Commissioning & Interface With Engineering

1. PRE-COMMISSIONING &
COMMISSIONING
A discussion on
Pre-commissioning /
Commissioning &
Start Up of Projects
1

2. Contents
 Objective
 Common work at process plant at pipe
line
 Definition of Mechanical Completion
 Pre-Commissioning Definition and
Procedure
2

3. Contents(Continued)
 Activities (Piping & vessels, Mechanical,
Electrical, Instrumentation, Operations)
 Check Sheets
 Punch Listing
 Completion Activities
3

4. Objectives
 Start-up and hand-over of the completed
plant to the Client.
 To support client in operation of plant
.
4

5. COMMISSIONING
& START-UP
MECHANICAL
COMPLETION
SYSTEM / OPERATION
Inclusive of PLANT
COMMISSIONING PACKAGE STAFF
Pre-commissioning START-UP
HANDOVER TRAINING
Activities
5

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
6

7. Commissioning Works
At Pipe Lines
PRECOMMISSIONING SPECIALIZED PIPELINE CLEANING
•Cleaning •Dewaxing
•Flooding •Descaling
•Hydro testing •De-oiling
•Dewatering & Drying •Pit cleaning
•Flushing •Chemical cleaning
•Nitrogen Inserting •Combined cleaning methods
ASSOCIATED SERVICES PIPELINE INSPECTION
•Temporary pipeline repair •Geometry inspection
•On-site supervision •Metal loss inspection
•Cathodic protection •Crack detection
•Hot tapping & stoppling •Leak detection and location
•Flow assurance Etc. •Profile monitoring and mapping
7

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.
8

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
10

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
11

12. Pre-Commissioning Activities –
Mechanical Discipline
 Verification of coupling and belt
alignment
 Pumps / compressor checks
 Bearing lubrications
 Inspection / checking of filters & strainers
12

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.
13

14. Pre-Commissioning Activities –
Electrical Discipline(Continued)
 Motor installation
– Resistance maggering
– Rotation confirmation
– No load test run
14

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
15

16. Pre-Commissioning Check Sheets
 Vessel & Piping Check Sheets
 Mechanical Check Sheets
 Electrical Check Sheets
 Instrumentation Check Sheets
16  Operation / Process Check Sheets

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
17

18. Completion Activities
 Flushing Blowing Certificates
 Box Up Certificate
 Mechanical Completion Certificate for
each Utility and Process Unit
 Handover Certificate
18

19. COMMISSIONING
 Definition
 Utility Description
 Commissioning Activities
 Check Sheets
 Commissioning / Start Up Procedure
19

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
20

21. Systems Description
 Instrument Air Package
 Inert Gas Package
 Fuel Gas System
 Closed Drain & Waste Water Systems
 Condensate Transfer System
 Process Units; Reactor
21

22. Commissioning Check Sheets
 Commissioning check sheets are given in
the Commissioning Protocol.
22

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.
23

24. Issues for Discussion.
 Less re-work SS304, 304L
 Carbon filter back flow
 Go for the standard packages
 15 KM pipeline
24

25. THANK YOU
25