PROJECT:

RELOCATION OF 138MMSCFD GEREGU EARLY GAS

FACILITY TO ALAOJI METERING STATION

DOCUMENT TITLE:
PRE-COMMISSIONING AND COMMISSIONING
PROCEDURE

CONTRACTOR:
MORPOL ENGINEERING SERVICES LIMITED

For: MORPOL ENGINEERING SERVICE LIMITED For: NIGERIAN GAS COMPANY. (NGC )

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 TABLE OF CONTENTS

1.1 GENERAL REQUIREMENTS................................................................................................................

1.2 RECORDS....................................................................................................................................................

1.3 REQUIREMENTS FOR PRE-COMMISSIONING.............................................................................................

1.4 REQUIREMENTS FOR COMMISSIONING....................................................................................................

1.5 BACKGROUND...........................................................................................................................................

1.5.1 SCOPE OF WORKS...............................................................................................................................

1.6 EQUIPMENT / FACILITIES...........................................................................................................................

1.6.1 PRMS OVERVIEW................................................................................................................................

1.6.2 GAS HEATING......................................................................................................................................

1.6.3 GAS FIRED BOILER...............................................................................................................................

1.6.4 PRESSURE REGULATION......................................................................................................................

1.6.5 GAS METERING...................................................................................................................................

1.6.5.1 PROCESS CONDITIONS:....................................................................................................................

2.0 PRECOMMISSIONING........................................................................................................................

2.1 PROCEDURES FOR PRE–COMMISSIONING.................................................................................................

2.2 SYSTEM READINESS FOR PRE-COMMISSIONING........................................................................................

2.2.1 BOILER AND HEAT EXCHANGER..........................................................................................................

2.3 GENERAL CHECKS...................................................................................................................................

2.5 PRE-COMMISSIONING CHECK LIST.......................................................................................................

3.0 COMMISSIONING............................................................................................................................

3.1 NITROGEN PURGING AND PRESSURE TESTIN PROCEDURE......................................................................

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3.1.1 PRESSURE TESTING...............................................................................................................................

3.1.2 NITROGEN PURGING.........................................................................................................................

3.2.INTRODUCING NATURAL GAS..............................................................................................................

3.3 START UP OF THE STEAM BOILERS.......................................................................................................

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 1.1 GENERAL REQUIREMENTS

Upon completion of the installation and fabrication works, instruments, wiring systems and
equipment shall be checked and tested. It is intended to ensure that all components of the
instruments and equipment satisfactorily perform their intended function and conform to standards.

1.2 RECORDS
1.2.1 Contractor shall maintain and make available to Client, as may be requested, suitable records
indicating the performance and results of instrument Check-Out.
1.2.2 As-built drawings incorporating field revisions in piping and wiring shall be issued by Contractor at
the conclusion of the job.

1.3 REQUIREMENTS FOR PRE-COMMISSIONING

The aim of the pre-commissioning/loop check is to verify that the field instruments and control
system will operate and meet the design specification. This will be accomplished by, but not limited
to the following specific objectives:

1.3.1 Client has supplied the instruments specified; and that the instruments have been properly
installed.
1.3.2 Verification will be made to ensure that all instruments associated with the project are properly
tagged.
1.3.3 After loop check is completed, all junction boxes and panels through which loop wiring passes, will
be Locked.

1.3.4 A copy of the loop diagrams will be provided as a formal record of each loop test performed and
shall be witnessed and signed by the client.

1.4 REQUIREMENTS FOR COMMISSIONING

The purpose of the commissioning is to introduce product into the plant. At this stage all the Pre-
Commissioning activities have been completed. And all the loops and electrical equipment

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 described in the Pre-commissioning specification shall be completed and signed. The following
systems must be operational:

1.4.1 The electrical power must be fully operational. Instruments, controls, and electrical equipment shall
have the appropriate voltage to operate safely.

1.4. 2 All the pipes, tubing’s shall be tested for leaks, dried, cleaned and free from any Debris.

1.4.3 The station shall be fully purged and pressurized with Nitrogen to 5 bar for a period of 24 hour.

1.4.4 All instrument valves shall be opened unless specified.

1.4.5 The commissioning of the plant will be performed in multiple phases. Each portion of the plant will
be commissioned and carefully tested separately. Testing will be performed in two steps of
operational pressures and shall include use of Soap solution around flanges, welded joints, and
other connections to ensure there is no leakage.

1.5 BACKGROUND

The Alaoji PRMS project is scheduled to be completed in January 2015 and considering the
readiness of Alaoji power plant for full gas off-take so as to meet Federal Government’s drive to increase
power generation to 5,000MW by November 2014, it is considered expedient to relocate the 138MMSCFD
Geregu Early Gas supply facility, to Alaoji metering station as a stopgap measure pending the availability of
the Alaoji PRMS. Similarly, there is need to also relocate and install a gas heating system from the
upgrade project at Ewekoro metering station in order to enhance the quality of gas to be delivered to the
power plant.

The contract of this relocation and installation was awarded to us at Morpol Engineering Services
Limted to be executed to standards.

The proposed modification will interconnect the existing 18inch inlet and outlet flanges to NDPHC power
plant to replace the existing make-shift 30MMSCFD PRMS skid already supplying gas to the power plant
since 2011.

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1.5.1 SCOPE OF WORKS

This procedure covers the commissioning of the relocated Geregu Early Gas 138MSCFD PRMS and
the boiler/heat exchanger package from Ewekoro to Alaoji metering station.
Commissioning is a procedure involving Morpol and NGC representatives.
NGC and Morpol will cooperate closely to ensure the commissioning is carried out under safe conditions.

1.6 EQUIPMENT / FACILITIES

1.6.1 PRMS Overview

The PRMS has an inlet of 12” X 600# , outlet of 18” X 300# and flow rate of 138MMSCF. The system is
meant for natural gas with inlet pressure of 60 to 65 Barg and outlet pressure of 32 to 35 Barg. The total
natural gas will be conditioned through a boiler and heat exchange package, pressure regulators and
metering systems. The design pressure of PRMS is 70 Barg inlet piping for #600 and 45 Barg outlets piping
for 300# at design temperature of 65°C. The pipelines are designed in a manner that ensures adequate
public safety under all conditions likely to be encountered during operating conditions.

1.6.2 Gas Heating

Gas heating is done at the Heat Exchanger to ensure that no liquids are formed in the gas stream as a
result of Joule Thompson effect (temperature reduction) associated with the pressure reduction.

1.6.3 Gas Fired Boiler

The boiler is a horizontal, three pass, smoke tube type, in full wetback construction. The combustion
chamber (furnace) forms the first pass in which the fuel is atomized and combusted. The radiant heat from
the combustion is transmitted to the water contained in the shell, submerged in the furnace, reversing
chamber and smoke tubes. The hot flue gases are diverted through the internal reversing chamber
(wetback chamber) and subsequently to the second and third pass of tubes transferring the convective heat
to the boiler. The generated steam is transported to the heat exchanger through boiler steam outlet, for
natural gas heating.

1.6.4 Pressure Regulation

The desired outlet gas pressure is accomplished via gas regulating valves. The systems consist of a worker
regulator, monitor regulator and slam shut valve. The primary source of pressure reduction is accomplished

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through the work regulator. This regulator senses the pressure of the gas downstream of regulating valve
and then adjusts the travel of the valve as required to maintain the desired outlet pressure to a low enough
level, the monitor regulator automatically start to close and assist in the pressure reduction. Finally, if there
is a failure in both regulators to maintain a low enough outlet pressure, the slam shut valve will initiate and
shut off all flow through the system thereby protect the downstream systems from over pressurization.

1.6.5 Gas Metering

The gas measurement is accomplished by the use of Senior Daniel orifice fittings for the metering system.
Orifice metering is a proven, reliable technology for the metering of natural gas in industrial applications.
The systems include flow conditioners upstream of the orifice fitting to ensure the most accurate
measurement possible. The determination of flow through an orifice meter is accomplished by measuring
the static pressure, differential pressure across the orifice fitting and temperature through the use of
multivariable sensors and transmitters. This information is then transmitted to a flow computer and human
machine interface (HMI) for calculation of the gas flow rate and storage of the flow rate information. In
addition to the flow computer, there is a traditional chart recorder as backup source of flow data in the event
the information is lost in the flow computer. In the main time however, only the chart recorder shall be in
use for calculation of the gas flow rate through the relocated Geregu Early Gas PRMS.

1.6.5.1 Process Conditions:

SERVICE NATURAL GAS

FLOW 138 MMSCFD

INLET PRESSURE: 60/65 Barg

OUTLET PRESSURE 32 Barg

DESIGN PRESSURE 70/45 Barg

WORKING TEMERATURE 20 TO 30ºC

DESIGN TEMPERATURE 65ºC

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 INLET SIZE 12” X 600#
OUTLET SIZE 18” X 300#

2.0 PRECOMMISSIONING
Pre-commissioning note provides procedures for final loop test to ensure compliance with process
conditions and engineering requirements.
The tests described in this section are to be performed in dry mode and the station shall not contain the
product.
Pre-Commissioning is performed prior to start up of the plant by the vendor and contractor, and witnessed
by the client. For safety and operational reasons, client personnel shall witness the Pre-Commissioning
exercise, thereafter commissioning shall be carried out in line with the standards.

2.1 Procedures For Pre–Commissioning

In advance of commissioning, each mechanical and electrical system shall be checked for completeness
and accuracy of installation. In addition, all systems shall be examined against a checklist for readiness for
commissioning and startup.

2.2 System Readiness For Pre-Commissioning

2.2.1 Boiler and Heat Exchanger

 Verify installation of all components of system are installed erected in accordance with P&IDs and
design drawings
 Using Pen or Pencil, update P&IDs to show any details that have changed from that shown on the
factory As-Built Drawings. Save for permanent record.
 Check all mechanical, electrical and tubing connections for completeness
 Verify installation of boiler’s control panel
 Verify mini water treatment plant for the boilers functionality
 Verify that boiler is filled with water to the top of the sight glass
 Determine that volume of make-up water is available for use once operations commence.
 Check instrument/fuel gas line pressure reduction devices PCV-101A, PCV-101B.
 Verify all gauges are installed and ready for operations

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  Confirm the tagging of equipment in accordance with the P&ID
 Verify installation of the Temperature Control Valve (TCV-101).

2.3 General Checks

 Verify installation of all system and components in accordance with design drawings, best practices
and appropriate completion prior to commissioning.
 Check all mechanical, electrical and tubing connections for completeness
 Verify site readiness to commence commissioning including Closure of all open pits and trenches,
activation of adequate lighting / illumination for night operations of gas equipment, installation of all
safety items deemed necessary including fire fighting devices, ESD controls and operator
communications with management.
 Verify that gas operators, site management and equipment commissioning technical staff hold a
communications meeting discussing pending gas purging and gas system commissioning
activities, all safety issues and concerns.
 Verify issuance and review of Gas Hazards and Safety Training Guidelines to all Operators and
Maintenance personnel
 Verify implementation of Operator Training program in advance of Commissioning.
 Verify existence and execution of Civil/Structural Certificate of Completion between Owner and
General Contractor
 Verify existence and execution of Mechanical Certificate of Completion between Owner and
General Contractor
 Verify existence and execution of Electrical and Instrumentation Certificate of Completion between
Owner and General Contractor
 Once the above are complete, pre-commissioning activities are complete and progress can
advance to Commissioning activities and to start of gas flow.

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 2.4 Pre-Commissioning Check List

(A = Action, M = Monitor, AP = Approve, AC=Accept ) ACTIONS

MORPOL NGC

A. ELECTRICAL : GENERAL

1. Check the correct installation of the instruments as required

from the P&ID, assembly drawings and specific
documentation for each instrument

2. Check the tag for each instrument, the relevant data sheet
and certificate of calibration

3. Check all loops and the response of the instruments.

4. Check all electrical connections for electrical continuity

5.

6. Turn on lighting systems, fire fighting, leak detection gas, air

conditioning/heating (where applicable)

B. CONTROL PANEL AND INSTRUMENTATION

7. Check for proper grounding of the panel

8. Check the voltage and the phases sense at the entrance of

the panels before switch on

9. Check the activation of the systems within the cabinet

(lighting, cooling etc)

10. Sequentially energize all outputs of the panel and checking

the voltages on the terminal

11. Ensure that all equipment connected to the control panel are

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 energized and working. After verifying their efficiency, switch
off any equipment that requires the presence of process
fluids to work (water and gas)

12. Field verification of the operating range, the correct wiring

and the correct setting of alarm thresholds in the output for
the following:

 Transmitters: (pressure & Temperature)

• gauges (Temperature &

Pressure)

• Differential pressure indicators;

• Flow meters (turbines, calibrated discs)

• Pressure switches

C Manual valves

13. Check operation of manual valves (lever or gear) wide

opening and closing them. If required proceed with the
lubrication of the stem.

D Actuated valves

14. Check the actuators’ operation using compressed air or

nitrogen. Wide open and close them and check the action of
the limit switches

15. Verify the absence of any slack on the actuator shaft during
movement. Check the complete opening and closing of the
valve, in case set the limits

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16. Check electric feeding of the solenoid valves and their
effective functioning

E Safety shutoff valves

17. The operation of the valves shall be tested by taking them to

fully open position and then applying pressure on the
sensing line

F Pressure regulators

18. Check the correct installation according to the P&ID. Set

point and performances shall be checked during

commissioning and start up activities

G MECHANICAL : GENERAL

19. Visual inspection of the exact location of instruments and

equipment

• Visual inspection of all flanged and threaded connections;

• Check the tightness of flanges

20. ELECTRIC MOTORS

21. Check the input voltage to the electric motors and the
phases sense

22. Start the engine and check for proper rotation. Make any
speed calibrations (e.g. pumps with variable speed). Once
the activity have been done switch off the engine until the
station have been put in service

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3.0 COMMISSIONING

3.1 Nitrogen Purging and Pressure Testing Procedure

3.1.1 Pressure Testing

The PRMS will be divided into two sections for the pressure testing activities:

1. Section between the tie-in point and Reduction

2. Section between Reduction and Outlet

To pressure test each of the sections, the valves at the beginning and the tail end of each section will be
closed and Nitrogen introduced through an instrument tube in the section. This will continue until pressure
of 20bar is achieved after which all the joints (flanged, welded, threaded etc) in this section will be tested for
leakages using soap solution.

When all leakages, if any, are arrested at this stage, Nitrogen introduction will continue until pressure of
40bar is attained. All the joints will be tested again for leakages and the section made to retain Nitrogen at
this pressure for about 12hrs. Whit the 40bar retained for this period, section 1 shall be raised to a pressure
of 60bar and leak test carried out again on all the joints. When all leakages are arrested at this stage and
the section retains Nitrogen at this pressure for 12hrs, the section shall be certified ok.

The section 2 shall be tested in this manner up to a pressure of 40bar as the expected maximum pressure
after reduction is 35bar.

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3.1.2 Nitrogen Purging

Once all systems have been successfully pre-commissioned, PRMS facilities can be purged with Nitrogen
to remove oxygen from inside the entire station piping.
The goal of these Nitrogen Purging and Pressurization Procedures is to make ready all equipment for the
start-up of gas flow to the power generating plant downstream of the PRMS.
Nitrogen Purging is done in a sequential and logical manner so as to displace all air (oxygen) from inside
the equipment and piping. The process of purging with Nitrogen to displace all oxygen will be subdivided
into purge “segments/sections” with the source of Nitrogen at the front-end and a VENT location at the tail-
end of the segment. Once a segment is successfully purged, the VENT valve will be CLOSED, the block
valve into the next segment will be OPENED and the vent valve at the tail end of the next segment
OPENED.
The purging of any segment shall be deemed successful when a valid Oxygen Sensor, placed in the flow of
vapors at the segment vent, reads 0.5% or less of oxygen content. This oxygen content is an allowable
percentage as it cannot support or sustain a flame or an explosion.

3.2 Introducing Natural Gas Into The Prms

This step will be carried out in a sequential and logical manner so as to pressurize the piping and
equipment to FULL PIPELINE Pressure up to the Pressure Reduction Valves and to the reduced pressures
of the gas pressure regulators.
Segments for Pressurizing the System
1) From station Tie-in to the CLOSED manual valves at the PRMS inlet
2) From the manual valves at the PRMS inlet up to the inlet of Reduction unit.
3) From the inlet of the Reduction Unit (using 1” bypass) up to the outlet of Reduction Unit.
4) From the outlet of Reduction Unit to the inlet of Metering.
5) From the inlet of metering to the outlet sales line manual valve.
6) From the outlet sales line manual valve to NDPHC line.
All these steps shall be undertaken by crack opening appropriately the right valves in every stage until the
whole station is fully commissioned.

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3.3 Start Up Of The Steam Boiler
The boiler start up procedure is as follows:

 Open the valve on the water lines to the boiler.

 Open the valves to the feed pumps.
 Start the feed pump.
 Open the gas valves to the boiler gas train.
 Check the presence of the pilot flames on the burners.
 The water boiler starts.
 Check if it is running with the right parameters
 Open VBF valve to the heat exchanger.
Attachments
1. Boiler P & ID
2. Boiler Service Connection Drawing.

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