The station piping, pumps or compressors, electricals, instrumentation, and control systems and safety systems have to be ready for operation before the pipeline can be commissioned. All temporary strainers shall be periodically checked during flushing and if contaminated with sediment, shall be cleaned. These visual checks will be carried out to find the gaps / deviations in the constructed facility with respect to the approved drawings issued for construction. 4. Start-up and Commissioning of the Pipeline (With PDF) Percentage bias current test shall be carried out. Pre Commissioning Of Pipelines This procedure gives minimum requirements for dewatering, cleaning, drying & preservation of pipelines. A commissioning checklist is used to ensure the safety and functionality of new or modified systems in a facility. The hydrostatic testing is done by construction personnel. A commissioning inspection is performed to verify that the end result of a commissioning process is done according to the projects specifications and based on the requirements of the client. Experience has shown that the time and effort put into flushing and blowing systems and pipelines prior to start up results in less trouble encountered during and immediately following start up. Once this is complete, the pipe is ready for testing preparations. The equipment undergoes analysis at each stage to ensure the plant process is operating as specified. Welding sockets shall be energized and phasing, earthing and output voltage shall be checked. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Title Pre-commissioning Manual Document Number Page Rev. Verify that all buildings have been constructed in accordance with the applicable drawings, specifications, and standards C. ELECTRICAL 1. Precommissioning Definition | Law Insider and blown through to remove deposits. 2. The programming display will be checked to verify the functionality of all controls, inputs/outputs, status, alarm, measurement, etc. Date 29 of 45 0 16-11-2016 Should flash over occur during high voltage testing then the test shall be deemed to have failed. For mechanical systems, pre-commissioning activities consist of cleaning and flushing of pipes, pressure testing, and leak testing. Check the correct relief valves are installed in equipment/piping as per the P&IDs (check tag plate details). Easily customize or build your own checklist usingSafetyCulture template editorto meet specific equipment design requirements and fulfill company needs. PDF PROJECT STANDARD AND SPECIFICATIONS off shore commissioning procedures Date 15 of 45 0 16-11-2016 Report completion status throughout all project completion stages. Valve positioner gauges should also be checked during this stage. Since it will not be practical to pressure test all equipment in the plant simultaneously, the plant should be divided into sections (namely Test packs) as governed by the test pressure for each section. After the above test & setting, current injection 2 times the set current and then current injection 5 times the set current shall be done. The categorized punch list shall be transmitted to Company for review and approval. Once all mechanical and electrical components are complete, system commissioning can begin, where all the electrical and mechanical equipment works together as a system for the first time. 13. Verify instrument piping and / or tubing shown on the P&IDs and the Instrumentation Schematic Drawings for fitting type, materials, connection sizes, and rating. The construction team will verify that drawings are marked up (red-green drawings) to indicate the as-installed condition, and mechanical completion is the point in time when the red-line drawings are delivered to the commissioning team. B - Items are those activities that must be completed prior to Hydrocarbon Introduction. 2) Check valves, globe valves, and choke valves are installed in the correct flow direction. At each mechanical completion, a deficiency list is generated and any Type-A deficiencies rectified before moving into the pre-commissioning phase. Pre-commissioning means tests and verifications on the equipment and associated accessories as per specification which is required to be carried out by the Contractor in preparation of commissioning. Safe Chemical Commissioning authorization and Pre-commissioning Procedures . Male / female contacts mating for both power & control circuitry shall be checked for proper operation. I worked as a commissioning engineer for several projects, including an offshore platform, a few petrochemical plants, and an LNG terminal. This manual will be used by the Pre-commissioning Team to verify and document that all equipment and systems have been checked out and are ready for commissioning. Verify that discharge check valves are installed in the proper flow direction on all pumps. Check that proper clearances are maintained between rotating parts and guards. b. The operations staff have a vested interest in the operation and maintenance of the systems, and are often the best to manage any document management systems or setup of asset management systems. PDF PRE COMMISSIONING SPECIFICATION FOR #03-12 Block Aronia, CLEANING OF On installations which involve instrument seal pots or reference legs, the system shall be filled with the recommended fluid. 15. Same vents should also be opened before draining the test water. Telephone: 810-664-1801. ISS International Standard Pre-Commissioning,Commissioning and Start-up Methodology is organizedconsidering the entire project frame and having in mindthe following objective: TO CONDUCT THE PLANT IN OPERATION. Precommissioning Procedure - [PDF Document] It also proactively identifies any modifications needed through detailed assessment of the commissioning project. f) Disconnect field wiring from transmitter and connect a receiver test instrument and check for zero error & span and get it corrected. Pre-commissioning or Commissioning Activities Before a plant or facility is handed over for normal operation, it should be inspected, checked, cleaned, flushed, verified and tested. [emailprotected] Allowable tolerance is four or less bubbles per minutes. As you can see, there is a lot involved in commissioning and starting up an industrial plant. When project managers useSafetyCultures scheduling feature, key personnel automatically receives scheduled inspection notifications via SafetyCulture mobile app, email, or text messages (SMS). Vary the process input signal to the transmitter, as required by the checklist, and check output for proper zero and span. i) Where possible all float or displacer elements shall be checked for pin hole leaks i.e. An air conditioning commissioning checklist is used to validate that packaged air conditioning units still conform with design specifications after installation onsite. e. Verify that hydro testing (or pneumatic testing) has been successfully completed at the required pressure, either by witnessing the work or checking construction records. The check sheet for Lighting and Small Power Fittings shall be completed. 3. However, the overall process to plan, commission, and startup a project is similar in each case. The warranty period may require more specific maintenance requirements in order to maintain warranty, and this needs to be implemented in the asset management system for future demonstration of compliance to maintenance requirements to the contractor. Some . Potable water is the recommended for hydrotesting purpose. Pre-Commissioning Pre-commissioning activities are Site Acceptance Tests (SAT) and Factory Acceptance k) After the above check, all elements will be replaced in their protective wells ensuring that the element length matches the associated well length. System and Sub-system boundaries shall be prepared utilizing design data in the form of marked-up: P & IDs Electrical Single Line Diagrams (SLD) Fire & Gas Drawings Telecom Drawings Instrument Block Diagram HVAC Flow Diagrams Plot Plans (for Civil) WinPCS administrator will maintain pre-commissioning completion status including other supporting information such as punch list etc. Blind all safety valves and disconnect all instruments. These procedures are an important part of the transition process from pipeline construction to operation. The starter shall now be closed and the motor bumped to check the direction of rotation. c) Connect a 5.5 bar(g) air supply to the shutdown valve actuator supply. Each craftsman such as mechanical technician, instrument technician, or electrician, who is assisting the Pre-commissioning Team, shall have his normal tool kit available. Precommissioning is the physically/ mechanically finishing of construction work and cold alignment check of each system, unit, and overall area that conducted by the Contractor, and witnessed/ approved by the Owner. The pre-commissioning phase includes three main types of activities a) conformity checks, b) static (or) de-energized tests and c) piping tests; whereas the commissioning phase comprise of activities such as a) dynamic verification, b) testing with substitute fluids for start-up, c) piping and vessels start up. b. Oil temperature indicators shall be calibrated with a standard thermometer. PICK UP test shall be carried out by keeping the pick up current tap setting at various set points and injection of current shall be done on all three phases and pick up values shall be recorded. On completion of these documents, these will be stored system wise / sub-system wise in WinPCS. Precommissioning and Commissioning Procedure | PDF | Natural Gas This checklist includes, This piping pre-commissioning checklist can be used by pipeline engineers to perform flooding spread set-up (dry commissioning), pipeline pig valve, A plumbing commissioning checklist is used to carefully examine the piping system in a facility and prove it works according, A pump commissioning checklist aims to validate the operation of pumps through correct installation, proper lubrication, and simulation of instrumentation, A chiller commissioning checklist is used to thoroughly record observations before and after the start-up of chiller systems. Date 35 of 45 0 16-11-2016 Testing of Motors 4.7.1 Initial Check The details of the motor shall be recorded in the check sheet for Electrical Motor 4.7.2 Pre-commissioning Test 4.8 Polarization Index (PI) for stator windings shall be measured. The intention is to ensure that the pipeline are clean up to the equipment throat. Detailed procedures for these activities are provided in the next section of the manual. Date 33 of 45 0 16-11-2016 4.3 Power Management System Panel Testing 4.3.1 Visual inspection to ensure that all components/equipments are intact & free from damage. These require blowing out using a hand held air hose/blower. The energization of the electrical distribution network is part of this activity. As a standard practice for air blowing, care must be taken, not to blow into a vessel or equipment. PDF Commissioning System File - Elsevier Im glad you enjoyed my 3-day mini-course and hope it can help you in your career! Transmitters are to be rechecked at 0%, 25%, 50%, 75% and 100% of span. 4.0 Testing and Pre-commissioning Procedures 4.1 Hazardous Area Equipment 4.1.1 Installation All items of electrical equipment including bulk ordered material installed in a hazardous area shall be inspected strictly in accordance with Area Classification requirements. are correctly installed and verify for any damage to internals. The usual steps included in a commissioning process are preparation, design, pre-construction, construction, commissioning of services, pre-handover, initial occupancy, and post-occupancy care. PRE-START UP ACTIVITIES: process operations of preparing the system / sub system ready for oil or gas-in. The asset management system contains information on each asset, the hierarchy of installation, nameplate data for each, preventative maintenance requirements, and warranty information. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. Efficiently validate the performance of HVAC, pumping, piping, and lighting systems using this comprehensive checklist. d) Check for free access for operation and maintenance. Pre-Commissioning, Commissioning, and Start-up - CommTech Global The completion activities are separated in two phases, called Pre-commissioning and Commissioning, this split generally corresponds to static and dynamic testing phases respectively. At the same time the project will achieve a full set of records related to installation, calibration, functional tests and certificates, in the form of electronic copy. Date Precision temperature potentiometer Precision wire wound resistor decade box +1 deg. Document Title Pre-commissioning Manual Page Rev. 4.2. These will be stored in WinPCS. All connections used for the leak testing are soap leak tested after the bubble test. 3.1.1 Insulation Resistance (IR) Test IR testing shall be carried out using a DC voltage megger. integrity test procedure, if this is the case commissioning need to create a list of Commissioning is considered complete, after completion of Performance Test Run. An elevator commissioning checklist aims to clearly detail elevator specifications and accurately measure the elevator ride quality. Check the printout of the software output data. All the field inputs & outputs including both serial & hardwired cables shall be hooked up to the system. Witness or calibrate and test all instruments in accordance with the Pre-commissioning Procedures, and record all the calibration & test data on the checklists provided for each instrument and instrument loop. Automatically generate and share commissioning reports before leaving the facility. The procedures stated in this Testing and Commissioning (T&C) Procedure cover the activities in preliminary tests and inspections, functional performance tests and the . Based on 14 documents. Leaks and defects, if any, shall be rectified after the pressure is brought down and media is drained. If the constructor is required to provide any specialized equipment, this is defined as well. Hydrostatic Testing This test is carried out by filling water in the pipe to be tested and increasing the pressure to the specified pressure. For identical connections the measured value shall not differ by more than 20%. Close this message to accept cookies or find out how to manage your cookie settings. Commissioning activities can only be carried out after pipelines have been duly pre . PDF Start-Up and Commissioning at Water Treatment Facilities Date 9 of 45 0 16-11-2016 Hard Hats First Aid Kit Face Shield Chemical Gloves Safety Goggles Safety Boots Boiler suits/overalls Safety belts / harness to work at height Self Contained Breathing Apparatus-SCBA (if required during Nitrogen handling) Permit to Work (PTW) will be controlled by PETROJET till mechanical completion (MC) stage or energization of substation, whichever is early. All field devices are installed at this point, so field wiring is confirmed to be correct, and a subset of FAT tests are repeated to ensure the equipment can communicate to all field devices and that equipment is calibrated. Pipe work to be tested is generally divided into groups (hydrotest packs) of similar test pressures and isolated from other sections by installing suitable blinds or disconnection. The preparation for air blowing shall include following: Preparation of detailed procedure outlining the proposed methods and loop covered, supported by marked up P&IDs. The approval of Company shall be obtained for the clearance of all punch list items. All Rights Reserved, Common Pipeline Pigging Terminology to Know, How Gas Pipeline Leak Detection Has Changed Through Time, American Pipeline Solutions, Inc., 84 A Johnson Avenue, Hackensack, NJ 07601, USA, Pipeline Inspection / Pipeline Condition Analysis, Municipal Water Main & Force Main Pigging, Checklist for Pipeline Pre-Commissioning Procedures. E. MISCELLANEOUS MECHANICAL EQUIPMENT Verify that all Miscellaneous Mechanical Equipments have been installed according to specification and applicable drawings. Flow Element (Orifice) a) Check the meter run with the mechanical flow diagram to ensure proper installation in relation to the direction of flow. For each system, a set of installation / Pre-commissioning check list banks shall be compiled covering all the items in the system. On completion of construction, the pipeline system is to be put on operation. The filling hose from the pressure generator is connected to the lower most drain point of the system to be tested. All orifice plates can then be installed and joints tested. In case of any discrepancy, these shall be rectified. Commissioning Checklists: Free PDF Download | SafetyCulture Check the functioning of input/output signals from serial link with DCS,ESD,MV/LV Switch gears, Vests Controller, GTG control panel, AC/DC UPS system etc. This project commissioning checklist can be used by commissioning teams during the planning, designing, construction, and post-construction phases of a project to achieve desired outcomes. 2. 3. A pipeline must be pigged before any other step to ensure all construction debris has been removed. Everything explained in brief manner. Test shall start with verification C.T shorting switches by withdrawing the relay elements. Should an item in the check list is not completed or not meeting the design drawings and specifications, the Pre-commissioning / Commissioning Coordinator shall compile a punch list of all such items. Switchgear Installation Check Sheet Ductor Test shall be carried out on all bus bar joints, circuit breaker bus bar plug in contact and isolator contacts. 4.2.5.3 Trips for the breakers shall be simulated from the protective relays and process interlocks. Date 28 of 45 0 16-11-2016 installation. It is recommended to use the Rota-align (Laser Alignment Device) for the alignment of all critical rotating equipment. C - Items are those activities that must be completed prior to issuance of Performance Acceptance Certificate When all A punch list items from the Pre-commissioning Punch list are attended and cleared then the system is considered as Ready for Commissioning (RFC). Refer to vendor data books. INSPECTION AND TESTING 17 B.1.1 CHECKING AGAINST P&IDs 18 B.1.2 VESSELS AND TANKS 19 B.1.3 ROTATING EQUIPMENT 19 B.1.4 VENDOR PACKAGE ITEMS 21 B.1.5 PROCESS PIPING 21 B.1.6 HYDROTESTING AND CLEANLINESS OF LINES 23 B.1.7 LEAK TESTING & INERTING 26 B.1.8 BUILDINGS 27 2 of 45 0 16-11-2016 SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. PDF Commissioning & Start-up Directory - ISS International Site hydrotest is not required for shop fabricated vessels. Published online by Cambridge University Press: Contracts will typically define the training that the contractor is required to provide. physical description of that subsystem. COMMISSIONING The commissioning phase essentially includes the four categories of tasks as follows: a) Dynamic verifications of each elementary electrical and instrument function that the plant equipment is designed to achieve, performs properly. 4.2.5 Circuit Breaker Test 4.2.5.1 Individual CBs, shall be checked / tested as detailed in the form for HV Circuit Breaker and Cubicle Test Sheet and the results recorded. The P&ID (Piping and Instrumentation Diagram) of each system / sub-system shall be colormarked when each item in the list is checked against the Issued for Construction P&ID of the system / sub-system subjected to punching. PDF UPS Commissioning Guide - Critical Power Resource A plumbing commissioning checklist is used to carefully examine the piping system in a facility and prove it works according to its design. Rating. This is the point where pre-commissioning ends and commissioning begins. Open hydrotest vents to ensure complete draining. Blinds must be made and installed in the system to isolate sections. What do we need prior to commissioning? b) Slowly increase the input using the test device while observing the positioner output pressure and valve position. During this test, the isolator shall be in manual position. What Is Precommissioning & Commissioning? | Bizfluent Glass shall be left clean. When run through the pipe, these mechanical fingers or arms help record the internal structure of the pipeline. thank you. Total loading time: 0 The tightness of all terminals shall be verified. . Contents 1.0 INTRODUCTION 2.0 SCOPE READY FOR START-UP: status of the plant when all systems of the plant are commissioned and are ready to receive the Hydrocarbon Introduction for operation start up. Check all electrical closures. Blanks and spool pieces provided for test purposes shall be removed and permanent service gaskets shall be provided where test gaskets were used during the test. Ratio test shall be done by applying low voltage on high tension side and measuring on low tension side of the transformer. Use this checklist to easily inspect control systems, wiring, sensors, field control devices, and the site communications network. Cooling water System 3. All the gaps thus found out will be listed on the punch lists. Special care must be taken in case of rotating equipment so that dirt does not enter the machine. We use cookies to distinguish you from other users and to provide you with a better experience on our websites. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. 10. Commissioning is the on-site process to verify that equipment has not been damaged during shipping since the FAT was completed. Effectively test programmable thermostats, condensing units, and variable air volume (VAV) terminals and handling units using this intuitive checklist. 1. Orifice plates shall not be installed. Please check this article to learn more aboutOperational Readiness, Training is a key deliverable for the operating individuals to obtain from the project. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. e) Verify that the external paint and coatings are in accordance with the specifications as to application, type, color, and thickness, and that any damaged coating has been repaired. Some equipment may have extended warranty, such as battery systems, or others, than extend longer than the project warranty duration. This checklist has been designed, This electrical commissioning checklist is used for the commissioning of low voltage installations in a building. 12. g. Verify that insulation and heat tracing is installed in accordance with the specifications, plans, and drawings. Normally, a portable positive displacement pump will be used to raise the pressure. Pre-commissioning is primarily done to ensure that all pipeline construction was satisfactory and meets the standard safety specifications. Dry commissioning confirms proper function of mechanical systems without process fluids, while wet commissioning adds the process fluids and chemicals to confirm operation. Testing for Lighting & Other Distribution Boards & Sockets etc.