PREPARATION INSTRUCTION FOR

EQUIPMENT START-UP AND

COMMISSIONING N I O C
Pars Oil and Gas Company

EQUIPMENT NAME: Filtration Package

DOCUMENT TITLE: Preparation Instruction for Equipment Start-up and Commissioning

Code1 (Approved ) Vendor to submits " For Final"

(No comment & release for manufacturing)

Code2 ( Approved with comments) : Vendor shall

correct / revise & resubmit it as " For Final "
(Released for manufacturing if change
incorporated as indicated)

Code3 (Commented) : Vendor shall correct / revise &

resubmit . It as " For Approval" of the date
specified : ( Corrected documents to be
resubmitted before starting manufacturing )

Code4 Not Acceptable quality (Reject)

The above checking result by OIEC shall in no way relieve Vendor

of any liability, obligation and responsibility out of the purchase
order and the mutual agreement in writing

Date: 05-11-2014
Dept: Machinery
OIEC – SP20 &21 Signature: M.Asgari
Only for internal review
CV PI EL IN ME MA

ST BU PR SA HV TL

1 23.09.14 ISSUED FOR APPROVAL NARA VM MKG

0 08.08.14 ISSUED FOR APPROVAL NARA VM MKG

REV. DATE DESCRIPTION PRE’D CHK’D APP’D

SOUTH PARS GAS FIELD CONTRACT NO.: POGC 572-88-35

DEVELOPMENT (PHASES 20&21),
ASSALUYEH, IRAN
REQ’N NO.: MR-SP2021-ON-MA-0700-0029
ONSHORE FACILITIES

ITEM NO.: 101-U-102/202/302/402 & 116-U-112/212

DrM DOCUMENT NO.: VP-SP2021-ON-MA-0700-0029-0200

VENDOR NAME: Dr. Müller AG

 PREPARATION INSTRUCTION FOR
EQUIPMENT START-UP AND
COMMISSIONING N I O C
Pars Oil and Gas Company

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Section 1 – Reference Documentation

Listed below are the reference documents applicable to this

procedure. All approved Code 1 version of the following documents
shall be used.

1. INSTRUCTION and DRAWING FOR SITE ERECTION INCL.

LIFTING PROCEDURE - VP-SP2021ON-MA-0700-0029-0180

2. PIPING and INSTRUMENT DIAGRAM Units 101-U-

102/202/302/402 - VP-SP2021-ON-MA-101-U-102-2120

3. PIPING and INSTRUMENT DIAGRAM Units 116-U-112/212 - VP-

SP2021-ON-MA-116-U-122-2130
U112

4. PROCESS DESCRIPTION AND DESIGN BASIS - VP-SP2021ON-

MA-0700-0029-2140

5. PROCESS CONTROL PHILOSOPHY (INCL. INTERLOCK AND

SAFETY SYSTEM FUNCTIONS) – VP-SP2021ON-MA-0700-0029-
2150

6. SEQUENCE LOGIC DIAGRAM - VP-SP2021ON-MA-0700-0029-

2180

7. SHUTDOWN MATRIX - VP-SP2021ON-MA-0700-0029-2190

8. CAUSE & EFFECT MATRIX - VP-SP2021ON-MA-0700-0029-2200

9. INSTALLATION OPERATION AND MAINTENANCE MANUAL

(Package) - VP-SP2021ON-MA-0700-0029-0230

10. LUBRICANT LIST WITH SPECIFICATION - VP-SP2021ON-MA-

0700-0029-0100

11. INSTRUMENT LIST Units 101-U-102/202/302/402 - VP-SP2021ON-

MA-101-U-102-1680

12. INSTRUMENT LIST Units 116-U-112/212 - VP-SP2021ON-MA-116-

U-112-1690
Section 2 – Requirements to be fulfilled prior to start-up

Listed below are the requirements and the level of readiness required
prior to start-up of the Amine Filtration package.

1. All activities mentioned in document number VP-SP2021ON-

MA-0700-0029-0180 (Instruction & Drawing for site erection
including Lifting procedure have been completed.

2. All equipment upstream and downstream of the Amine

Filtration package is ready for operation.

3. All piping battery limit connections to the Amine Filtration

package are completed.

4. All temporary transportation supports have been removed

from the Amine Filtration package (Carbon Column, Filter
vessel discharge butterfly valve etc..)
5. All Instrumentation multi-pair signal cables have been
connected from the Control system to the Junction boxes
and Local Control Panel mounted on the Amine Filtration
system.

6. All electrical power cables have ben connected to the

electrical consumers

7. All lighting on the Amine Filtration package is connected

and functional

8. All fire and gas detection for the Amine Filtration system is
functional, prior to start of commissioning.

9. All earthing relevant to the Amine Filtration package (Plant

dirty earth, electrical earth and clean instrument earth) has
been completed and checked for resistance and
continuity.

10. Relief valves any other safety equipment, outside the

battery limit of the Amine Filtration package, are correctly
installed.

11. All utilities required for the Amine Filtration package are
operational and available (Instrument air, Plant air,
Nitrogen, Electric Power supply, Instrument Power supply,
Utility water etc..)
12. The Control Logic has been programmed in the Control
system based on Code 1 Approved documents.

13. Fundabc®Filter Internals, Filter Aid, activated carbon and

Cartridges for the Cartridge filter are available for use and
have been stored in the site warehouse as per guidelines in
the instruction manuals.

14. Crane with a minimum lifting capacity of 2000 kgs is

available for installation of the Filter Internals and other
equipment.

15. Calibrated torque wrenches covering the range from 20 Nm

to 200 Nm are available

16. All necessary instrumentation and electrical test equipment

for pre-commissioning (Spanner, screw drivers, Ammeters,
Voltmeters, Noise tester, portable temperature and pressure
gauges, HART communicator etc..)

17. All lubricants required for first charge as per lubricant list are
available. First fill of lubricants, first fill of Precoat material
and first fill of activated carbon are included in DrM’s scope
of supply.

18. A clean and leveled table of 2 metres by 3 metres is

available for preparation of the installation of the Filter
internals.

19. The following manpower with knowledge of English

language is available.

Construction supervisor for co-ordination of all activities

Responsible Process Engineer
Plant operator(s)
Electrical technician
Instrumentation technician
Mechanic
Control System programmer
Crane operator
Fitters and helpers
Section 3 – Checks and activities prior to start-up

1. Listed below are the various checks and activities to be

performed prior to start-up of the Amine Filtration package

2. Perform a P&ID check of the Amine Filtration package

against Code 1 approved P&IDs.

3. All piping connections to be verified for correction

installation and tightness

4. Installation of Pre-commissioning strainer at the inlet of the

Precoat pumps should be verified, to prevent damage to
pump impeller from any debris in the system.

5. Installation of the Agitator in the Precoat tank to be verified

for correct installation as per relevant approved Code 1
drawings.

6. Correct installation of the rupture disc across the Carbon

column bed plate should be verified.

7. Check that all valves are installed with correct flow direction
as per the approved Code 1 P&ID.

8. All piping should be flushed with water at 4 barg to remove

any debirs from the system. Prior to start of this activity all
instruments should be isolated to prevent any damage
during the flushing operation.

9. A low pressure water leak test should be carried out on the

piping and vessels at 3 barg to identify any leaks in the
system. Any leaks identified should be eliminated by
tightening of the affected flanges. After elimination of all
leaks the test should be continued and the pressure should
hold at 3 barg for a minimum duration of 30 minutes. The
leak test should be carried on the entire filter package as
one system. The filter package (piping and vessels) should
be filled with the necessary of volume of water and then
pressurized with a hydraulic pump to reach the required test
pressure of 3 barg. Site utility water used for back washing of
the carbon column can be used for this test.
10. Flush the instrument air header, all pneumatic and impulse
tubing to get rid of any dust or debris for the instrument air
piping and tubing for the Amine Filtration Package

11. Check tightness of all pneumatic and impulse tubing

connections for actuated ON/OFF valves and control
valves.

12. Perform a low pressure test with air at 2 barg for all
pneumatic tubing and check all pneumatic and impulse
connections for leaks with soap solution. Tighten any leaks
identified. The pressure test should be continued after
tightening of all leaks for a minimum duration of 30 minutes
to verify that test pressure holds at 2 barg.

13. Apply normal instrument air pressure as per Project

specifications and verify the pressure regulator settings for
all ON/OFF and Control valves at 4 barg.

14. Verify completion of cabling for all instruments (from

Instruments to Junction boxes and from Junction boxes to
Control room) and electrical equipment.

15. Verify lubrication and oil levels for all rotating equipment as
per relevant Instruction Manuals and Lubricant list.

16. DrM Commissioning technician should verify that the

packages containing filter internals, Cartridge Filter
Cartridges, Active Carbon and Filter Aid have been
correctly stored as per guidelines in the Instruction manuals.

FILTER INTERNALS – CAUTION !!!

1. DO NOT attempt to install the internals to Fundbac®Filters.

This will be
conducted under supervision of a DrM Commissioning
technician during pre-commissioning.

2. DO NOT attempt to fill the Carbon Filters. This will be

conducted under supervision of a DrM Commissioning
technician during pre-commissioning.

3. DO NOT attempt to install the internals to Cartridge Filters.

This will be
 conducted under supervision of a DrM Commissioning
technician during pre-commissioning.

Any attempts made by non-DrM personnel with reference

to installation of the filter internals, as listed in the three
points above, will nullify with immediate, the warranty /
guarantee of the Amine Filtration packages. DrM will NOT
accept any liability or responsibility resulting from non-
compliance to these guidelines.

17. Installation of Filter cloth on Filter candles, connecting filter

candles to Filter Registers and installation of registers in the
Fundabac®Filter vessel should be carried out under strict
supervision of DrM Commissioning technician

18. Installation of Cartridges in the Cartridge Filter should be

carried out under strict supervision of DrM Commissioning
technician

Section 4 – Pre-commissioning activities prior to start-up

1. Listed below are the various pre-commissioning activities to be

performed prior to start-up.

2. Perform continuity test for the Valves, limit switches and

Instruments. Check proper isolation of ground shield and signals.

3. Perform earthing checks (resistance check and continuity

check) for equipment and skid earthing (Plant dirty earth)
instruments (Clean earth) and electrical equipment (Electrical
earth).

4. Verify instrument ranges on the field instruments and Control

system with Code 1 Approved Instrument lists

5. Perform software simulation of the Amine Filtration package

control logic in the Control system in accordance with Code 1
approved process documentation.

6. Perform loop checks from the Control system to verify operation

of valves and instrumentation.

7. Pre-commissioning of Precoat pump to be performed as follows.

Check that commissioning strainer is installed at the pump inlet.
Remove coupling between Pump and motor shafts. Perform a
 no load test of the motor for 30 minutes, check for current
consumption, temperature rise, noise and direction of rotation.
Proceed with installation of the coupling and a load test of the
Pump with the Precoat tank as the feed to the Pump with at
least 80% liquid level. The Pump should recirculate through the
Precoat tank and check for Pump vibration, discharge pressure,
temperature and noise. Maintaining 80% level in Precoat is a
must to ensure adequate NPSH and back pressure on pump.
Load test duration should be a minimum of 30 minutes.

8. Perform a load test of the agitator, with at least 50% level in the
Precoat tank for a duration of 30 minutes. Check for current
consumption, temperature and noise during the test.

9. Charging of the carbon column with active carbon should be

carried out as follows. Fill Carbon column to approximate 50%
capacity. Then introduce activated carbon. While handling
activated carbon ensure that the breakage of the carbon
particles is avoided as carbon fines can block the Cartridge filter
during normal operation. Keep adding active carbon till Carbon
column level reaches 100% and drain off excess water. Once the
filling of active carbon is completed, back flush the carbon
column at 7 barg and low flow for 4 hours so that the carbon
fines are eliminated and the active carbon is uniformly
distributed on the carbon bed. Leave the manhole on the
carbon column open for 12 hours to allow any air trapped in the
suspended carbon bed to bubble out.

10. A wet function test of the Filtration system should be carried out
as follows. Amine Feed tank and Amine feed pumps upstream of
the Amine Filtration package should be used. Amine Feed tank
should be filled with water. Water from Amine feed tank should
be used through Amine feed pumps to Filter and filtered water
should be transferred to Amine storage tank downstream of the
Amine Filtration package. Check functionality of all equipment in
the package, during this test and verify correct functioning of
sequence from DCS.

General Notes applicable to the above Procedure

1. DrM will only send it's Commissioning Technician to carry

out the above activties. All other resources required for this
work, such as testing instruments, tools, tackles, additional
manpower etc. are excluded from DrM's scope of supply.
2. It should be noted that the above activities have to be
carried out by site personnel under supervision and
monitoring of DrM’ Commissioning technician.

3. Some of the activities listed above can be carried in

parallel.
4. The sequence in which the activities have been listed
above, is not necessarily the sequence to be followed. The
sequence of activities and completion of parallel activities
shall be in accordance with DrM commissioning
technician’s instructions.
5. There are no special tools required for the start-up and
commissioning.