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. This process is called
commissioning and involves both the contractor and operator of a facility.
The transition from construction to operation is the commissioning and startup.
Processing plant commissioning embraces activities such as cleaning, flushing,
verifications, leak tests, performance evaluation and functional tests essential
for bringing a newly installed plant or facility into routine operation.
Correct commissioning is vital to the satisfactory operation of any plant or
facility. A schedule must be established with benchmarks and monitoring
activities in order to keep track of progress.
Health, Safety, and Environmental (HSE) Management plan:
HSE Plan should be developed for the project. In addition, other plans and
procedures to cover the inherent risks associated with pre-commissioning,
commissioning, and other activities as well as risks associated with the
performance of these activities while others are working in adjacent areas of
the facility.
Instrumentation Commissioning takes place when Mechanical completion is
completed for a system or part of a system.
Commissioning can be divided into three main activities:
Commissioning preparation
Commissioning execution
Commissioning documentation and handover to operation
Commissioning Preparation
commissioning preparation required to maintain two types of records
1. Commissioning Preparation Check Record
Valves and equipment flow direction correct.
Orifice plates installed check plate tab and its description.
All instruments hooked up.
2. Instrument Installation and Inspection Installation check
1. Check the instrument against the datasheet.
2. Check CE marking.
3. Check calibration certificates.
4. Installation check.
5. Leakage test.
6. Flushing carried out.
Few example checklists:
Transmitter Loop Checklist
Process Switches Checklist
PID Controller Checklist
PLC Digital Input Checklist
Instrument Installation Checklist
Commissioning Execution
Calibration and testing of instruments prior to installation.
Visual inspection for complete and correct installation.
Insulation and continuity testing of cables.
Cleaning, flushing, pressure and leak testing of pneumatic and hydraulic
tubing.
Adjustment of control, alarm and shutdown settings.
Loop testing.
Function testing of control systems.
Function testing of field instruments.
Punch point list for field instruments
Area completion.
Commissioning Documentation Preparation & Handover
Following are the documentation is prepared before the startup or at the end of
commissioning and to be handed over once the commissioning process has
been completed.
Engineering Documentation
Cable Diagrams/Schedules
Instrument Indexes
System & Marshalling cabinet cable schedules and Junction Box cable
Schedules
Vendor Lists
Vendor Manuals including all vendor documents/drawings, Contractor
Commissioning and Start-Up plans (CSU) and Operating Manuals
Commissioning Spares Lists
Valve Lists
Cause and Effects Charts
Trip Register/Schedule
System P&IDs
Punch points list.
Final Documents for Commissioning
After the successful completion of all pre-commissioning activities, the following
list of final documents should be available readily for the commissioning
activities.
1. System P&ID’s
2. Decontamination procedure & isolation register
3. System cleaning procedures
4. Hazard Study and actions
5. Equipment Check Sheets, off and on-site checks
6. System Punch lists
7. Action upon Alarm Sheet
8. Handover Certificate Construction/Maintenance to Commissioning
9. Project documentation check sheet prior to the introduction of safe
chemicals
10. Safe Chemical Commissioning authorization and Pre-commissioning
Procedures
11. Leak Test Checklist and Procedures
12. Instrument Check Sheet
13. Motor Check Sheet
14. Interlock Check procedures
15. Emergency Shut Down System check procedures
16. DCS sequence test procedures
17. Relief Stream Check Sheets
18. Critical Insulation Checks
19. Critical Gasket Installation Checks
20. Lubrication Check Sheet
21. PSSR, Plant Check-out prior to the introduction of Hazardous
Chemicals
22. Documentation Requirements for Ongoing Maintenance Group
23. Authority to Introduce Process Chemicals, check sheet & Certificate
24. Commissioning Procedures
25. Standard Operating Procedures
26. Commissioning to Plant Handover Certificate
