROJECT. In this document describe detail executions
of precommissioning and commissioning activities including readiness/preparation and
acceptance criteria for each activity.

2. TERMINOLOGY & ABBREVIATIONS

OWNER : PT. Kaltim Amonium Nitrat
CONTRACTOR : PT. Wijaya Karya (Persero) Tbk – SEDIN
Engineering Co., Ltd
PROJECT : Ammonium Nitrate Project
VENDOR : is the party, which manufactures or supplies
the equipment and services to perform the
duties specified by the OWNER/CONTRACTOR
Precommisioning : is activities after construction work is
completed and precommissioning team is
responsible to check mechanical, electrical,
instrument, and piping equipment that has been
installed, ready to operated, and appropriate
with engineering design
Commissioning : is a trial implementation activity of all
equipment, system and subsystem that has
been installed. Commissioning team and
operators will operate the equipment and will be
supported by construction team
Mechanical Acceptance : satisfactory completion of mechanical tests for
such individual unit or for the entire PROJECT.
Mechanical Completion : a milestone that marks handover from
precommissioning to commissioning that ready
to start up. Mechanical Completion Test Report

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(MC) for Unit (System) must be submitted to

OWNER before release Mechanical Acceptance
Certificate.
Readiness Demonstration : operation testing of the plant continue for 100
hours to demonstrate and guarantee quantity
and quality of products can be sustained
Performance Test : Integrated testing of all equipment, systems
and subsystems to produce products according
to design capacity (minimum 227 metric tons of
ammonium nitrate per stream day and 182
metric tons of nitric acid per stream day) and the
specifications carried out for 7 consecutive days.
Plant Acceptance : means when facilities and equipment are
considered to be sufficient for the acceptance
after Performance Test are completed.
CONTRACTOR and OWNER shall jointly study
and evaluate the test result and complete
calculations required to determine whether the
Performance Test have been successfully
completed.
Punchlist : Identification, records, monitoring, and
deficiencies in material, installation, fabrication
in construction and precommissioning activities
those are not in accordance with project
specifications. Punchlist items are categorized
into 3 categories.
Warranty Period : warranty period after Plant Acceptance for 365
days and CONTRACTOR must recover
warranty items if any breach happen by
correction or replacement after received
notification from OWNER
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PRECOMMISSIONING & COMMISSIONING PLAN

3. REFERENCES
The procedures take as reference
· Site Quality Control Procedure : AMNIT-QC-100-ITP-1002
· Pre-Commissioning Check Sheet Form : AMNIT-CU-100-LST-1002
· Pre-Commissioning Test Sheet Form : AMNIT-CU-100-LST-1003
· Piping Cleaning Procedure : AMNIT-CU-100-PRC-1012
· Steam Blowing Procedure : AMNIT-CU-100-PRC-1013
· N2 Purging Procedure : AMNIT-CU-100-PRC-1014
· Tightening Procedure : AMNIT-CU-100-PRC-1015
· Leak Test Procedure : AMNIT-CU-100-PRC-1016
· Lube Oil Flushing Procedure : AMNIT-CU-100-PRC-1017
· Motor Solo Run Procedure : AMNIT-CU-100-PRC-1018
· No Load Test Conveyor : AMNIT-CU-100-PRC-1019
· Mechanical Run Procedure : AMNIT-CU-100-PRC-1020
· Mechanical Cleaning & Box Up Procedure : AMNIT-CU-100-PRC-1021
· Instrument Loop Test Procedure : AMNIT-CU-100-PRC-1022
· Electrical Energize Procedure : AMNIT-CU-100-PRC-1023
· Mechanical Completion Procedure : AMNIT-CU-100-PRC-1024
· Commissioning of Diesel Generator Procedure : AMNIT-CU-100-PRC-1025
· Process Description : To be added
· P&ID all System : To be added
· Single Line Diagram : To be added

4. SCOPE OF WORK
General scope of work for precommissioning is to convince that all equipment are ready
to be operated and could start its own function normally. Commissioning performed by
CONTRACTOR based on classification of system and subsystem of this PROJECT.
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PRECOMMISSIONING & COMMISSIONING PLAN

AREA SYSTEM PRECOMMISSIONING COMMISSIONING

200 Nitric Acid WIKA SEDIN
300 Ammonium Nitrate WIKA SEDIN
310 AN Condensate Purification WIKA SEDIN
320 Bagging Storage AN WIKA SEDIN
330 AN Warehouse WIKA SEDIN
430 Power Distribution of Plant WIKA SEDIN
440 Telecommunication WIKA SEDIN
450 Substation WIKA SEDIN
460 Central Control Building WIKA SEDIN
470 PA and IA Station WIKA SEDIN
480 Cooling Water System WIKA SEDIN
490 Water Supply System WIKA SEDIN
500 Plant Water Supply and Drainage WIKA SEDIN
Drainage Pump Station and WIKA SEDIN
510
Emergency Pool
550 Hazardous Waste Warehouse WIKA SEDIN
560 Fire Fighting Equipment & WIKA SEDIN
Automatic Fire Extinguishing
800 OSBL Area WIKA WIKA
Note : System and Subsystem based on EPC contract. Furthermore, it will be updated
during engineering design.

5. COMMISSIONING REQUIREMENTS
Ø Before executing commissioning, make sure that all precommissioning activities
already conducted and all punchlist “A” categories already completed
Ø Commissioning team has been formed consist of leader, engineer, supervisor and
other that involved in commissioning.
Ø During commissioning, plant Ammonium Nitrate Project must be stated closed for all
public activities except who get permission. Identification card (badge) must be used

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PRECOMMISSIONING & COMMISSIONING PLAN

by employees who work in Ammonium Nitrate Project and must be checked by

security before entering plant area.
Ø Commissioning control will be done by CONTRACTOR team and assisted by
OWNER team.

6. PREPARATION BEFORE COMMISSIONING

6.1. HSE and Security
o Before executing commissioning, Job Safety Analysis (JSA) and Permit To Work
must be completed for all activity
o Before executing commissioning, safety organization, emergency response team,
and supporting equipment must be available. Emergency response team must be
trained and know coordination line if there is accident/emergency condition
o Emergency drill has been done
o Before executing commissioning, the safety sign must be installed
o Security team as part of safety team conduct safety function especially for
checking the completeness of employees and visitors before entering plant.
o All operators have to wear Personal Protective Equipment (PPE)
o Fire extinguisher must be available and stand by for all area that already
determined
o Make sure there are no unauthorized people around commissioning area
o Make sure the area of commissioning activities are clear
o Safety officer coordinate with commissioning team for checking all area
o all walkway, platform, handrail, cover, and safety cages have been installed
properly and safe to be used
o Make sure safety guard on rotating equipment has been installed
o Socialization and briefing to ensure all commissioning members know about
detail activity, job description, and JSA before commissioning activity is carried
out
o Conduct LOTO procedure.
· Make sure the equipment is already turned off
· All equipment that is in maintenance, troubleshooting and in not used must be
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PRECOMMISSIONING & COMMISSIONING PLAN

installed LOTO
· The personnel who responsible to conduct LOTO is supervisor and operator.
· Uninstall LOTO only can be conducted by operator/supervisor who installed it
or by someone who already coordinate and have permission from
operator/supervisor who installed it.
6.2. Equipment
o First, check and make sure all equipment are ready for conducted commissioning
activities. Check all report related to installation, erection and precommissioning
work. It must be completed
o All system already energized and ready for running equipment
o Rotation of rotating equipment already checked
o Rotating equipment has been lubricated
o Measurement tools has been prepared for taking data during commissioning
o The measurement tools are already calibrated
o General tools are available for troubleshooting necessity
6.3. Personal
o Make sure that all personnel are in good condition
o All personnel understand about the activity, the risk of the activity and how to
handle the risk
o All personnel must be ready on the location that already plotted
o Each personnel understand their job
o Each personnel know what have to do if any emergency situation happen and
know to coordinate with
6.4. Communication
o Communication system is using handy talky (HT)
o Before executing commissioning, a coordination meeting must be held to
determine the radio channel for each personnel
o Emergency contact must be shared before executing commissioning

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PRECOMMISSIONING & COMMISSIONING PLAN

7. PRECOMMISSIONING, COMMISSIONING, START UP & PERFORMANCE TEST

CONTRACTOR will develop sequence for precommissioning and commissioning
activities in Ammonium Nitrate Project. There will be some stages in execution of
precommissioning and commissioning works in order, according to priority of system and
subsystem in Ammonium Nitrate Project. This sequence will be developed and detailed
during Engineering design.
In general, the sequence of precommissioning and commissioning works will be staged
into following stage :
1. Precommissioning and commissioning of utility systems that would be used by all
other systems, for example power distribution, substation, central control building,
plant air and instrument air, etc.
2. Precommissioning and commissioning of safety system for example, fire fighting
equipment & automatic fire extinguishing
3. Precommissioning and commissioning of other utility systems for example cooling
water system, water supply systems.
4. Precommissioning of process systems for example nitric acid system, ammonium
nitrate system.
5. Commissioning of process systems for example nitric acid system, ammonium nitrate
system.
6. Start Up and Performance Test
All equipment must be ready before introduced with actual media as integrated system
including piping system, mechanical system, electrical system and instrument system. All
those system must be completed. The activities to prepare the plant to be introduced
with actual media are conducted in precommissioning phase. These are activities that
must be accomplished in precommissioning phase :
Piping Mechanical Electrical Instrument
1. Tightening 1. Mechanical 1. Electrical 1. SAT Fire
2. Air Blowing Cleaning and Box Function Test Protection
3. Steam Blowing Up 2. Electrical 2. Loop Check &
4. Leak Test 2. Solo Run Test Energize Function Test
3. Mechanical Run 3. SAT PAGA &
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Test CCTV Telecom

4. SAT Fire Fighting 4. PLC Power Up &
System SAT Testing
5. No Load Test of
Conveyor
6. Commissioning of
Diesel Generator
Beside all above activity, there are some other work that need to be accomplished :
1. Vendor & Training Plan
2. Commissioning & Start-Up JSA Review
3. List of Consumable Spare Parts
In commissioning phase utility system will be operated and run into the plant. Before
conducted commissioning phase, punchlist “A” items must be closed and no issues.
These are activities that must be accomplished in commissioning phase :
1. Logic Test
2. Sequence Test
3. Cause and Effect Test
4. Put Utility System in Service
5. SAT Packages
6. Purging
7. Lock Out Tag Out (LOTO)
After commissioning phase is ready, the plant will be introduced by actual media in
readiness demonstration. This is a phase for tuning the setting of all equipment and
introduced ammonia into the plant by ramp up gradually until the plant could be operated
at the 100% design capacity. These are activities that must be accomplished in
readiness demonstration :
1. Introduced Raw Fluid into the System
2. Mechanical Run Test with Actual Media
3. Conveyor Load Test
4. Fine Tuning
5. Troubleshooting
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PRECOMMISSIONING & COMMISSIONING PLAN

6. Analytical Test Load Test 100% Design Capacity

When the plant are already load tested with 100% design capacity and the result of
analytical test is approved and accepted so, the plant are ready for Performance Test.
The performance test will be conducted for 7 days and must fulfill the acceptance criteria
of performance test. These are activities that must be accomplished in performance test :
1. Performance Test
2. Analytical Test
3. Handover Plant
When the result of performance test is approved and accepted so, the plant could be
handover to OWNER, and milestone Plant Acceptance could be reached then,
PROJECT entering warranty period. CONTRACTOR will prepare one team with one
maintenance advisor for warranty period.

8. ATTACHMENT
Attachment – 1 Precommissioning, Commissioning and Start Up Execution Plan

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ATTACHMENT – 1
PRECOMMISSIONING, COMMISSIONING, START UP, & PERFORMANCE TEST
EXECUTION PLAN

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 PT KALTIM AMONIUM NITRAT
75.000 MTPY AMMONIUM NITRATE PROJECT PLANT

PRECOMMISSIONING, COMMISSIONING AND START UP EXECUTION PLAN

CONSTRUCTION PHASE PRECOMMISSIONING PHASE COMMISSIONING PHASE START-UP PHASE

LEAD BY EPC COMMISSIONING, LEAD BY EPC COMMISSIONING, LEAD BY EPC COMMISSIONING,

EPC CONTRACTOR SCOPE
SUPPORT BY KAN PROJECT AND OPERATION SUPPORT BY KAN PROJECT AND OPERATION SUPPORT BY KAN PROJECT AND OPERATION

Construction Activities Readiness Demonstration Performance Test

Major Activities for Construction Group :
Piping - Piping System and Tie-Ins
- Clean and Erection
- Hydrostatic / Pneumatic Test
- Bolt Torque and/or Tensioning
- Safety Device Installation
- Painting and Insulation Works
Electrical / Instrument - Electrical Tie-Ins
- Mechanical Checks
- Cable Continuity Checks
- Insulation Resistance Test
- Grounding Resistance Test
- Lighting Circuit test
Mechanical - Mechanical Checks
- Rotating Equipment Pre-Alignment
Civil / Structure - Civil / Structure Constructed
- Tightening Flange - Logic Test - Introduce Raw Fluid into the System - Performance Test
- Air Blowing - Sequence Test - Mechanical Run Test with Actual Fluid - Analitycal Test
- Steam Blowing - Cause and Effect Test - Conveyor Load Test - Handover Plant
- Leak Test - Put Utility System in Service - Fine Tuning
- Mechanical Cleaning & Box Up - Packages Commissioning - Troubleshooting
- Electrical Function Test - Purging - Analitycal Test
- Electrical Energize - Lock Out Tag Out (LOTO) - Load Test 100% Design Capacity
- SAT Fire Protection
- Loop Check & Function Test
- SAT Fire Fighting System
- Solo Run Test
- Mechanical Run Test
- SAT PAGA & CCTV Telecom
- PLC Power Up and SAT Testing
- No Load Test of Conveyor
- Commissioning of Diesel Generator
- Vendor & Training Plan
- Commissioning & Start-Up JSA Review
- Consumable Spare Parts

Completion Punch "A" Items Completion Punch "A" Items Completion Punch "B" Items Completion Punch "B" Items Completion Punch "B" Items
MC

MC DOSSIER SUB MECHANICAL COMMISSIONING READINESS PLANT

SYSTEM (MC) ACCEPTANCE DOSSIER DEMONSTRATION ACCEPTANCE
(MA) REPORT (PA)

READY FOR READY FOR READINESS READY FOR

COMMISSIONING DEMONSTRATION PERFORMANCE HANDOVER PLANT