1. PRE-COMMISSIONING &
COMMISSIONING
A discussion on
Pre-commissioning /
Commissioning &
Start Up of Projects
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2. Contents
Objective
Common work at process plant at pipe
line
Definition of Mechanical Completion
Pre-Commissioning Definition and
Procedure
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4. Objectives
Start-up and hand-over of the completed
plant to the Client.
To support client in operation of plant
.
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5. COMMISSIONING
& START-UP
MECHANICAL
COMPLETION
SYSTEM / OPERATION
Inclusive of PLANT
COMMISSIONING PACKAGE STAFF
Pre-commissioning START-UP
HANDOVER TRAINING
Activities
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6. Commissioning Works
At Process Plants
PIPING / VESSEL ELECT / INSTRUM
•Flushing/Blowing •Preliminary Check
•Chemical Cleaning •Calibration
•Reinstatement •Circuitry Check
•Gross leak with N2 •Continuity Check
•Drying •Loop Test
•Inerting • Energization (Power Up)
•Hydrocarbon In •Performance Tests
MANAGEMENT
•Systems Breakdown
•Preparation of Procedures
•Loop Folder
•Circuit Folder
•Test Packs
CONTROL SYSTEM
ROTATING EQUIPMENT •SCADA / PCS SAT
•Alignment •Fire & Gas System
•Belt Tensioning •Safety Shutdown Sys.
•Motor Run in Test •Alarm Set-Up & Test
•Vibration Test •Simulation Test
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8. Definition of Mechanical Completion
& Construction Completion
Mechanical Completion: A series of
activities that MUST be completed prior to
the commencement of Commissioning and
Start-up of a Utility System or Main Process
Unit.
Mechanical Completion ALSO includes
ALL pre-commissioning activities.
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9. Pre-Commissioning Overview
Process: Confirmation of Loops
according to P& ID’s
Vessels: Internal Inspection & Box up
Piping: Hydro testing, reinstatement &
verification of main gaskets.
Stationary Equipment: Tightening and
Final Box Up.
Rotary Equipment: Leveling, Rotation,
9 Alignment & lubrications
10. Pre-Commissioning Activities –
Piping & Vessels
Field checks as per isometrics and P&ID’s
Verification of hydro testing
Verification of flushing , blowing & drying
Internal inspection of equipment as
required
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11. Pre-Commissioning Activities –
Piping & Vessels(Continued)
Verification of Internals
Re-instatement of all flanges, control
value, orifices, Psv’s and steam traps.
Verification of blinds / spades installation
and / or removal
Box up: Pre-commissioned and closed
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12. Pre-Commissioning Activities –
Mechanical Discipline
Verification of coupling and belt
alignment
Pumps / compressor checks
Bearing lubrications
Inspection / checking of filters & strainers
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13. Pre-Commissioning Activities –
Electrical Discipline
MCC & UPS installation
Field electrical installation
– Cable Meggering (Continuity)
– Termination of wiring; end devices
to JB’s & MCC
– Termination & Glanding according
to area classification.
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14. Pre-Commissioning Activities –
Electrical Discipline(Continued)
Motor installation
– Resistance maggering
– Rotation confirmation
– No load test run
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15. Pre-Commissioning Activities -
Instrumentation
Instrument installation checks
PSV calibration
Calibration of transmitters and switches
Loop checking of device end to PLC
Function testing of PLC & ESD systems
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17. Punch Listing
Punch Lists are created and sorted as per disciplines
– Piping and Vessels
– Mechanical
– Electrical
– Instrumentation
– Operations
Punch Lists are categorized on a priority basis
– Category “A”; MUST be completed prior to
Commissioning
– Category “B”; MUST be completed prior to Start-up
– Category “C”; Signifies end of job
Construction Contractor MUST have a coordinated
management plan of Punch Listing including categorizing
of punch list items
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18. Completion Activities
Flushing Blowing Certificates
Box Up Certificate
Mechanical Completion Certificate for
each Utility and Process Unit
Handover Certificate
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20. Systems Description
Commissioning of The Following Systems
Air Compression System
MCC & Plant Lighting System
UPS, PLC & Plant ESD System
Fire Water System
Fire & Gas Detection System
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21. Systems Description
Instrument Air Package
Inert Gas Package
Fuel Gas System
Closed Drain & Waste Water Systems
Condensate Transfer System
Process Units; Reactor
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23. START-UP OF PROCESS UNITS
Utilities in Service
Introduction of Raw material (Vacuum Residue
Feed)
Introduction of Process Air & Steam
Production of required grades of products
Maintaining required proportion of off gases as
per specs
Achievement of required steam temperature
Obtaining steam temperature compatible to
system steam temperature.
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24. Issues for Discussion.
Less re-work SS304, 304L
Carbon filter back flow
Go for the standard packages
15 KM pipeline
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