RUWAIS REFINERY EXPANSION PROJECT PROJECT NO.

5578 (Crude Distillation Unit & Associated Downstream Units)

Commissioning & Start-up Strategy

September 2012 EPC PACKAGE #1 SK Engineering & Construction

TABLE OF CONTENTS

1. Objective
2. Scope of Work 3. Process Configuration 4. Priming Fluids 5. Commissioning & Start-up Sequence 6. Schedule 7. Work Definitions & Flow 8. Organization & RR Involvement 9. Areas of Concern

1. Objective
Safe Completion
- Implementation of HSE Plan & Procedures - Safety Audit - Pre-Startup Safety Review - Safety Training & Emergency Drill - TRA & Risk Assessment

Schedule On-Time
- Well Planned Preparation - Implementation of CMS - Tight Control of Commissioning & Start-up Activities/Schedule - Interface Management - Harmonized Communication & Coordination

Good Performance
- Qualified & Experienced Commissioning Work Force - Develop Detailed Procedures - Implementation of Training - Faultless Execution of Pre-commissioning / Commissioning Activities

Safety Turnover Schedule

Quality

2. Scope of work
Nov.2012 35 M May.2013 41 M Aug.2013 44 M Dec.2013 48 M Feb.2014 50 M

Construction Pre-commissioning
By Unit / Discipline
By Subsystem

Commissioning
Start-up & Stabilization
By Subsystem /System

Commercial Production

Test Run
By Unit

Construction Team
Pre-Commissioning Team

Commissioning & Start-up Team

COMPANY Operation / Maintenance Team

Punch A Clear

Punch B Clear

Punch C Clear

CONTRACTORs Care, Custody & Control

MC Certificate & Ready For Commissioning

CONTRACTORs Care, Custody & Control COMPANYs Assistance

Commercial Production Certificate & Ready For Test Run Certificate Provisional Acceptance Certificate & Hand-Over

Commissioning Completion

3. Process Configuration
Process Units - EPC #1
Unit No.
1 2 3 4 5 6 7 1100 1110 1120 1130 1210 1300 1400

Unit Name
Crude Distillation Sat. Gas Plant Sat. LPG Treating Sat. LPG Splitter SR Heavy Naphtha Hydrotreating H2 Manufacturing Kerosene Hydrotreating

Capacity
417.1 KBPSD 142.4 KBPSD 22.2 KBPSD 23.7 KBPSD 68.9 KBPSD 151.2 kNm3/h 107.8 KBPSD

Licensor / (FEED)
(Bechtel) UOP (Bechtel) UOP Haldor Topsoe (SSW) UOP

8
9 10 11 12 13 14 15 16 17

1510
1520 1530 1690 1700 1800 1810 1900 1036 1045

LGO Hydrotreating
HGO/LCO Mild Hydrocracking MHC H2 Recovery Benzene Reduction Sour Water Stripping MDEA Regeneration DEA Regeneration SRU & TGTU Spent Caustic Acid Gas Flare

74.8 KBPSD
57.4 KBSPD 2 t/h 26.9 KBPSD 120 m3/h 440 m3/h TBA 400 TPSD -

UOP
UOP (Bechtel) UOP (Bechtel) (Bechtel) (Bechtel) CB&I (Bechtel) -

3. Process Configuration (Main)

LPG 1110 SGP
Hvy Naphtha Intermediate Tank

1120/1130
LPG Treating / Splitter

C3 & C4
Lt. Naphtha Tank

Gasco Alkylation Unit

Hvy Naphtha
Kero Intermediate Tank

1210 H/N HDT 1400 Kero HDT

HDT H/N, S<0.5 ppm Naphtha Tank HDT Kero, S<10 ppm Jet Fuel Tank

Crude Oil

SR Kero

1100 CDU

SR LGO

LGO Intermediate Tank

SR HGO

HGO Intermediate Tank

1510 LGOHDT

HDT LGO, S<10 ppm Diesel Tank

1520 MHC AR RFCC Unit PRU WCN HDT LCO/LLCO Natural Gas 1300 HMU 1690 BRU H2

Naphtha, S<5ppm Blending

1530
MHC H2 Recovery

H2

H2 Users

Reformate

Treated Reformate Treated Reformate Tank

3. Process Configuration (Auxiliary)

Phenolic SW (RFCC) Non-Phenolic SW (Process Units) Brine (CDU)

1700 Sour Water Stripping

Stripped Water to WWTU Phenolic Stripped Water to RFCC

Rich MDEA Unit 1110/1520/1530

1800 MDEA Regeneration

Lean MDEA Unit 1110/1520 1530

Acid Gas

Rich DEA Unit 1600/1220

1810 DEA Regeneration

Acid Gas

Lean DEA Unit 1600/1220

1900 SRU & TGTU

Molten Sulfur to Granulation Plant

1045 Acid Gas Flare

Spent Caustic Unit 1120 Unit 1610/1620

1036 Spent Caustic Treatment

Oxidized Caustic to WWTU

4. Priming Fluids
Approx. Required Amount (BBls) Priming Fluid
Heavy Naphtha LGO - Flushing Oil Expected Date Required

Unit

Total

EPC1

EPC 3 Intercon. Piping

EPC 4 Intercon. Piping/Tank

Reasons for Requirement

- Inventorying for facilitates of Initial S/U - Removing remaining water in LPG service line to avoid icing during Initial S/U. - Allows flushing of System & checking out of Rotating Machinery. - For cleaning of filters & strainers during flushing rather than using Crude Oil. - Allows earlier S/U of Unit 1110, 1120 & 1130 before feed off-gas introduction from Unit 1100 - Earlier introduction of main feedstock from existing Ruwais Refinery - Allows the pre-sulfiding of catalyst per Licensors requirement. - Allows the pre-sulfiding of catalyst Per Licensors requirement. - Allows the pre-sulfiding of catalyst per Licensors requirement.

1100 1110 1100

6,000

6,000

Same line with Unit 1210 Heavy Naphtha feed line Same line with Unit 1520 LGO line

26 Jun 2013

26,600

26,600

21 Jun 2013

1110 1120 1130 1210 1400 1510 1520 1900 1300

LPG

1,586

1,500

86

25 Jun 2013

Hydrotreated Naphtha or SR Naphtha SR Kerosene - S/U Oil LGO - S/U Oil LGO - S/U Oil Granular Sulfur Methanol

68,219

46,700

134

Line: 925 Tank: 20,465 Line: 308 Tank: 20,165 Line: 264 Tank: 20,165 Line: 509 -

15 Jul 2013

100,400 70,963 59,195 6 tons 14 tons

79,600 50,400 58,600 6 tons 14 tons

327 134 86 -

04 Jul 2013
06 Jul 2013 06 Jul 2013

12 Jul 2013

24 May 2013

- Allows the pre-sulfiding of catalyst per Licensors requirement. - From Unit 1510 LGO Feed Tank - Allows fill-in of Seal Leg & Sultrap to avoid toxic H2S gas release from Sulfur Condenser to Sulfur Degassing Pit - Allows production of recycle H2 for Initial S/U before feed Natural Gas in. - No need if H2 is available from OSBL

4. Priming Fluids (continued)

* Tank Volume is based on Min. Operating Volume

5. Commissioning & Start-up Sequence

High Level Unit Interface For Start-up
EPC #1 UNITS Start-up
UNIT 1300

UNIT 1100

UNIT 1110 UNIT 1400 UNIT 1510

UNIT 1120

UNIT 1130 UNIT 1036

UNIT 1210

UNIT 1520 UNIT 1045 UNIT 1690 UNIT 1700 UNIT 1800

UNIT 1530 UNIT 1900

UNIT 1810

UNITS / UTILITY SYSTEM REQUIRED FOR STARTUP BY OTHER EPCS

EPC #2 UNIT 1600

EPC #3 EPC #4

Utilities
Crude Storage Tanks

Flare
Reformate Tanks

FG

NG
Intermediate Product Tanks Balance & Product Tanks

5. Commissioning & Start-up Sequence

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6. Schedule
Overall

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6. Schedule (continued)
Unit - Typical

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7. Work Definitions & Flow

System Approach
The System is defined as a major subdivision of an installation, being either process or non-process, which performs a major operational function of the unit.
Each System is further broken down into a Sub-System, which performs a given operational function, with no or little interference from other SubSystems for the Commissioning execution.

The most efficient way for achieving plant completion in a limited period of time will be to carry out Pre-commissioning and Commissioning activities by Systems and/or Subsystems according to the predetermined Mechanical Completion and Commissioning priorities.
The Pre-commissioning & Commissioning Schedules are prepared based on

Sub-Systems.
Each Sub-System will be tied to a database containing all elements of each Sub-System for tracking & recording the status of Sub-System Mechanical Completion and Commissioning.

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7. Work Definitions & Flow (continued..)

Mechanical Completion incorporating Pre-commissioning
The System / Subsystem has been erected in accordance with approved drawings,

specifications and applicable codes.

Activities include non-operating checks, inspections, testing, adjusting and cold alignment, etc. of equipment, piping, instrumentation, electrical to bring the System / Subsystem to MC and Ready for Commissioning. Piping Cleaning : Flushing / Air Blowing / Steam Blowing / Chemical Cleaning Reinstatement & Box-up Energize Electrical Network Rotating direction, Driver Solo-run, Alignment Instrument & Electrical System / Equipment SIT Loop Test & Functional Checks Operational Tightness Test Purging & Inerting (O2 Free)

Punch List A Clear

Utilities in service

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7. Work Definitions & Flow (continued..)

Work Flow for Pre-Commissioning & Mechanical Completion

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7. Work Definitions & Flow (continued..)

Work Volume _ No. of Components

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7. Work Definitions & Flow (continued..)

Commissioning
All works, activities and tests associated with preparing the Plant for the introduction of feedstock for the purpose of starting initial production of the end products prior to commencement of Test Runs.
Introduce Fuel Gas Flares / Hydrocarbon Drains activation Heater Firing & Drying out / Boil out Catalyst Loading Initial filling of Chemicals Operational Test

Priming Fluids Introduction Pre-Sulfiding & Cold Circulation Punch List B Clear Company assist with experienced refinery plant operation supervisory and shift operating personnel to supplement Contractor Commissioning Team.

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7. Work Definitions & Flow (continued..)

Work Flow for Commissioning Completion

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7. Work Definitions & Flow (continued..)

Start-up & Commercial Production Operation Feedstock-in Initial Start-up & Stabilization The plant will achieve stable, safe, continuous operation at no less than 80% of guaranteed capacity for a continuous period of 15 days at guaranteed product quality conditions. Performance Test Run To demonstrate to Company that Units can be operated safely under all operating conditions in accordance with Contract

- At Design Capacity for 72 hrs - At Turndown Capacity for 72hrs

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8. Organization Commissioning & Start-Up Organization Chart

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8. Organization (continued)
RR Operations Involvement
Contractor will provide sufficient and suitably experienced manpower for the successful completion of Commissioning, Start-up and Turnover.
To accomplish smooth handover of the facilities, early integration from precommissioning stage will be recommended. Smooth transfer of skills or know-how by close co-working with skilled and experienced CONTRACTOR or Vendors/Licensors man-power at the earlier stage can be possible. This will be helpful for RR personnel to develop their capability and to operate the plant in stable as a result. Suggested number of RR personnel to be integrated is the same number as the number of operating personnel during normal operation.

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9. Areas of Concern
1) Early Involvement of Companys Personnel for Integrated One-Team - Familiarization with Facilities - Witness & Supervision - Training 2) Interface between with other Contractors - On-Time Power Energizing & Introduction of Utilities 3) PSSR (Pre-Startup Safety Review) - Timing of Implementation

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