2.0 Performance Testing_Sue06052010_PT

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EPC-1 PRODUCTION PROCESSING FACILITIES OF BANYU URIP

PROJECT

ONSHORE PRE-COMMISSIONING & COMMISSIONING SCOPE

Tender No.:B-3207067 PERFORMANCE TESTING

PROCEDURES

Revision :0 Page : 1 of 15

Description: Issue for proposal Rev. Date :06-May-2010

CLIENT NAME : MOBIL CEPU LIMITED

PROJECT TITLE : BANYU URIP PROJECT

PROJECT NO : B-3207067

REV

#

DATE REASON FOR ISSUE PREPARED

BY

DISCIPLINE

CHECK

TECHNICAL

INTEGRITY

PROJECT

APPROVAL

CLIENT

APPROVAL

DOCUMENT TITLE : PERFORMANCE TESTING PROCEDURES

DOCUMENT NO : CONFIDENTIALITY RATING:

CLIENT REF:

THIS DOCUMENT INCLUDING DRAWINGS, PROCEDURES, SPECIFICATIONS, AND ITS CONTENTS IS THE EXCLUSIVEPROPERITY OF EJ JOINT VENTURE INTERNATIONAL LIMITED AND IS FURNISHED ON A CONFIDENTIAL BASIS, AND

WITH THE EXPRESS AGREEMENT THAT IT WILL NEITHER BE USED, SOLD, TRANSFERRED, COPIED, TRACED,

PHOTOGRAPHED, NOR REPRODUCED IN ANY MANNER WHATSOEVER IN WHOLE OR IN PART, NOR ANY ITEM HEREIN

BE SOLD, MANUFACTURED OR ASSEMBLED WITHOUT THE WRITTEN AGREEMENT OF EJ JOINT VENTURE

INTERNATIONAL LIMITED THE RECIPIENT OF THIS DOCUMENT AGREES NOT TO DISCLOSE TO ANY OTHER PARTY

INFORMATION CONTAINED HEREIN, OR NOT TO USE SUCH INFORMATION, EXCEPT FOR THE SPECIFIC PURPOSE

INTENDED AT THE TIME OF RELEASE OF THIS DOCUMENT.


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PERFORMANCE TESTING PROCEDURES

PERFORMANCE Testing The process of testing each system to ensure that it meetsthe design criteria established in the design specification and shown on the P&Ids.

PERFORMANCE TESTS means the operating tests of the functional systems of the PLANT in

the conditions specified, with the objective of demonstrating that the PLANT can satisfactorily be

operated in accordance with the design parameters and achieve the performance warranties

required under the CONTRACT.

1. PERFORMANCE TESTS

1.1 GENERAL

The purpose of the PERFORMANCE TESTS is to demonstrate that the commissionedfacilities comply with the design performance requirements. In the event that thefacilities fail to meet the design performance requirements, a Performance Defects listshall be prepared and actions shall be assigned to CONTRACTOR, COMPANY andOthers.

1.2 BASIS OF TESTS

Performance test runs on the systems shall be carried out under conditions as given onthe latest revision of the relevant flow diagrams/schematics and shall have a continuousduration as specified in

(i) this manual to determine various operating characteristics of the WORK and

(ii) to demonstrate the PERFORMANCE TESTS for the WORK. SpecificPerformance requirements are listed for each system in the Attachment ofthis Manual. EJ Joint Venture Pty. Ltd (EJJV) shall write the procedures forall Onshore Performance Tests and the Offshore Performance Tests. EJJV

shall prepare procedures that will integrate the test runs to obtain themaximum data with the minimum number of individual test runs.

EJJVs personnel shall continue to perform the services specified under until such timeas all performance test runs have been successfully completed.

1.3 REPORTING


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Within four (4) DAYs after the completion of each Performance Test, preliminary testresults shall be provided to COMPANY. Within seven (7) DAYs after receipt of testresults, COMPANY is to give notice to the CONSORTIUM either advising of thesuccessful Performance Test results or specifying areas of concern which requireCONSORTIUM action to correct. CONSORTIUM shall acknowledge receipt of suchnotification and include plans to remedy the deficient areas.Within seven (7) DAYs after the completion of each Performance Test, COMPANY willnotify CONSORTIUM of the Performance Test results and specify all areas of concernwhich require CONSORTIUM action to correct. CONSORTIUM shall acknowledgereceipt of such notification and include plans to remedy the deficient areas.

1.4 CORRECTION OF DEFICIENCY

CONSORTIUM shall correct all deficiencies due to failure to meet design performanceas defined in PFDs, P&IDs and Equipment Data Sheets and for construction errors.


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Attachment 1TYPICAL EXAMPLE OF PERFORMANCE TESTS

1. CONSORTIUM PERFORMED PERFORMANCE TESTS (ONSHORE)

CONSORTIUM shall perform the following Performance Tests after Commissioning andprior to load out. Each Performance Test shall be separately conducted anddocumented.

1.1 VOICE AND DATA COMMUNICATIONS PERFORMANCE TEST

The voice and data communications provides radio and data highway communicationsThe platform Local Area Network for business data will be connected to the system toprovide the Wide Area Network link.A simulated test will be performed prior to load out. The Performance Test shall beconducted for a continuous period of twenty four (24) hours. The Performance Testshall be performed in accordance with the SUPPLIERs test procedures and shallmeasure the complete end-to-end bit error rate for each communication circuit (to bothdestinations and repeated for stand-by equipment). The system shall be normallyloaded with voice and data communications.

All operating data shall be recorded at 15 minute intervals during the test.

Test Performance PointEnd-to-end bit error rate


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1.3 MAIN POWER GENERATION PERFORMANCE TEST

The dual fuel turbine driven generator, LAN-9530A, shall be tested at full load whileoperating on diesel fuel. All other generators, permanent and temporary, shall be out ofservice for the test and LAN-9530A shall supply the entire load. The load shall beadjusted by operating both duty and stand-by electrical equipment which does notrequire production of hydrocarbons on the platform. Where necessary, equipment maybe set to manual mode to maintain a constant system load.

The Performance Test shall be conducted for a continuous period of six (6) hours.

Test Performance PointElectrical Power Load (measured at the LAN-

9530A UCP)

minimum of 1040 kVA at PF of 0.8

average of 1100 kVA at PF of 0.83 Phase voltage (measured at LAN-9530AUCP)

415 V 5 V

Frequency (measured at LAN-9530A UCP) 50 Hz 1 Hz

All results shall be logged and trended on the platform DCS. Maximum and minimumdeviations on all measured parameters shall be reported in the test results.

1.4 STANDBY DIESEL GENERATOR PERFORMANCE TEST

The diesel engine driven standby diesel generator, LAN-9540, shall be tested at fullload. All other generators, permanent and temporary, shall be out of service for the test

and LAN-9540 shall supply the entire load. The load shall be adjusted by operating bothduty and stand-by electrical equipment which does not require production ofhydrocarbons on the platform. Where necessary, equipment may be set to manualmode to maintain a constant system load.

The Performance Test shall be conducted for a continuous period of six (6) hours.

Test Performance PointElectrical Power Load (measured at the LAN-9540 UCP)

minimum of 225 kVA at PF of 0.8average of 250 kVA at PF of 0.8

3 Phase voltage (measured at LAN-9540UCP)

415 V 5 V

Frequency (measured at LAN-9540 UCP) 50 Hz 1 Hz

All results shall be logged and trended on the platform PCDAS. Maximum and minimumdeviations on all measured parameters shall be reported in the test results.


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1.5 PEDESTAL CRANE

The platform pedestal crane shall be installed and tested in the fabrication yard. ThePedestal Crane Performance Test shall be performed offshore.

Test Performance PointMain Hook Load Test at minimum workingradius, maximum working radius and at 20 ftintervals between the minimum andmaximum

In accordance with manufacturersinstructions and load tables.

Auxiliary Hook Load Test at minimumworking radius, maximum working radius andat 20 ft intervals between the minimum andmaximum

In accordance with manufacturersinstructions and load tables.

Secondary Hook Load Test In accordance with manufacturersinstructions and load tables.

Engine Maintenance Jib Load Test In accordance with manufacturersinstructions and load tables.

Hoist Removal Jib Load Test In accordance with manufacturersinstructions and load tables.

Main Hook Hoist Rate 80 ft per minuteAuxiliary Hook Hoist Rate 160 ft per minuteSwing Speed minimum 0.1 revolutions per minute

maximum 1.5 revolutions per minute

Load tests shall be performed in accordance with API 2C and with the ABS inspectorpresent.

1.6 BRIDGE CRANES (2)

The platform Bridge cranes shall be installed and tested in the fabrication yard. ThePlatform Bridge Crane Performance Test shall be performed offshore.

Test Performance PointLoad Test (125% of rated capacity) In accordance with manufacturers

instructions and load tables.Bridge travel Speed 10 meters /minBridge creep Speed 3.3 meters / minTrolley travel Speed 5 meters/minTrolley creep Speed 1.7 meters/minHoist Speed Main 3.2 meters/minHoist Speed Creep 1 meters/min


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Load tests shall be performed in accordance with API 2C and with the ABS inspectorpresent.


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1.7 POTABLE WATER PERFORMANCE TEST

The potable water system needs to be operational to make the washroom habitable.The potable water system includes the potable water storage tanks, potable waterpumps and potable water day storage tank.

Test Performance PointPotable Water Microbiological Content asmeasured by sampling at the furthest user.COMPANY will provide the laboratoryanalysis service.

to World Health Organization standard

Potable Water Pumps flow rate (measured

by change in level in the storage tank)

45 USGPM

Potable Water Pumps discharge pressure 15 PSIG and evidence of air beingevacuated from the potable water daytank

1.9 INSTRUMENT AIR SKID PERFORMANCE TEST

The instrument air skid shall be tested with no utility air usage and with all loads on theinstrument air system. The test shall be repeated for each air compressor and each airdryer.The Performance Test shall be conducted for a continuous period of six (6) hours.

Test Performance Point

Instrument Air flow rate, measured atthe outlet of the skid

75 SCFM

Instrument Air pressure, measured atthe instrument air receiver

at least 165 PSIG

Instrument Air Dew point 40F at an instrument air flow rate of 75 SCFM

2.0 CONSORTIUM PEFORMED PERFORMANCE TESTS (FLOATING TRIAL)

CONSORTIUM shall perform the following Performance Tests after Commissioning andafter load out. Each Performance Test shall be separately conducted and documented.

2.1 FIRE WATER PUMPS


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Each fire water pump shall be tested separately.The Performance Test shall be conducted for a continuous period of six (6) hours.

Test Performance PointWater flow rate, measured through the testline and test meter (FT-9600T/FT-9601T)

2600 US gallons per minute

Water pressure, measure at the dischargeflange (PI-9600N/PI-9601N)

150 PSIG

2.2 UTILITY SEA WATER PUMPS

Each utility sea water pump shall be tested separately. The fire water test line and testmeter shall be used by isolating the fire water pumps and replacing the check valves

with temporary spool pieces.The Performance Test shall be conducted for a continuous period of six (6) hours.

Test Performance PointWater flow rate, measured through the firewater test line and test meter (FT-9600T)

80 US gallons per minute

Water pressure, measure at the PI-9624B 150 PSIG

2.3 FLOATING TRIAL BALLAST AND INCLINE TEST

The hull shall be tested to confirm performance under Ballasting, De-Ballasting andIncline situations. The Fire Water pumps are used for the Ballasting and De-ballasting

operation and are to be commissioned and tested prior to performance of theBallasting/De-Ballasting and incline tests.The floating trial tests are:

Test Performance Point

Installed draft 31.29 m with all #5 tanks full and WPC andEPC empty

Ballast System Function Test Confirm all valves operate during Installed Drafttest

De-ballast System Function test Eductor flow 1500 USGPM gross (500 USGPMnet)

Incline test 1.28 Degrees on any side.

3.0 COMPANY PEFORMED PERFORMANCE TESTS (OFFSHORE)

COMPANY will perform the following Performance Tests after the TLPB is installed atsite and has been received Mechanical Acceptance. Each Performance Test will beseparately conducted and documented. COMPANY will endeavor to perform


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COMPANYs Performance Tests within three (3) months after MECHANICALACCEPTANCE. However, CONTRACTOR recognizes that events beyond COMPANYscontrol may affect the timing of the tests.

3.1 PRODUCTION PERFORMANCE TEST

The purpose of the Production Performance Test is to demonstrate the overallhydrocarbon process facility meets its design intent. The Production Performance Testwill confirm that the facility can operate while meeting key performance conditions.

The performance test will be performed within the first months of operations, and thuswill be at a reduced flowrate from maximum design conditions. The reduced feedconditions to the platform shall be set by COMPANYs operators and shall be fully at the

discretion of COMPANY. The Production Performance Test shall be conducted over acontinuous twenty four (24) hour period and will confirm operations with stable levelsand pressures throughout the system. Additionally, proper operation all equipment willbe confirmed. Actual performance will be compared with required design performanceas defined on the PFDs, P&IDs and data sheets and a judgment will made byCOMPANY as to the whether the system can be reasonably be expected to meetdesign performance .

3.2 METHANOL STORAGE TANK AND INJECTION SKIDS

The Methanol Injection Skids (ZZZ-9850A/B) shall be tested by transferring methanol

from one storage tank to the other using the 2 return line to the storage tanks. The testwill be performed for each pump on the skid. A temporary line will need to be installed atRO 9830F to test pumps PBA9830A/B and at RO9832F to test pumps PBA-9830C/D

The following tests shall be measured.

Test Performance PointPBA-9830A Discharge Pressure measured atPI-9830C

60 PSIG

PBA-9830A flow rate, measured by levelchange in the storage tanks (remove RO

9830F)

30 USGPM

PBA-9830B Discharge Pressure measured atPI-9831C

60 PSIG

PBA-9830B flow rate, measured by levelchange in the storage tanks (remove RO9830F)

30 USGPM

PBE-9845A Discharge pressure measured atPI-9845C

6700 PSIG

PBE-9845A flow rate measured at FI-9845J 13.5 USGPM


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PBE-9845B Discharge pressure measured atPI-9846C

6700 PSIG

PBE-9845B flow rate measured at FI-9845J 13.5 USGPMPBA-9840A Discharge pressure measured atPI-9840C

500 PSIG

PBA-9840A flow rate measured at FI-9840G 1.0 USGPMPBA-9840B Discharge pressure measured atPI-9841C

500 PSIG

PBA-9840B flow rate measured at FT-9840G 1.0 USGPMPBA-9830C Discharge Pressure measuredat PI-9832C

60 PSIG

PBA-9830C flow rate, measured by levelchange in the storage tanks (remove RO9832F)

30 USGPM

PBA-9830D Discharge Pressure measuredat PI-9833C

60 PSIG

PBA-9830D flow rate, measured by levelchange in the storage tanks (remove RO9832F)

30 USGPM

PBE-9845C Discharge pressure measured atPI-9845C

6700 PSIG

PBE-9845C flow rate measured at FI-9848J 13.5 USGPMPBE-9845C Discharge pressure measured atPI-9847C

6700 PSIG

3.2 CHEMICAL STORAGE AND INJECTION SKIDS

The Chemical injection skidS shall be tested by pumping Chemical back to its storagetank. The test will be performed for each pump on the skid. A temporary line will need tobe installed from the pump discharge to the storage tank fill connection.

The following tests shall be measured:

Test Performance PointPBE-9700A Discharge pressure, measuredat PI-9700E

500 PSIG

PBE-9700A flow rate, measured byCalibration Chamber LG-9700F

2.3 USGPH

PBE-9700B Discharge pressure, measuredat PI-9701E

500 PSIG

PBE-9700B flow rate, measured by

Calibration Chamber LG-9700F2.3 USGPH

PBE-9710A Discharge pressure, measured 500 PSIG


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at PI-9700EPBE-9710A flow rate, measured by

Calibration Chamber LG-9710D0.25 USGPH


500 PSIG



PBE-9720A Discharge pressure, measuredat PI-9720E

500 PSIG

PBE-9720A flow rate, measured by


PBE-9720B Discharge pressure, measuredat PI-9721E 500 PSIG




500 PSIG




500 PSIG


Calibration Chamber LG-9730D

0.25 USGPH


500 PSIG




500 PSIG



PBE-9690A Discharge pressure, measured

at PI-9690E

500 PSIG




500 PSIG



PBE-9750A Discharge pressure, measured 500 PSIG


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at PI-9750EPBE-9750A flow rate, measured by



500 PSIG




500 PSIG



5.65 USGPH


500 PSIG




500 PSIG



PBE-9770B Discharge pressure, measuredat PI-9771E 7500 PSIG



PBE-9770C Discharge pressure, measuredat PI-9772E

7500 PSIG

PBE-9770C flow rate, measured by


PBE-9770D Discharge pressure, measuredat PI-9773E

7500 PSIG

PBE-9770D flow rate, measured byCalibration Chamber LG-9770D

0.51 USGPH

PBE-9770E Discharge pressure, measuredat PI-9774E

7500 PSIG

PBE-9770E flow rate, measured by


PBE-9770F Discharge pressure, measured 7500 PSIG


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at PI-9775EPBE-9770F flow rate, measured by


PBE-9770G Discharge pressure, measuredat PI-9776E

7500 PSIG

PBE-9770G flow rate, measured by



7500 PSIG



0.51 USGPH


7500 PSIG



PBE-9780C Discharge pressure, measuredat PI-9782E

7500 PSIG

PBE-9780C flow rate, measured by


PBE-9780D Discharge pressure, measuredat PI-9783E 7500 PSIG

PBE-9780D flow rate, measured by


PBE-9780E Discharge pressure, measuredat PI-9784E

7500 PSIG

PBE-9780E flow rate, measured by


PBE-9780F Discharge pressure, measuredat PI-9785E

7500 PSIG

PBE-9780F flow rate, measured byCalibration Chamber LG-9784D

0.51 USGPH


500 PSIG



PBE-9790B Discharge pressure, measured 500 PSIG


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at PI-9791EPBE-9790B flow rate, measured by


3.3 HEAT MEDIA HEATER AND CIRCULATION SYSTEM

The performance test on this system will consist of circulation of fluid (at the hightemperature of 300 F) through the loop. This will confirm the integrity and correcthookup of the system, additionally the adequacy of the pumps to flow the fluidthrough the exchanger, fired heater coil, piping, and expansion tank.

Test Performance PointDifferential Pressure 50 PSIGFlow rate, 500 USGPM

3.4 WATER TREATING SKID

The performance test on this system will consist of circulation of fluid through thesystem. This will confirm the integrity and correct hookup of the system, theadequacy of the inlet pressure to flow through the hydrocyclones, flotation cell, andto the overboard discharge line. In addition, the hydrocarbon concentration of theinlet stream and the outlet stream will be measured to confirm proper operation ofthe IGF.

3.5 HP/LP FLARE TIP

The HP/LP Flare Tip shall be tested to confirm that the variable slot flare tips areadequately designed in order to produce sonic flow at the minimum flare flow rate of10 MMSCFD.

3.6 PRODUCTION PUMPS

The Production Pumps shall be tested to confirm that the performance is within thedesign tolerance of the API Pump Curves.

3.7 SHELL AND TUBE HEAT EXCHANGERS

The performance test on this system will consist of circulation of fluid through theexchangers with available process fluids in order to verify:

system integrity

operation within the design criteria at a reduced flow rate.

Documents

2.0 Performance Testing_Sue06052010_PT