Systems Completion, Commissioning & Startup Execution Plan

Systems Completion, Commissioning & Startup Execution Plan

PRECOMMISSIONING, COMMISSIONING START-UP AND OVERALL SYSTEMS COMPLETIONS EXECUTION PLAN

DANGOTE REFINERY AND POLYPROPYLENE PLANT NIGERIA

Confidential

Description Rev Date

By

Checked

Approved

Issued for Dangote Review

A

Jan 2, 2018

MC

RE

MC

1

Table of Contents 1 INTRODUCTION .......................................................................................................... 1 2 REV1, SERVICE OFFERING SUMMARY .................................................................. 1 3 EXECUTIVE SUMMARY ............................................................................................. 3 4 PURPOSE ..................................................................................................................... 3 5 SCOPE .......................................................................................................................... 3 6 PRE-COMMISSIONING, COMMISSIONING AND START-UP EXECUTION MANAGEMENT ................................................................................................................... 4 6.1 Preparation Phase Organization Chart .................................................................................5 6.1.1 Commissioning Manager ........................................................................................................6 6.1.2 Health Safety Security Environmental Manager (HSSE) ......................................................... 6 6.2 Execution Phase Organization (Please refer to Organization Chart attached) .......................7 6.3 Schedule of Deliverables ......................................................................................................9 6.4 Planning Phase.....................................................................................................................9 6.4.1 Define the Systems ................................................................................................................. 9 6.4.2 Set sub-system limits ..............................................................................................................9 6.4.3 Prepare Commissioning Procedures....................................................................................... 9 6.4.4 Set the CSU sequence logic and milestones .........................................................................10 6.4.5 Prepare Manpower estimates ..............................................................................................10 6.4.6 Prepare the CSU plan............................................................................................................10 6.4.7 Integrate the CSU Plan..........................................................................................................10 6.4.8 Prepare the Leak Testing strategy ........................................................................................10 6.4.9 Prepare Workplace risk assessments ...................................................................................11 6.4.10 Identify Commissioning Management Tools....................................................................11 6.4.11 Populate Commissioning Management Tools..................................................................11 6.4.12 Prepare preservation procedures and schedules.............................................................11 6.4.13 Prepare Vendor attendance plans ...................................................................................11 6.4.14 Prepare plans for SIT/FAT.................................................................................................11 6.4.15 Prepare Sub-Contractor plans ..........................................................................................11 6.4.16 Identify and schedule OR requirements...........................................................................12 6.4.17 Prepare the PSSR Procedure ............................................................................................12 6.4.18 Identify Plant and temporary equipment requirements..................................................12 6.4.19 Identify Commissioning and Start-up spares....................................................................12 6.4.20 Prepare Initial and Final fill schedules..............................................................................12 6.4.21 Prepare Operating manuals .............................................................................................12 6.4.22 TRAINING PROGRAMS......................................................................................................13 6.4.23 Deliverables......................................................................................................................13 6.4.24 Documentation Required from Dangote / EPC (EIL) ........................................................14 6.5 Execution Phase .................................................................................................................14 6.6 Operations Phase...............................................................................................................16 6.7 Continuing Operations .......................................................................................................17

6.8 TrackerDB ® .................................................................................................. 17 6.9 Completions.......................................................................................................................17 6.10 Readiness Reviews and Periodic Audits..............................................................................18 6.11 Reporting ...........................................................................................................................19 7 RESOURCING STRATEGY .......................................................................................21 7.1 Selection and Screening .....................................................................................................21 7.2 Mobilization/ Demobilization ............................................................................................22 7.3 Personnel Mobilization ......................................................................................................22 8 ATTACHMENTS: .............................................................................................................24 9 THE NEXT STEP .........................................................................................................24 10 CONTACTS .............................................................................................................24

1 INTRODUCTION On Nov 29 th 2017 a meeting was held with Mr Shukla, Director (Technology & Eng.) Dangote Oil Refining Company, Martyn Canham, President, Rev1 Oil & Gas and Ricky Erhgott, VP BD, Rev1 Global in AmecFosterWheeler Offices, Houston. The purpose of the meeting was to introduce Rev1 to Dangote Oil Refining Company and for Rev1 to express interest in supplying technology, people and services for the systems completion, pre-commissioning, commissioning, start-up of the Dangote Refinery. Following the presentation, Mr Shukla requested further information on how Rev1 could execute the required workscope. This document contains the execution strategy Rev1 would adopt to deliver the activities leading up to a safe and productive start-up of the refinery. 2 REV1, SERVICE OFFERING SUMMARY Rev1 Oil and Gas is a specialist provider of Commissioning and Support Services, comprising: • Project Execution Strategy and Organizational needs analysis. • Designing a Commissioning Strategy and optimal Commissioning team to deliver a safe and successful commissioning phase of the project. • Establish Key Performance Indicators for Commissioning and periodic reporting. • Proprietary CMS Software, TrackerDB® ensuring Technical Integrity has been achieved on the project and providing management optics on the real-time completion status. • Commissioning execution, Comprising the supply of top industry professionals (Subject Matter Experts) contained under the “People” column below to form a Project Commissioning Team scalable to manage the world’s largest Mega projects. Communication lines, meetings and reports established to ensure real-time management of the Commissioning Phase. • Technical Publications i.e. commissioning, operations, skimps and training manuals, procedures and work instructions, comprising the elements of the ‘Documentation” column below • Commissioning Consultancy services. • Systems Completion Management (CMS)

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• Training, Operator Training through OJT with the Commissioning phase and simulation software, ensuring operators are fully competent on project handover to Operations • A structured, documented and ongoing Competence Assurance process of identifying, defining, assessing, developing, and managing the continuous competence of commissioning personnel to ensure all personnel are highly competent to complete tasks to a determined standard. • Operational Readiness – use of ORA software to ensure the requirements of the

Owner Operator are addressed during the project lifecycle thus validating the Operability and maintainability and overall viability of the asset is achieved.

This time proven model is equally applicable to both Brown and greenfield contacts and scalable to provide a management framework for the largest of Commissioning projects.

3 EXECUTIVE SUMMARY Dangote Group is involved in the Construction of a 650,000 b/d oil refinery in the Lekki Free Trade Zone in Nigeria. The plant will also comprise of a 750,000 tpa polypropylene plant. The refinery will produce 153,000 b/d of gasoline 104,000 b/d of diesel, 73,000 b/d of jet fuel, 4,109 b/d of LPG and 12,300 b/d of fuel oil. The refinery will include a crude distillation unit (CDU), a single-train residual fluid catalytic cracking (FCC) unit, diesel hydrotreating, continuous catalyst regeneration unit, alkylation unit, polypropylene unit, utilities and off-sites, including a captive power plant and infrastructure for a single-point mooring terminal for crude oil and product handling. Construction of a petrochemical complex adjacent to the Dangote refinery includes a new mixed feed cracker with a capacity of 1.1 million tonnes per annum (tpa) of ethylene and 350,000 tpa of propylene. The plant will also include a fertiliser unit, which will produce 2.8 million metric tonnes of assorted fertiliser per annum. 4 PURPOSE The purpose of this document is twofold; i, to explain the role and methodology of Rev1 in the delivery and execution of this project and ii, to ensure a high level of technical knowledge is imparted to the owners from the coordination and management of the Construction, Pre-commissioning, Commissioning and Start up phases, until performance guarantee is achieved. 5 SCOPE Specialist Rev1 personnel shall act on Dangotes behalf to monitor, control and advise in every aspect of the project during the Construction, Pre-Commissioning, Commissioning and Start-up phase of the project. Rev1 specialist personnel shall form an INTEGRATED COMMISSIONING AND ACCEPTANCE TEAM (ICAT) made up with complementary members of the Dangote project management team. Technical Knowledge sharing / transfer to the Client’s personnel will be the core concept along with the On the Job Training (OJT).

6 PRE-COMMISSIONING, COMMISSIONING AND START-UP EXECUTION MANAGEMENT The following is a proven 9 phased approach for the safe and successful Commissioning and Startup of the Dangote project. Phase 1 Prepare and implement plant

and equipment construction/ installation and Hydrotesting Phase 2 Carry out Pre-commissioning: Prepare and check equipment installation, instrumentation and control systems. Phase 3 Prepare and check protection systems, DCS, F&G. Alarms and trips, Loop testing Phase 4 Final preparation – Introduction of catalysts and Inerting. Leak test, Closure of Punch List and System System Mechanical Completion Phase 5 Commissioning plant installation checks and testing Phase 6 Introduction of fluids for equipment Commissioning Phase 7 System/Start-up block Commissioning Phase 8 Charge with Feed Stock and Start-up Phase 9 Performance and Plant Reliability Test and Acceptance

Construction and Pre-Commissioning

Commissioning

Start-up and Testing

6.1 Preparation Phase Organization Chart

DANGOTE REFINERY PROJECT DIRECTOR

COMMISSIONING MANAGER

DEPUTY COMMISSIONING MANAGER

HEAD OF HSSE

DISCIPLINE TEAM LEADER MECHANICAL DISCIPLINE TEAM LEADER ELECTRICAL

ICAT CO-ORDINATOR

ENGINEERING MANAGER

COMPLETIONS TEAM LEADER Rev1

DISCIPLINE TEAM LEADER INSTRUMENTATION

HEAD OF PLANNING

PROCESS TEAM LEADER

HEAD OF UTILITIES & OFFSITES

Rev1 will appoint a Project Commissioning Manager to manage the delivery of completions and commissioning services. The primary responsibilities of the Commissioning Manager will be to ensure that all elements associated with the preparation and execution of completions and commissioning have been fully identified and all deliverables from Contractor(s) made available in a timely manner. Interactions and interfaces with Client and Contractor(s) are adequately managed. The Commissioning Manager will call on the Rev1 functions in Houston / Abu Dhabi / Nigeria / India to support the provision and execution of services including: • Technical resourcing

• Technology • Operations

A key role of the Commissioning Manager will be to maintain communication and meet with the Company representatives on a regular basis with regards to monitoring and advising in every activity of the project.

6.1.1 Commissioning Manager

This position reports to the Project Director and is responsible for the implementation of the schedule, physical commissioning and preparing for Handover of all systems. Leads development of the strategies, execution plan and procedures that are aligned with Start-Up strategies. Coordinates/supervises the activities of the Commissioning Discipline Engineers. Is responsible for coordinating and executing activities required by the Plan. Manages interfaces between EPC Contractors to facilitate successful commissioning and handover. This position reports to the Project Director and is responsible to: • Coordinate and assist to resolve among the various project teams and contractors on any technical HSSE requirements regarding commissioning and operation issues • Ensure all works are executed in compliance with Company’s requirement covering HSSE, quality and technical requirement within the framework of the contract • Support Project Director / CSU Manager to develop and review to ensure all relevant HSSE documents & procedures are in place for all stages of commissioning and start up • Review MOPO / SIMPOPS prior to and during handover to operations • Ensure Leaders are held accountable for demonstrating correct HSSE behaviors, by clearly defining HSSE specific roles and responsibilities, by 6.1.2 Health Safety Security Environmental Manager (HSSE)

providing needed resources, and by measuring, reviewing and continuously improving HSSE performance. • Establish Project HSSE audit program & schedule and perform the Project HSSE Audits as described in the project execution plan (PEP) • Act as company focal point to ensure that the administration of the Rev1 contract is maintained to the highest level, both from a financial and personnel perspective. • Ensure that Rev 1 complies with its corporate social responsibility during the comMarisha01 • plete project which will include the engagement of local support staff in accordance with local content guidelines. 6.2 Execution Phase Organization (Please refer to Organization Chart attached) For each role identified, Rev1 will provide a role specific Job Description (JD) which outlines the role and responsibilities of the individual within the proposed organization. In addition, the JD will identify the required level of qualification, experience, competencies and primary objectives of the role.

6.3 Schedule of Deliverables The Completions, Pre-Commissioning, Commissioning and Performance testing activities identified and planned to be executed in three discrete phases and these phases are defined as follows:

• Planning Phase • Execution Phase • Operations Phase Commissioning Delivery Plan

6.4 Planning Phase

During the planning phase, as illustrated on the Delivery Map the Commissioning deliverables will be developed in a logical and systematic manner by Commissioning professionals and will comprise of the following activities:

6.4.1 Define the Systems

The main Systems will already have been set by the Design Engineer. These Systems will be reviewed and checked by the ICAT and if necessary adjusted or reset for CSU purposes. This activity also allows for a set of specific identifiers for Commissioning and Start-up to be developed.

6.4.2 Set sub-system limits

Where practical, limits for sub-systems are identified to break down the Commissioning schedule into smaller, manageable blocks of work that will help to optimize the Commissioning program. This is performed on PFDs, or if available P&IDs.

6.4.3 Prepare Commissioning Procedures

Develop Procedures in the agreed formats to derive the detailed commissioning activities for the overall Project; this includes the subsequent handover of responsibilities from one group to the next. The procedures are broken down into subsystems where meaningful commissioning can be achieved on part systems.

6.4.4 Set the CSU sequence logic and milestones

Once the Commissioning Systems and sub-Systems have been identified and the equipment allocated to them, this should give enough detail to work out the CSU sequencing and priorities. From the details prepared by the preceding activities, an initial logic for Commissioning and Start-up is prepared by System and sub-System showing sequences, predecessors, successors and concurrences for each of the systems identified. Milestones are also identified at this stage.

6.4.5 Prepare Manpower estimates

From the details contained within the Commissioning Procedures, manpower estimates are generated to determine how many and what type of operatives will be required to complete the activities listed.

6.4.6 Prepare the CSU plan

The CSU Plan uses the logic to list the activities that are aimed at proving either the functionality of the design or the correct installation of Plant and equipment such that it meets the Project acceptance criteria and the sequence of events required to be executed to reach a safe and effective plant start-up. Associated with this plan is a manpower estimate and a cost estimate. These will be prepared using standard norms for estimating and expected costs for the manpower. The completed CSU Plan illustrates which Systems and sub-Systems are to be commissioned and started up safely in the optimum sequence and has resources and durations allocated to show manpower requirements for each activity.

6.4.7 Integrate the CSU Plan

When the CSU plan has been developed, it will be integrated with the interfacing departments and Engineering, Construction and Operations to ensure that the plan fits with the sequence of activities of these parties, is achievable and can meet all the required milestones.

6.4.8 Prepare the Leak Testing strategy

Using the CSU marked-up drawings, work out the boundaries for leak testing hydrocarbon systems and sub-systems, noting that there may be requirements for additional isolations, vents and drains and break flanges.

6.4.9 Prepare Workplace risk assessments

Preparation of Safety and Workplace risk assessments for each Commissioning procedure to ensure that occupational safety is not compromised during completion and testing activities.

6.4.10 Identify Commissioning Management Tools

Review the availability of tools for helping the management of Commissioning and Start- up and recommend which of these will be of use to the Project.

6.4.11 Populate Commissioning Management Tools

Set up and populate the chosen Commissioning Management tools with the required >Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28

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