D.

Commissioning manual: -
● What procedures are available covering all commissioning activities?
● Is there a commissioning procedure index?
● Is there a commissioning procedure completion plan with clear
responsibilities identified?
● How is progress on the procedure completion plan reported?
● Is there a project approved revision control system in place?
● Is the procedure layout including space for sign off upon completion and/or
for regulatory witness sign off?
● Do they include Piping and Instrumentation Diagrams (P & IDs)
commissioning boundary limit markups?
● Who has reviewed the procedures and how is it controlled?
● Do the procedures include a prerequisite list?
● Do the procedures include a safety section?
● How was the various discipline input covered by responsible engineer?
● Where is the master controlled copy kept?
E. Planning philosophy/procedure.
F. Punch List procedure.
G. Progress reporting structure.
H. Commissioning (Design) query system.
I. Permit to work system.
J. Electrical isolation.
K. Mechanical isolation
L. Commissioning jumper/bypass log system.
M. Blinding list log.
N. Operation and Maintenance (O & M) manual.
Contents: -
1. Why is this important?
2. When should this be done?
3. Who should do this?
4. What should be done?
6. Preparation of operating manual general index and instructions: -
7. Basic considerations in preparing operating manuals.
8. The content of the Operations and Maintenance (O & M)Manual providing the
overview of the complete installation and covering individual systems,
equipment and material installed by Contractor shall include but not limited to: -
8.1 INTRODUCTION.
• Phase I) Basic Design Stage (Containing 7 Standards).
• Phase II) Detailed Design, Engineering and Procurement Stages (Containing 2
Standards).
• Phase III) Start - Up Sequence and General Commissioning Procedures
(Containing 2 Standards).
8.2 SCOPE.
8.3 REFERENCES.
8.4 DEFINITIONS AND TERMINOLOGY.
8.5 SYMBOLS AND ABBREVIATIONS.
8.6 UNITS.
8.7 FORMAT: -
1 original and 4 copies of each O & M manual shall be provided.
• General In principle.
• Covers and Size: -
•• Language.
• Titles.
• Dividers.
8.8 NOTEWORTHY POINTS: -
• General
8.9 CONTENTS OF OPERATING MANUAL: -
• Chapter Design Basis.
• Chapter Process Description: -
•• Nature of Process.
•• Process of flow.
• Chapter Operating Variables and Controls.
• Chapter Auxiliary Systems.
• Chapter Utility System operating manual.
• Chapter Equipment operation.
• Chapter Instrumentation and Control.
• Chapters Start - Up and Shut – Down.
• Chapter Normal shutdown procedures & Emergency Shut - Down Procedure):-
•• Normal shutdown procedures.
•• Emergency Shutdown Procedure:
• Chapter Miscellaneous Procedures.
• Chapter Health, Safety & Environment System operating manual: -
•• Health.
•• Safety.
•• Environment.
•• Safety manual/Quality manual.
 • Chapter Analytical Tests.
• Chapter Catalysts, Chemicals, Packing, lubricant oil, filters and …
• Chapter Drawings.
• Validation: -
9 APPENDICES.

Operations and Maintenance (O & M) manuals are central to training the Owner's
operating personnel in advance of the commencement of Commissioning and Start-
up activities. Operation Manuals describe each system's made of operations, and the
Overall Plant Operating and Maintenance philosophy. In addition to Operations and
Maintenance (O & M) manuals, owners sometimes procure generic and/or custom
built Operator Training Simulator(s) to ensure that process Operators are well trained
ahead of Start - up.
This will be produced by the Contractor as construction/installation proceeds and
reviewed by the Designer. It will be 90% complete prior to start - up inspections.
During the commissioning stage, all missing data will be added, so that it will be
100% complete prior to issuance of the Interim Certificate. During the Warranty
Period, it will be refined as required. This manual will be organized so that keeping it
up - to - date will require minimum time and resources
1. Why is this important?
▪ A manual that describes key components and systems within the building(s) and
explains how they should be operated and maintained will help ensure that the
 project fulfills its promise to its occupants and to its community.
▪ The team that designs and develops the building, especially if the team includes
the property manager, is in the best position to describe its efficient operation and
maintenance, and to create the manual over the course of the entire development
process.
2. When should this be done?
▪ After construction is complete but before the project is occupied.
▪ Prior to commencement of the Tests on Completion, the Contractor shall supply
to the Engineer provisional operation and maintenance manuals in sufficient detail
for the Employer to operate, maintain, dismantle, reassemble, adjust and repair the
Plant.
▪ The Works shall not be considered to be completed for the purposes of taking -
over under Sub - Clause Taking Over of the Works and Sections until the
Engineer has received final operation and maintenance manuals in such detail, and
any other manuals specified in the Employer's Requirements for these purposes.
3. Who should do this?
The owner/developer, the design team, the Contractor and the property manager.

4. What should be done?

▪ Identify key design elements, systems and materials that are critical to long term
quality and performance of your project: e.g. exterior wall and roof materials,
windows, exterior doors, landscaping, key mechanical equipment.
▪ Develop or collect any available operation and maintenance information/manuals
on each of these components. (Much of this information will already exist and
simply needs to be assembled.)
▪ Ensure that all materials: as - built drawings, final finish schedules and plans, and
all warranties, guarantees and certifications that are contractually owed to you are
collected from your design team and your Contractor before final payments are
made.
▪ Aggregate this information into a single resource that can be used by residents and
management personnel to guide overall O & M activities.
▪ If possible, create one or more “to do” checklists that synthesize key
recommendations in the collected material; i.e. what to do and when.
▪ Print out the Operation and Maintenance Manual Checklist Form and list all the O
& M materials and manuals that you have collected. Add the list to the Project
Book and include it in the O & M manual.
▪ If a “to do” list has been developed, add it to the Project Book and the Operations
and Maintenance (O & M) Manual as well.
5. How will doing this help move project forward?
• Effective operation and ongoing maintenance are critical to the long term viability
of any project.
• By making these activities easier to understand - especially by outlining what to
do when - an operations manual can help ensure that your project is efficiently
operated and well maintained long into the future.
6. Preparation of operating manual general index and instructions: -
• Documentation preparation: This process begins of assembling project
specific operation manual and training program, during this step the structure and
organization of the operation manual and draft training
agendas are developed.
• Collection and organization of basic materials are carried out during this time.
• Documentation review: As operation materials and training agendas are collected,
organized and assembled into their preliminary formats, review of this material is
undertaken.
• During this time, project specific documentation is added and the basic manuals
are developed along with training outlines.
• Draft Documentation: drafts submitted to design team and/or owner's
representative for review and comments.
• Emphasis is on verifying completeness, organization and that content is project
specific.
• Final Documentation: submitted after incorporating comments for review of drafts
manuals'.
• Final operation manual is ready for use.
7. Basic considerations in preparing operating manuals.
• Non - licensed Processes: -
- Purpose The purpose of an operating manual is not only to help the
operation engineers and staff at the customer side to operate the plant
safely, but also to present all detailed procedures for the plant start - up
and shut down in the various operation cases.
- Extent of description: -
-- Operating manuals should contain all operating procedures, guidances, hints,
cautions and troubleshooting guides necessary for plant safe and correct
operation.
-- The detailed operation procedures should also include the sequence of valve
operation, time schedule…etc.
-- The Contractor should carefully study the past history of troubles
experienced and counter measures, employed in similar processes and
provide and provide the latest instructions.
 -- Abnormal levels of operating variables (temperature, pressure, flow rate,
fluid level in vessel…etc.) together with appropriate countermeasures should
be listed in the operating manual as far as possible to avoid similar troubles.
- Final check of operating manual: -
-- Operating manual should be checked carefully against project design
document latest revision.
-- The operation philosophy or operation notes which were prepared at
the early stages of the basic design shall be reviewed.
-- The necessary facilities, equipment, instruments and lines…etc., for
each operation mode (namely start - up, normal shutdown,
emergency, regeneration, maintenance…etc.) must be taken into
consideration.
• Licensed Processes: -
- Detail designer shall prepare an operating manual for the Licensed Unit
in accordance with the conditions stipulated in this Standard for non -
licensed Units and based on the contents of operating manual furnished
by the Licensor.
All modifications/changes resulted from the detailed engineering activities
should be reflected in the final revision of the operating manuals.
- Before making any unavoidable modifications/changes by the
Contractor, it is necessary to obtain the approval of the process licensor.
• Documentation preparation: This process begins of assembling project specific
operation manual and training program, during this step the structure and
organization of the operation manual and draft trainingagendas are developed.
• Collection and organization of basic materials are carried out during this time.
• Documentation review: As operation materials and training agendas are collected,
organized and assembled into their preliminary formats, review of this material is
undertaken.
• During this time, project specific documentation is added and the basic manuals
are developed along with training outlines.
• Draft Documentation: drafts submitted to design team and/or owner's representative
for review and comments.
• Emphasis is on verifying completeness, organization and that content is project
specific.
• Final Documentation: submitted after incorporating comments for review of drafts
manuals'.
• Final operation manual is ready for use.
8. The content of the Operations and Maintenance (O & M)Manual providing the
overview of the complete installation and covering individual systems,
equipment and material installed by Contractor shall include but not limited to: -
8.1 INTRODUCTION.
The Standard Practice Manuals titled as "Fundamental Required for the Project
Design and Engineering" is intended for convenience of use and a pattern of follow -
up and also a guidance.
These Standard Engineering Practice Manuals also indicate the check points to be
considered by the process engineers for assurance of fulfillment of pre - requisitions
at any stage in the implementation of process plant projects.
It should be noted Company Standards, as Practice Manuals do not profess to cover
all stages involved in every process project, but they reflect the stages that exist in
general in process projects of oil, gas and petrochemical industries.
These preparation stages describe the following and related standard three main
phases which can be distinguished in every project & include, but not be limited to: -
• Phase I) Basic Design Stage (Containing 7 Standards): -
 - STANDARD TITLE: -
-- Basic Design Package & Recommended Practice for Feasibility Study.
-- Process Flow Diagram.
-- Layout and Spacing (Basic Engineering Design Data).
-- Piping & Instrumentation Diagrams (P&IDs).
-- Performance Guarantee.
-- Numbering System.
• Phase II) Detailed Design, Engineering and Procurement Stages (Containing 2
Standards): -
- STANDARD TITLE: -
-- Detailed Design, Engineering and Procurement.
-- Plant Technical and Equipment Manuals (Engineering Dossiers).
• Phase III) Start - Up Sequence and General Commissioning Procedures
(Containing 2 Standards): -
- STANDARD TITLE: -
-- Start - up Sequence and General Commissioning Procedures.
-- Plant Operating Manuals.
This Engineering Standard Specification covers.

8.2 SCOPE.
This Engineering Standard covers the minimum requirements of format, in preparing
process and/or utility units operating manuals, including essential instructions and
points of noteworthy.
The purpose of this Manual is to standardize the content and format of operating
manuals which shall be prepared by the Contractor. Although operating manuals
differ to some extent from process to process, the basic philosophy and general
aspects shall conform to the concepts of this Standard.
8.3 REFERENCES.
Throughout this Standard the following dated and undated standards/codes are
referred to. These referenced documents shall, to the extent specified herein, form a
part of this standard. For dated references, the edition cited applies. The applicability
of changes in dated references that occur after the cited date shall be mutually agreed
upon by the Company and the Vendor. For undated references, the latest edition of the
referenced documents (including any supplements and amendments) applies: -
• Basic Design Package & Recommended Practice for Feasibility Study.
• Process Flow Diagram.
• Detailed Design, Engineering and Procurement.
• Process Design of Plant Waste Water Sewer Systems.
8.4 DEFINITIONS AND TERMINOLOGY.
• Company or Employer/Owner: Refers to one of the related affiliated companies
of the petroleum industries
• Contractor: Refers to the persons, firm or company whose tender has been
accepted by the Employer, and includes the contractor’s personnel representative,
successors and permitted assigns.
• Project: Refers to the equipment, machinery and materials to be procured by the
Contractor and the works and/or all activities to be performed and rendered by
the Contractor in accordance with the terms and conditions of the contract
documents.
• Units: Refer to one or all process, offsite and/or utility units and facilities as
applicable to form a complete operable refinery/and or plant.
8.5 SYMBOLS AND ABBREVIATIONS.
8.6 UNITS.
This standard is based on international system of units (SI), as per Company except
where otherwise specified.

8.7 FORMAT: -
1 original and 4 copies of each O & M manual shall be provided.
• General In principle, a separate operating manual shall be prepared for each
process and/or utility unit. However, in the case of short volumes, operating
manuals for two or maximum three units can be integrated into one book upon
approval of the Company. The compiled operating manuals should consist of
related units, where possible.
• Covers and Size: -
•• Language.
The ruling language shall be in Local and/or English language. However from
time to time the Company may instruct that certain correspondence…etc. The
format of operating manuals shall essentially conform to company requirements.
Note: The quality of operating manual (binding, cover, paper…etc.) shall be
approved by the company. For covers, type and size and color of titles and any
other characters, shall be approved by company.
• Titles: -
•• The manual shall be named as Operating Manual.
 •• The titles on the front cover shall include: -
••• Company name and logo.
••• Project name.
••• Printing of Operating Manual.
••• Plant or unit name.
••• Lant or unit number.
••• Contractor(s) name and Logo.
••• Contract number.
••• Document number.
••• Date, it shall be referred to the month and year of the plant commissioning
date.
•• A typical arrangement of the front cover titles is illustrated in typical front
cover title
•• The titles on the bottom cover shall include all requirements as outlined in The
titles on the front cover above presents a typical arrangements of the bottom
cover titles.
• Dividers should be: -
•• Provided to separate each chapter with appropriate designations of the
concerned subject.
•• Provided to separate each chapter with appropriate designations of the
concerned subject.

8.8 NOTEWORTHY POINTS: -

• General
- Generally, the necessary documents providing a guide to operation comprise: -
-- Operating manual.
-- Analytical manual.
-- Vendor’s instruction manuals.
-- Safety manual. Vendor’s Instruction Manuals have priority over the
operating manual prepared by the Contractor in order to place the
responsibility for maloperation on the Vendors.
- The following figures and tables to be inserted in the operating manual for the
operator’s convenience and easy comprehension: -
-- Figures: -
--- Trip sequence (flow) diagram.
--- Simplified flow scheme of plant heat-up.
--- Simplified flow scheme of catalyst reduction, activation, oxidation and
regeneration (generally, for Licensed Units).
 --- Simplified flow scheme of feed cut - in, shutdown and other operation
modes.
--- Furnace drying curve.
--- Other charts as needed.
-- Tables: -
--- Pressure relief valves load summary tables.
--- Setting point list for instruments (especially alarm and trip elements).
--- Analytical schedule.
--- Utility summary tables.
--- Heat and material balance tables.
--- Major Equipment Specification Summary.

8.9 CONTENTS OF OPERATING MANUAL: -

• Chapter Design Basis: -
•• Capacity.
•• Duty of plant.
•• Plant design, normal and turn down capacity.
•• Feedstock & Products and byproducts specifications: -
- Type and source of feed and unit different operating modes to be specified.
- Molecular weight and composition.
- Sulfur and/or mercaptane {in mass% or mass parts per million, (ppm)
(mg/kg)}.
- Any specific characteristic {e.g., Paraffinic, Olefinic, Naphthenic, and
Aromatic (PONA test)} of feed for Licensed Units.
- Vol % on feed (for products).
- ASTM distillation curve {Initial Boiling Point (IBP) through Final Boiling
Point (FBP)}.
 - American Petroleum Institute (API) (Sp Gr at 15.6°C) for oils and/or
relative mass density for non - oils.
- Universal Oil Products Factor (UOP K)…etc.
- Characteristics of Products Where Applicable: -
-- Reid Vapor Pressure (RVP), kPa (abs.).
-- Flash point, °C.
-- Viscosity at 2 temperatures, Pa.s.
-- Pour point, °C.
•• Effluent summary shall cover all unit effluents except those streams consider
as the unit products/byproducts and shall include the following streams where
applicable: -
- Sour water.
- Oily water.
- Spent caustic solution.
- Chemical sewer.
- All other disposed liquid and solid wastes.
The following characteristics for each effluent shall be specified: -
-- Quantity, kg/h and/or m3/h.
-- Impurities such as H2S, NH3, Oil, Cl - , Na + …etc. in ppm (wt),
(mg/kg)
-- Sources including all equipment involved.
-- Destinations such as oily water sewer, non - oily water sewer, chemical
sewer…etc.
Any health, environmental or safety hazard associated with the effluent.
Note: All waste items disposed to environment.
•• Maintenance instructions.
•• Battery limits conditions.
•• Specifications and consumptions of utilities, chemicals and catalysts.
•• Heat and material balance tables: -
- Characteristics of each stream (e.g. Enthalpy).
•• Utility conditions shall cover: -
- Operating pressure and temperature.
- Application of each type for all utilities concerned in the plant.
•• Utility summary tables shall be provided separately for summer and winter
operating cases: -
- Item number.
- Service.
- Load BKW (BHP), kW.
- Electrical power, kW.
- Steam, 1000 kg/hr.
 - HP steam, pressure in, bar (g): -
-- MP steam, pressure in, bar (g).
-- LP steam, pressure in, bar (g).
-- LLP steam, pressure in, bar (g).
-- Condensate, 1000 kg/h
-- Cold Cond., Pressure in, bar (g).
-- HP hot Cond., Pressure in, bar (g).
-- LP hot Cond., Pressure in, bar (g).
-- LLP Hot Cond., Pressure in, bar (g).
- Boiler Feed Water (BFW) 1000 kg/hr.
- Pure demineralized water, 1000 kg/hr.
- Loss {(Steam, Condensate, Boiler Feed Water (BFW)...)},
1000 kg/hr.
- Cooling water m3/hr. Temperature rise, °C.
- Tempered water, m3/hr. Temperature rise, °C
- Fresh water, m3/hr. Temperature rise, °C
- See Water, 1000 kg/hr.
- Fuel {Low Heating Value (LHV)} - Oil, 1000 kJ/sec. - Gas, 1000 kJ/sec.
- Nitrogen, Nm3/hr.
- Air, Nm3/hr. - Instrument - Plant.
- Plant water & Potable water, m3/hr.
- Inert gas, Nm3/hr.

• Chapter Process Description: -

•• Nature of Process: -
- Introduction.
- Characteristic of the process.
- Chemistry of the process (if where applicable).
- Typical reactions (If any).
- Reaction rates and heats of reaction.
•• Process of flow: -
- Detailed line up of the process flow separately for each section of the unit
to be provided.
• Chapter Operating Variables and Controls: -
•• Section A (Control points): This section embodies the main process features
and is prepared to help the plant operators overcome troubles not mentioned in
the next chapters (start - up and shut - down procedures). Any operating
variable such as pressure, temperature, chemical additions, feedstock
properties, hydrogen to hydrocarbon ratio (if any), and…etc. which has a
 significant effect on the unit operation and main product specifications shall be
mentioned.
•• Section B (effect of operating variables) any significant deviation in product
quality and/or unit operation resulting from any changes of operating variables
shall be elaborated in this section.
•• Section C (Troubleshooting guide) Special attention should be paid to specify
all the possible troubles which the unit operators may face during the
operation. The causes, preventative actions and troubleshooting guides for any
trouble shall be clearly demonstrated.
• Chapter Auxiliary Systems: The following sections shall be included with full
operation description and useful operating guidelines where applicable: -
•• Tempered water system.
•• The ram pump.
•• The flushing oil circuit.
•• Soot blowers.
•• Fuel oil and fuel gas systems.
•• Chemical injection systems.
•• Chloride and/or condensate injection to the reactor system.
•• Any other auxiliary system as applicable.

• Chapter Utility System operating manual: This section describes in detail the
operation philosophy and data for utility facility. The items should be description
of utility of process for easy understanding and operation guidelines. Utility
systems which supplement the main process should be described as a separate
subsection. Wherever possible, process description should be supplemented by
simple sketches showing the major equipment and process control for a particular
unit /utility operation. This enhances the understanding of the utility requirement
data and consumption. The following section shall be included with full
description of operating guidelines for utility in process plant where application.
The Utility Flow Diagram (UFD) consumption list shall be prepared during detail
of engineering phases and attached to the manual. In some cases licensor shall be
submitted utility data and consumption. Some of utility systems as below: -
•• Steam Boiler System.
•• Power Generation System.
•• Fuel Gas System.
•• Cooling Water System.
•• Instrument/utility Air and Nitrogen Package.
•• Flare and blow down system.
 •• Firefighting system.
•• Diesel Generator package.
•• Etc.
• Chapter Equipment operation: The detailed start - up, operation and inspection
prior to operation for all main equipment and relevant accessories as well as
packaged units to be outlined in this section. Reference to the operating and
maintenance instructions prepared by the equipment manufacturer for each item
shall be given. Main operating points and all useful operation guidelines shall
also be pointed out. Machinery equipment auxiliary systems such as anti - surge
system, lube oil, sealing system, tempered water…etc. and fired heater burners,
forced draft and induced draft fans operations should be explained in detail and
all possible troubles and their relevant troubleshooting guide of such systems to
be described: -
•• Machineries.
•• Heat exchangers.
•• Fired heaters.
•• Towers, vessels and reactors.
•• Package units.
•• Tank and storage facilities.

• Chapter Instrumentation and Control: -

•• Simplified logic diagrams for the unit, plant and equipment with step - wise
operation guide - line shall be given.
•• Main features of the advanced control systems and optimization to be
specified where applicable. Reference to the relevant specifications shall be
made.
•• Set points of all alarms and shut down switches shall be listed.
• Chapters Start - Up and Shut - Down: -
•• Standard operating procedures and operating philosophy and may be revised
for the following reasons: -
- Introduction of new equipment into the process.
- Conditioning and Special equipment.
- Significant change to process, task, personnel or equipment covered by the
procedure.
- Plant trials have been successful and need to be incorporated into standard
operating procedures.
- Detailed description of the plant facility (process, utilities and major
 equipment) including technical and operational performance data, set
points (i.e. trip, cut - in relief …etc.).
- The condition of main process plant/utilities/ equipment/special
equipment.
- Operating parameters and set points of different alarms and trip devices.
- Diagrammatic drawings of the facility i.e. location, general arrangement,
Utility Flow Diagrams (UFDs), Process Flow Diagrams (PFDs) together
with clear references to Original Equipment Manufacturers (OEM)
drawings and other technical information for individual major items of
equipment.
- Starting procedure.
- Process monitoring and recording.
- Shutdown procedure.
- Vendor instruction for all equipment for start - up, normal operation,
trouble shooting and shutdown.
- Emergency procedures (internal and external).
System and equipment emergency operating instructions together with
fault finding instructions/techniques.
- Operator training manual.
- Dosage rate of chemical used and emergencies handling procedures.
- Operator selection and training records.
- Electrical Single line diagrams, area classification drawings and control
schemes.
- Detail of interlock logic/trip…etc.
- Cause and Effect drawing.
- Pump characteristic curves.
- Recommended Performa for recording routine parameters during normal
operation for all equipment.
- Quality of products and effluent disposals.
- Laboratory analysis requirement and procedure.
- Gas detection system operation, calibration and maintenance procedure.
- Fire and safety system.
- Life saving devices operation and maintenance procedure.
- Equipment and instrument data sheets in accordance with purchase order .
- List of equipment (showing skid size, weight, purchase order no., vendor
data book.
- Sampling of raw materials, intermediates, final products and effluent
disposals.
- Pre - commissioning checks and Commissioning procedures.
- Equipment Layout & Safety Escape Routes.
•• All phases of operation, including initial startup, normal startup, normal
 operation, normal shutdown, emergency shutdown and subsequent startup,
emergency conditions and any temporary operations.
•• The properties and hazards of all materials.
•• Safety and health precautions and required personal protective equipment.
•• Safe operating limits and associated indications, alarms and interlocks, the
consequences of exceeding these limits, the actions by operations personnel
to correct the deviation or the actions taken by interlock systems.
•• Quality control procedures for Liquefied Natural Gas (LNG), flammable
refrigerants, and any other toxic or flammable materials stored or handled
onsite.
•• Procedures to control the inventory of flammable materials so as not to
exceed the capacity of impoundment areas and calculated exclusion
zones.
•• Any changes to these procedures shall be reviewed under the Management of
Change procedure.
•• Shall be accessible to all affected employees.

•• Preventive maintenance. (Procedures and Schedules) delivered by

contractor(s): -
- Procedure for routine maintenance, inspection, cleaning, replacing,
repairing, adjusting and calibrating critical equipment.
- Recommended schedules for which critical equipment and system shall be
examined.
- A schedule for daily, weekly, monthly, quarterly, biannual and annual
preventive maintenance schedules shall be included for unique system or
equipment as necessary and appropriate.
Mechanical integrity and inspection procedures.
- Safety and firefighting procedures and instructions.
- Project commissioning engineers report.
- Register of safety related devices (or equivalent).
- Approved permits.
- Schedule of system equipment with Original Equipment Manufacturers
(OEMs) reference number, named, addresses, telephones and facsimile,
details of mechanical handling (i.e. weight, size, special requirements
…etc.).
 - Approved permits.
- Lubrication Schedule (include Indian equivalent, initial fill, frequency of
change of lubricant and 6 months requirement).
- Punch list of incomplete construction items.
- List of items not accepted by operator.
- Details of all maintenance instructions, relative to the system and
equipment therein, including schedule of all routine and periodic
maintenance activities as appropriate.
- Relevant drawings and sketches are to be included as deemed necessary by
Owner.
- Functional description of the plant Distributed Control System (DCS).
- Schedule of numbering used for valves, electrical circuits…etc. together
with a functional description of the associated item.
- Details of associated control systems together with wiring diagrams and
plant interconnections.
- Where available, details of internal wiring for major items of equipment
shall be included.
- Details of relevant commissioning data accepted by Owner as the actual
final settings for the system and associated major equipment therein.
- Schedule of lubricants, chemicals, solvents…etc.
- Pre - commissioning checks and Commissioning procedures.
- Roles and responsibilities of individuals involved in plant operations.
•• Corrective maintenance (Repair requirements).
•• Parts lists.
•• Operation/Maintenance - Significant drawings.
•• Equipment specific Operations and Maintenance (O & M) information,
organized into a vendor/ manufacturer data library.
•• Several operating activities shall be conducted at the same time during the
start - up and shutdown period. So, all such activities which shall be performed
in parallel for a safe and reliable startup and shut - down operation shall be
described.
•• Special attention shall be made to the Vendor’s or Licensor’s instruction
manuals and the operating manual shall be reviewed carefully to be in
congruent with the Vendor’s or Licensor’s instructions.
•• All start - up and shutdown procedures shall be prepared in detailed step - wise
activities which will be performed by the operators with simplified start -
up/shutdown sketches.
•• Preparation for initial start - up: -
- General.
- Plant inspection after completion of mechanical side: -
-- Field checking.
-- Commissioning of utilities.
 -- Mechanical running test of rotary machinery.
- Cleaning of piping and equipment.
- System drying.
- Chemical cleaning and preparation of chemicals.
- Catalyst loading.
- Leakage and pressure test.
- Purging.
- Vendor instructions for all equipment for normal operation and
troubleshooting.
- Specific prestart - up operations.
- Start - up procedure (for each configuration).
Note: Start - up and shutdown procedure will include detailed equipment
procedure. Systems will be divided into "Main Equipment", such as
turbines, special motors…etc., and "Common Equipment".
For each Main Equipment will be developed a specific "TAG"
procedure while for the “common equipment”, such a centrifugal pump,
exchangers…etc. will be developed a typical equipment configuration
procedure non referred to a specific TAG.

•• Initial start - up procedures: -

- General.
- Prepare units for charging.
- Steam out and purge.
- Pressurize systems.
- Reduction and activation of catalyst.
\

- Establish gas circulation through catalytic reactor sections.

- Feed in and circulation.
\

- Heating up of plant.
- Establish operation.
- Start chemical injection.
\

- Line out.
•• Normal start - up procedure: -
- General.
- Re - start - up after short shutdown duration (hot start).
- Re - start - up after long shutdown duration (cold start) (to be continued).
•• Normal operation procedures.
- Operating procedures should clearly lay down instructions for operation of
process plant that take into consideration Control Of Substances
Hazardous to Health (COSHH), Manual Handling, Permit To Work,
Personal Protective Equipment (PPE) Regulations, quality, Hazard
Operability (HAZOP), Risk Assessment and Health, Safety and
Environmental (HSE) requirements.
- The procedure should represent a definition of good or best practice that
should be adhered to at all times. Process operatives should be provided
with guidance concerning the required operating philosophy to ensure that
they comply with procedural requirements.
- Operating procedures should be controlled documents, generally covered
under the owner’s quality system.
- Any changes should be fully controlled and documented and should be
subject to company change procedures.
- Normal operating instructions at both system and major equipment level
including details of all associated safety precautions: -
-- General.
-- Normal operating conditions.
-- Check points and adjustments.
-- Reduced operation.
-- Safe operating limits and associated indications, alarms and interlocks,
the consequences of exceeding these limits, the action by operations
personnel to correct the deviation or the actions taken by interlock
system.
- Operating instructions should be close to the user and kept up to date. The
following issues should be considered in assessing operating procedure
documentation: -
-- There should be no easier, more dangerous alternatives than following
the procedure.
-- There should be a suitable Quality Assurance (QA) system in place to
ensure that the procedures can be kept up to date and that any errors are
quickly detected and hence corrected.
-- The procedures should not be needlessly prescriptive.
-- The best way of Ensuring that procedures do not become overly
prescriptive is through involving the operator during the design stage.
-- Procedures should contain information on the requirements for the
wearing of personal Protective equipment during the task.
-- Any risks to the operator should be documented at the start of the
procedure, based on a risk assessment of the task.
-- An appropriate method of coding each procedure should be used.
-- Each time a procedure is produced it should be dated and also marked,
 where appropriate, with a shelf life, i.e. ‘This procedure is only valid
for 6 months after the date hereon’.
-- There should be no ambiguity between which procedures apply to which
situations.
-- Procedures do not always have to be paper based.
-- At the start of the procedure an overview of the task should be
provided.
-- Prerequisites should present clearly at the start of the procedure to
ensure that the operator can check that it is safe to proceed.
-- The most important information on the page should be identified and
this should be designed to be the most prominent information.
-- Separate headings should be used to differentiate clearly between sub
tasks.
-- Any warnings, cautions or notes should be placed immediately prior to
the instruction step to which they refer.
-- The nomenclature should be consistent with that on controls or panels.
-- Symbols, colors, and shapes used for graphics should conform to
industry standards.

•• Emergency operating procedures: -

- Any potential deviations to normal operation that can and cannot be
addressed by design or control identified in the Hazard and Operability
studies should be covered by emergency procedures. These should detail
how to make plant and process safe, minimizing risks to operators at all
stages.
- They should cover Personal Protective Equipment (PPE), the level of
intervention which is safe and when to evacuate. The procedures will need
to tie in closely with the on and off - site emergency plans.
- Process change.
- Plant change.
• Chapter Normal shutdown procedures & Emergency Shut - Down Procedure): -
•• Normal shutdown procedures: -
- General.
- Load down.
- Shutdown procedure.
•• Emergency Shutdown Procedure: -
- General.
- Safeguarding systems and equipment provided to protect the plant during
emergency cases such as emergency shutdown plant depressurizing shall be
elaborated: -
-- Trip sequence system.
-- Safety relief valves load summary table.
- The minimum requirement for load summary data of pressure
relief valves shall be specified.
- Since measures to be considered in an emergency vary
according to the type, degree and duration of the emergency
encountered, determining measures to be taken into account
 during commissioning and performance test period. This
should be emphasized in the operating manual.
- Steps to be taken in each emergency case shall be outlined in full
description such that to help operators to recognize and act upon
immediately.
- Causes of emergency shutdown: -
-- Feed failure.
-- Power failure.
-- Steam failure
-- Cooling water failure.
-- Instrument air failure.
-- Fuel failure.
-- Machine (mechanical) failure.
-- Explosion.
-- Fire.
-- Line rupture.
-- Serious leaks.
-- Other faults and failures.

• Chapter Miscellaneous Procedures: -

Miscellaneous procedures called by the nature of unit process and/or special
equipment operation not included in the other chapters shall be covered as required.
•• Catalyst oxidation.
•• Catalyst regeneration
•• Catalyst unloading.
•• Decoking.
•• Neutralization.
•• Bulk loading and unloading.
• Chapter Health, Safety & Environment System operating manual. This section
describes the HSE aspects of the facility that need to be considered for HSE
operating manual: -
•• Health.
This operation relates to the health of the people and working in the plant or
living in the vicinity of the plant whose health should be a concern for the
management of the plant. This should also address the health and well being of
animals and other living organisms present in the vicinity of the plant, for e.g.
marine life in any water body which would be affected by the operations of the
plant. A brief description of toxicity of the chemicals used in the plant /unit,
acceptable noise levels for humans and other animals, magnitude of injuries due
to fire and explosion, first aid measures for treating injuries…etc. should be
provided.
•• Safety.
This section relates to the safe start - up, operation and shutdown of the plant
during its entire lifetime. This section should address the normal hazards those
are encountered in day - to - day operations of the plant. This section should also
address the safety measures available to prevent any accident. Some of the
normal hazards could be loss of containment of any hazardous fluid due to
overflow, leak or rupture, static electricity build - up, accidental fall from heights,
burns due to exposure to hot surfaces, exposure to toxic fluids while collecting
samples and piling up of flammable solid waste (wood, paper, cloth…etc.).
- General.
- Safe place to work.
- Hazards and Hazid (Hazard identification).
- Good housekeeping.
- Requirements for welding permits.
- Hazardous chemicals.
\

- Flammable gas/air mixture.

- Firefighting equipment.
- Properties and hazards of all materials (Material safety data).
- Quality control procedures for Liquefied Natural Gas (LNG), flammable
refrigerants and any other toxic or flammable materials (If applicable)
stored or handled onsite.
- Procedures to control the inventory of flammable materials so as not to
exceed the capacity of impoundment areas and calculated exclusion zones.
- Safety and health precautions and required personal protective equipment.
- Any changes to these procedures shall be reviewed under the Management
of Change procedure.
•• Environment.
This section describes the limits for discharge of hazardous solid, liquid and
gaseous effluents to the environment based on local laws and regulations and
procedures for compliance to them.
•• Safety manual/Quality manual: -
- A recommended general index for plant safety manuals is shown below.
- The index consists of section titles (one digit numbering) and paragraph
titles (2 digits numbering). Subparagraph titles exceeding 2 digits do not
appear.
In the general index. A detailed section index listing. All subparagraphs titles
are given before each.
- Sections of the manual: -
-- Introduction: -
--- General.
-- Pre - Commissioning and commissioning. Emergency procedures: -
--- Emergency contact numbers.
-- General site hazard: -
--- Pressure testing and air freeing of process.
--- Safety in plant commissioning.
--- General fire protection and prevention.
-- Protective clothing and equipment: -
 --- Respiratory protective equipment.
--- Compressed air breathing apparatus.
--- Escape filter.
-- Pre - commissioning & commissioning: -
--- Safety training concept.
--- Training modules common to pre - commissioning, and
commissioning activities.
--- Safety training modules content.
-- Permit to work procedure: -
--- Lockout and tagging.
--- Working inside energized buildings.
--- Vessels/Confined space entry.
-- Project safety forms: -
--- General.
--- Permits to work.
--- Lockout/Tagging.

-- Safety information: -
--- Fire water network - overview.
--- Deluge system - overview.
--- Inert gas system - overview.
--- Fire equipment - overview.
--- Arterial safety data sheets.
--- Firefighting and protective equipment.
--- Personal protection.
--- Fire and safety point shelters.
--- Fire & Gas detection.
--- Fire proofing.
--- Data sheets for Pressure Safety Valves (PSVs).
--- Data sheets for car sealed valves.
--- Cause & Effect diagram.
--- Emergency Shut Down (ESD) system description.
--- Safety Instrumented system description {includes Safety Integrity
Levels (SILs)}.
 --- Recommended Safety Instrumented System (SIS) testing schedule.
--- Instrument alarms.
--- Alarm management protocol.
--- Selected element of the process safety management system.
--- Maintenance of safety equipment and housekeeping.
--- Control of Work (COW) procedures, e.g. isolation, purging, venting
of process systems in preparation for safe work…etc.
--- Testing schedules for hydrocarbon content in effluent streams and
levels of air particulates.
--- Testing schedules for noise (Decibels) at plant battery limit.
-- Safety concepts: -
--- General.
--- Codes and standards.
--- Climatic condition.

-- Hazardous area: -
--- Typical sources of hazard to be considered for area classification.
--- Machines, equipment, or their parts for production and processing
of dangerous substances which can be released into
atmosphere in normal and abnormal operating conditions have to
be generally considered as a source of hazard.
--- The items listed here below will be particularly taken into account: -
---- Pump glands and shaft glands on rotating and reciprocating
shafts of rotary filters, contactors, mixers and other machines.
(In centrifugal, reciprocating and rotary compressors the
glands are the main hazard, but other sources of hazard should
be regarded as the compressor casing and in some cases, parts
of the gland sealing system).
---- The drain rims around the pump pad.
---- Cooling water effluent systems from hydrocarbon service.
---- Vents of safety valves and rupture disk when non convoyed to
flare gas meter.
---- Drain connection used in process operation and permitting
release of flammable vapor to atmosphere.
 ---- Sample points.
---- Vents to atmosphere.
---- Motorized valves.
---- Some types of stream analyzers.
---- Drum and container filling plant.
---- Fixed roof storage tanks, including water draw - off
arrangement.
---- Floating roof storage tanks including water draw - off
arrangement.
-- Hazardous area classification: -
--- Gas group.
Gases and vapors are classified into groups as follow: -
---- Group A: Acetylene.
---- Group B: Hydrogen.
---- Group C: Ethylene.
---- Group D: All hydrocarbons.

American Standard NEC System Ignition temperature

0C
Group Gas or vapor
Acetylene 305
A Carbon disulphide 100
Wthyl nitrate
Acryladehyde (acrolein) 220
Butadiene – 1.3 420
Coke – oven gas
B
Ethylene oxide 429
Hydrogen 400
Propylene oxide 449
Acetaldehyde 175
CO 610
Cyclopropane 500
C Diethyl ether 160
Ethylene
Hydrogen cyanide 490
Tetra - fluoro – ethylene
Acetone 465
Ammonia 651
Aniline
D Benzol 560
Butane 405
Butanol 365/405
Butanone 516
 Butyl acetate 425
Di - chloro – ethylene 413
Ethane 515
Ethanol 356
Ethyl acetate 427
Ethyl nitrate
Heating oil
Heptane 280
Hexane 225
Methane 539
Methanol 385
Methyl acetate
Octane 220
Pentane 260
Pentanol 300
Petroleum (incl. petrol) 280 - 456
Petroleum – naphtha 288
Propane 450
Propanol 440/339
Propylene 460
Pyridine 482
Styrene 490
Toluene 480
Vinyle acetate 427
Vinyle chloride 472
Xylene 530

--- Temperature classes.

International Electro - technical Commission (IEC) VS NEC
Temperature Classification Comparison
IEC (EU Standards) North America NEC System
Max. Ignition Ignition
Max. surface Temperature of
surface temperature of
temperature gases or vapors
Temperature gases or vapors 0
0 0 C 0
C
C C
T1 450  450 T1 450  450
T2 300  300 ≤ 450
T2A 280  280
T2 300  300 ≤ 450 T2B 260  260
T2C 230  230
T2D 215  215
T3 200  200 ≤ 300
T3A 180  180
T3 200  200 ≤ 300 T3B 165  165
T3C 160  160
T4 135  135 ≤ 200
T4 135  135 ≤ 200 T4A 120  120
T5 100  100 ≤ 135 T5 100  100 ≤ 135
T6 85  85 ≤ 100 T6 85  85 ≤ 100
Safe Equipment Operating Temperature.

Temperature Class of the Equipment

Spontaneous ignition
temperature of the gases T6 T5 T4 T3 T2 T1
85 C 100 0C
0
1350C 200 0C 300 0C 450 0C
85 0 ≤ T 0 ≤ 100 0
100 0  T 0 ≤ 135 0
135 0  T 0 ≤ 200 0
200 0  T 0 ≤ 300 0
300 0  T 0 ≤ 450 0
450 0  T 0
Equipment safe to use Explosion danger

--- Zone (Class / Division): -

---- International Electro - technical Commission (IEC) 79 - 10
Standard (EU Standards): -
----- Zone 0 = Continuous grade release.
Always air fuel mixture (explosive or flammable
atmosphere) is continuously present or present for long
periods > 1000 hrs/year.
Ex: tank vents, sump vents, closed process vessels,
closed containers.
N.B: No motors may be used in zone.
----- Zone I: Primary grade release.
Air fuel mixture (explosive or flammable atmosphere) is
likely (often) present for a short time during normal
operations >10 – <1000 hrs/year.
Ex Vapor or flammable pipeline flanges, valves,
maintenance of flammable equipment.
Area below the surrounding elevation or grade is such
that flammable liquids or vapors may accumulate
therein.
 ----- Zone 2: Secondary grade release: -
------ Air fuel mixture (explosive or flammable
atmosphere) is unlikely (accidentally) present
during bad operations. < 10 hrs/year.
Ex: Pressurized rooms where flammable gas/vapor
can enter in the case of failure of positive
mechanical ventilation.
------ Non Explosive: Air fuel mixture (explosive or
flammable atmosphere) <1 hr./year.
----- Non hazardous area (Safe Area): -
------ Areas where the piping system is without valves,
fittings, flanges or similar appurtenances.
------ Generators shed room/shed having adequate
ventilation.

---- American Standard NEC system: -

----- Class 1 Division 1: Corresponds to (Equals to) Zone 0 +
Zone 1
Where ignitable concentrations of flammable gases or
vapors may: -
------ Fuel mixture (explosive or flammable atmosphere)
Exists under normal operating conditions.
------ Fuel mixture (explosive or flammable atmosphere)
Exists frequently because of repair or maintenance
operations or because of leakage.
------ Fuel mixture (explosive or flammable atmosphere)
Exist because of breakdown or faulty operation of
equipment or process.
----- Class 1 Division 2: Corresponds to (Equals to) Zone 2
Where ignitable concentrations of flammable gases,
vapors, liquids are: -
------ Handled processed or used within closed
containers or sealed system.
 ------ Normally prevented by positive mechanical
ventilation.
------ Adjacent to class 1 Division1 locations.
Comparing IEC Zones and NEC Divisions
Zone 0 Zone 1 Zone 2
Division 1 Division 2
--- Class: -
---- Class 0 : Liquefied Petroleum Gas (LPG).
---- Class 1 : Liquids that have flash points below 21 0C: -
----- Class 1.1: Liquids that have flash points from 21 0C up to
and including 55 0C.
Handled below flash point.
---- Class 2 : Liquids that have flash points from 21 0C up to and
including 55 0C.
Handled at or above flash point.
---- Class 3 : Liquids that have flash points above 55 0C up to and
including 100 0C.
Handled below flash point.
----- Class 3.2: Liquids that have lash points above 55 0C up
to
and including 100 0C.
Handled at or above flash point.

--- Fluid category: -

Category A: A flammable liquid that, on release, would vaporize
rapidly and substantially, this category: -
---- Any Liquefied Petroleum Gas (LPG) or lighter
flammable liquid whether under pressure or
refrigerated.
---- Any flammable liquid at a temperature sufficient
to produce, on release, more than about 40%
vaporization with no heat input other than from
the surrounding.
Category B: A flammable liquid, not in category A, but at a
temperature sufficient for boiling to occur on
release.
Category C : A flammable liquid, not in categories A or B, but
which can, release, be at a temperature above its
flash point, or from A flammable mist.
Category D : A flammable gas or vapor.
--- Dusts: -
 ---- Zone 20: Includes area where explosive atmosphere containing
the mixture of air and combustible dust present
continuously or frequently or for long period.
---- Zone 21: Includes area where explosive atmosphere containing
the mixture of air and combustible dust probably.
happen in normal operation frequently.
---- Zone 22: Includes area where explosive atmosphere containing
the mixture of air and combustible dust probably
happen in abnormal operation or for a short period.

• Chapter Analytical Tests.

The analytical plan shall comprise the following requirements: -
•• Stream name.
•• Test name.
•• Test number (Analytical methods).
•• Sampling point.
•• Normal sampling frequency.
•• Start - up sampling frequency. Detailed analytical procedures shall be prepared
separately in the form of Analytical Manual.
• Chapter Catalysts, Chemicals, Packing, lubricant oil, filters and …
Summary of catalysts, chemicals, packing, lubricant oil, filters and …., minimum
requirements comprising of the following information shall be tabulated: -
•• Description of the catalyst/chemical/packing/lubricant oil, filters and …
•• Manufacturer name and type.
•• Quantity required for initial charge, m3 or kg.
•• Equipment number/where used.
•• Equipment name.
•• Estimated consumption rate [daily (d) and /or yearly (y)], m3 or kg. Typical
Summary table of catalyst/chemical/packing requirements.