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PRE-COMMISSIONING &
      COMMISSIONING

             A discussion on
             Pre-commissioning /
             Commissioning &
             Start Up of Projects




1
Contents

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

2
Contents(Continued)

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



3
Objectives


       Start-up and hand-over of the completed

        plant to the Client.

       To support client in operation of plant



                               .
4
COMMISSIONING
                                    & START-UP




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




                                                                           5
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
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
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
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
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
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
Pre-Commissioning Activities –
     Mechanical Discipline

        Verification of coupling and belt
         alignment

        Pumps / compressor checks

        Bearing lubrications

        Inspection / checking of filters & strainers

12
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
Pre-Commissioning Activities –
     Electrical Discipline(Continued)


        Motor installation

         –   Resistance maggering

         –   Rotation confirmation

         –   No load test run

14
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
Pre-Commissioning Check Sheets

        Vessel & Piping Check Sheets

        Mechanical Check Sheets

        Electrical Check Sheets

        Instrumentation Check Sheets


16      Operation / Process Check Sheets
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
Completion Activities

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


18
COMMISSIONING

        Definition

        Utility Description

        Commissioning Activities

        Check Sheets

        Commissioning / Start Up Procedure
19
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
Systems Description

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

21
Commissioning Check Sheets

        Commissioning check sheets are given in
         the Commissioning Protocol.




22
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
Issues for Discussion.


        Less re-work SS304, 304L

        Carbon filter back flow

        Go for the standard packages

        15 KM pipeline

24
THANK YOU



25

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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