Southern Luzon State University

College of Engineering

Lucban, Quezon

ME Laboratory 3

MCE23

VIDEO OUTLINE
9 KEY ELEMENTS OF COMMISSIONING

Submitted by:

May Grace D. Almirañez

BSME V-GO

Submitted to:

Engr. Ronelito San Jose

ME Department Faculty

September 18, 2018

 9 Key Elements for Successful Plant Commissioning

1. Planning

 Without proper planning, you will not be commissioned a plant safely and

in time.

2. Mechanical Completion

 This is the time when the commissioning team takes over the system from

the construction team.

3. P&ID Checking

 Commissioning Engineers were verify that everything in the field was built

according to specifications.

4. Pre commissioning

 It includes cleaning of pipes, by blowing and flashing, mechanical cleaning

of vessels and tanks, no load test rants of modules, etc.

5. Commissioning

 This step includes for example introduction to utilities, dry running trials,

safe fluid dynamic testing, solvent dynamic testing and process fluid test.

6. Start-Up

 This means the entire plant will be taken slowly to full operation.

7. Initial Operation

 This phase is necessary to prepare the performance test. During the initial

operation, the entire plant will be optimized.

8. Performance Testing

 Now, we have to prove that the plant meets all specifications under

normal operating condition.

9. Post Commissioning

 A reduced commissioning staff will take care and solved open punch

points. Don’t underestimate the time necessary for post commissioning

activities.
 PLANNING

The first priority during commissioning is safety. To ensure the safe work

you have to think carefully about the complete commissioning process. A good tool for

risk assessment is HAZOP (Hazard Operability Analysis). The pre commissioning and

commissioning of safe plans will be carried out using system by system and unit and unit

basis. Therefore each unit is divided into process and or piping and equipment systems

or subs systems. These systems are generally defined by process boundaries and

incorporate all equipment we carried for particular service or operation part. On a Master

P&Id Set, we mark the different system with different color.

Completion, prioritization means you have to think about the right order for

commissioning systems. Which unit or system do I need when? For example, usually we

need all utility system like plant air, instrument air, steam, etc. at first in the long time of

any process system.

After you wrote down the completion and prioritization, you have to

communicate it to the construction team to let them know which system to finish and

when. You have to consider which software tool you will used to re caught your

commissioning progress and to capture your test results. It can be one using extra sheets

with some kind of databases like excels or a very specialized software tools like ICAPS

(Integrated Commissioning & Progress System). It manages preparation, execution,

monitoring of all pre commissioning and commissioning activities.

Different documents that needs to prepare before the commissioning team will be
on site.

 Time Schedule

 Organizational Chart

 Checklists
  Operating Manual

 Pre-Commissioning Procedures

 Commissioning Procedures

 Safety Procedures

 Quality Control Procedures

 Security Procedures

 Emergency Response Procedures

 Status Progress Reporting

 Test Records

 Punchlist Template

We need to plan Manpower as well. That includes:

 Pre-Commissioning Team

 Commissioning Team

 Operating Team

 Maintenance Team

 Client’s Team

 Contractors

 Vendors

 Licensor

 Support from Office

It is important to plan the material which will be needed during pre-commissioning and

commissioning in advance. It includes:

 Blinds

 Spool Pieces

 Hoses

 Additional Gaskets

 Sample Bottles

It depends on the type of the plant you want to commission, which additional equipment

will be needed. Also, you should plan as well simple tools necessary.
 MECHANICAL COMPLETION

Checking and testing of equipment and construction to confirm that the

installation is in accordance with drawings and specifications and ready for pre-

commissioning or commissioning in a safe manner and in compliance with project

requirements.

Typical tasks for mechanical completion are divided by disciplines:

 Mechanical

 Visual inspection for complete and correct installation.

 Verification of name plate details at tanks, vessels, rotating equipment and

other machines.

 Internal inspection of tanks and vessels

 Hydrostatic test of vessels and tanks

 Vendor representatives for large and/or complicated equipment

 Piping

 NDT done (nondestructive testing)

 Pipe supports completed

 Removal of all items subject to damage during flushing, cleaning and

pressure testing

 Blowing

 Flushing

 Chemical cleaning

 Drying

 Preservation

 Reinstatement

 Bolt tensioning

 Insulation*

 Flow coding*
 Structural

 Inspection of all supporting machines

 Electrical

 Inspection

 Cable trays

 Cable tray supports

 Cable tray fill

 Cables

 Bend radius

 Wiring

 Termination

 Grounding

 Megger Testing

 Instrumentation

 Inspection

 Cable trays

 Cable tray supports

 Cable tray fill

 Cables

 Bend radius

 Wiring

 Termination

 Grounding

 Validation of instruments

 Validation of valves

 Loop checks

 Flushing of tubing

 Tightness test of tubing

 P&ID CHECKING

Can be considered as system check for construction and engineering errors.

Commissioning Team or Commissioning Engineers are responsible for executing the

checks. The things that need to checked are:

 Piping

 Equipment

 Instrumentation

 Point of View

 Safety  Operations

 Construction  Maintenance

We can also perform additional tasks to assist subsequent commissioning & start-up

activities. Such additional tasks can be the following:

 Temporary identification tags

 Temporary signs for various lines, valves and equipment

 Temporary signs for medium and flow direction

There are various documents you’ll need to perform for P&ID checks like:

 Plans  Standards

 Drawings  Hook Ups

 Checklists  Vendor Documents

 Specifications

When you performed the P&ID Check, you will for sure find one or more deviations from

the P&ID or other specifications. In such case, you have to put this deviations into a punch

list. If you are unsure of the validity of any item, just contact the lead unit process engineer.

Any punch items which changes any feature of the P&ID must be screened by the

lead unit process engineer from a design and safety point of view before implementation.

The punch list must be transmitted to the following departments:

 Construction

 Engineering

 QA/QC

As smooth start-up of any industrial plant depends to a large degree on the

thoroughness, the unit must be checked beforehand.

 PRE-COMMISSIONING

 The term Pre-Commissioning is used for activities after construction completion,

such as cleaning, catalyst loading, dry-runs and checks within the systems in order

to prepare these items/systems for the next step commissioning.

 Pre-Commissioning activities can be done after or as well before mechanical

completion.

 Since July 2013, Pre-Commissioning had been using API Recommended Practice

1FSC.

API Recommended Practice 1FSC

 Group of energized and static tests that constitute verification that the equipment

or component is fabricated, installed, cleaned, and tested in accordance with the

design and ready for commissioning.

 Also called “Static Commissioning”

Examples of Pre-Commissioning Activities:

 Flushing, blowing and drying activities

 Chemical cleaning

 Final inspection and closing of vessels and tanks

 Final reinstatement of systems or sub-systems

 Air tightness “Leak” testing of systems

 Lubricants application

 Pre-Commissioning “Run-in” of major rotating equipment and electrical motors

 Installation of filters

 Packing of distillation columns

 Loading of catalyst and molecular sieve beds

 Refractory dry-out (if possible-mostly commissioning activity)

 Vendor and factory acceptance testing

 Instrument, electrical and motor loop testing

 Punch listing(ongoing process)

Example of Pre-Commissioning (Petrochemical Plant)
1. Power and control system (electrical substations)

2. Building power, HVAC, fire & gas protection

3. DCS and PLC systems and instrumentation

4. Raw water and firefighting systems

5. Waste water treatment systems

6. Oily sewer/clean sewer systems and chemical sewers & neutralization pits

7. Service water/potable water/cooling water systems

8. Instrument air/plant air and refrigeration air systems

9. Water treatment systems, demineralization units and boiler water system

10. Nitrogen system

11. Flare system

12. Plant safety equipment and fire & gas detection

13. Fuel gas and fuel oil system

14. Slop systems

15. Flushing oil systems

16. Boiler systems with steam & condensate networks

17. Amine, aromatics and caustic drain systems

18. Feed & product storage systems

19. Product & feed systems

20. Sour water treatment section and chemical handling treatment section

21. Amine treatment section

22. All process systems in order of “priority”

Examples of Pre-Commissioning Procedures:

 Spectacle blind installation checks

 Non-return valve internals installation checks

 Thermal refractory lining installation checks

 Mechanical interlock checks

 Fitting of all locks on valves

 Packing of a distillation or scrubbing column

  Packing a reactor with catalyst

 Installation of filter medium and cartridges

 Air blowing

 Steam blowing

 Water flushing

 Chemical cleaning

 Tightness test

 Cooling water passivation

 Mechanical test run of pumps

Different Pre-Commissioning Checklists

 Is used to record the inspection and status of equipment items within the plant

 To conform readiness for commissioning

 Often to be witnessed by client, PMC & licensor

Pre-Commissioning Test Records

Pre-Commissioning test records are prepared to record the satisfactory completion

of various system preparation tasks & activities that includes:

 Cleaning

 Chemical cleaning

 Drying

 Air tightness test

 Loading of catalysts

 Blinds list

 Performance Indicators

 Construction QA/QC documentation

 Systems punch list (commissioning punch)

 Piping pre-commissioning activities

 Stationary equipment pre-commissioning activities

 Rotating equipment pre-commissioning activities

 Instrumentation pre-commissioning activities

 Tightness tests

 Reporting (Total, Completed & Remaining Tasks)

Pre-Commissioning Additional Records
 Request for mechanical completion acceptance

 Mechanical completion certificate

 Release for pre-commissioning notice

 Punch list report of outstanding punch points

During pre-commissioning, you will use also Vendor Specialists

 For major items or rotating machinery, major utility systems and special electrical

and instrument control equipment

 Package units

The licensor will responsible in conducting the:

 Final inspection of “critical” equipment installation

 Supervision of catalyst and chemical loading

At the end of Pre-Commissioning, we will get a Milestone called RFC.

 RFC (Ready For Commissioning) – means pre-commissioning activities are

completed and the systems are ready to commence commissioning

 API Recommended Practice 1FSC – is the minor milestone in project when pre-

commissioning activities for a discipline (electrical, instrumentation, mechanical,

piping, etc.) are essentially complete and ready to commence commissioning.

 Protocol – is used for documenting RFC

COMMISSIONING

 Commissioning is usually the phase in a project after pre-commissioning when

design process fluids are introduced to the systems and sub-systems. Sometimes

commissioning means running the systems with a safe fluid only.

 Commissioning moves the project from the “end of construction” closed to the

commercial operation status.

  A complete, well-planned and accurately documented commissioning effort is one

of the key factors that contributes to a trouble-free-start-up (the next step).

 API Recommended Practice 1FSC

 Group of energized and dynamic tests that constitute verification that each

system or subsystem is fabricated, installed, cleaned and tested in

accordance with design and the systems are ready for start-up.

Grey Area
 Cold Commissioning

 Hot Commissioning

Cold Commissioning

 Dry Commissioning

 are the tests and procedures that are conducted without solvents or process

fluids yet introduced to the plant.

 Sometimes already done during pre-commissioning

 Example activities

 Interlock and emergency shut-down tests

 Control system sequence checks

 Wet Commissioning

 Water or a solvent has been introduced into the systems or subsystems.

 Tests and procedures conduced with water or solvent

 We can play here operating scenarios and we see how system behave

 Example activities

 Running pumps with closed loops

 Interlock and emergency shut-down tests

Hot Commissioning
 synonym to “Live Commissioning”

 Design process fluids are introduced to the systems and sub-systems

 Activities similar to “Wet Commissioning”

RFC (Ready For Commissioning)
 Means pre-commissioning activities are completed and the systems are ready to

commence commissioning

 API Recommended Practice 1FSC – is the minor milestone in project when pre-

commissioning activities for a discipline (electrical, instrumentation, mechanical,

piping, etc.) are essentially complete and ready to commence commissioning.

 Protocol – is used for documenting RFC

In ensuring safety during commissioning, we must conduct:
 PTW (Permit to Work) – Is PTW system adequate?

 Security – Fencing of facilities, access control, protection from on-going

construction areas, etc.

 Emergency response – These procedures must be in place, commissioning staff

trained in their role in such procedures and practical drills held to confirm

effectiveness.

List of some commissioning common activities:

 Functional checks  Final drying

 Operating adjustments  Purging/Inerting

 Final leak testing  First fills

 Operation of systems and subsystems

 Completion of system turn over and completion package

Sequence for Commissioning process

 Commissioning of the facilities will be carried out on a system-by system and unit-

by-unit basis.

 Utilize a backwards approach

 Control systems, DCS, PLC

 Utilities (air, nitrogen, water, steam)

 Product storage, tank systems and loading

 Core process units (reaction, distillation)

 Raw materials feeds

 Raw materials storage

Commissioning Procedures Examples:
 Utilities and Services

 Water Solvent Commissioning

 Process Fluid Commissioning

Interfaces Examples:

 Operation and Maintenance

Done by the company

“Hands-on” activities for commissioning (and start-up operation and

performance test) of the plant under the direction, advice, and

supervision of the contractor’s commissioning staff, but directly

coordinated/supervised by company’s commissioning staff.

 Product Quality Control

Done by the company

Performing product quality control laboratory analysis for the new

facilities under the supervision of the contractor during the

commissioning and performance test phase.

 Production Planning

Done by the company & contractor

Company’s production planning for the existing facilities and contractor’s

production plan for the commissioning and operation of the new facilities

must be integrated during the commissioning, start-up and initial operation

phase.

This commence with first requirements for fuel gas, etc. from the existing

plant for boilers tart-up and heater’s dry through initial feedstock transfer

and final product storage, blending and shipping.

 Emergency Response, Security, Safety

Done by the company & contractor

Contractor’s emergency response plan for commissioning will require the

support of company and company’s local facilities/services.

 The new plant will be integrated with the existing facilities at commissioning

and start-up. Security of the new facilities requires coordination with the

existing.

Operations safety procedures and permit system for the new facilities must

be coordinated with the existing facilities from initial commissioning and

start-up.

 Maintenance Support

Done by the company

Company will perform “hands-on” duties and give technical support during

commissioning and start-up for routine maintenance activities and checks.

Such works will be coordinated with the company’s maintenance team.

 Vendors

Done by the contractor

All commissioning activities by contractor’s vendor specialist will be carried

out under the supervision of contractor’s commissioning team.

 Licensor

Where necessary, the process licensor may supervise the commissioning of

relevant systems and provide technical assistance.

Process operating parameters and conditions will be advised by process

licensor’s process engineers.

Pre-Start-Up Safety Review (PSSR)
 Last part of commissioning process

 Usually done by systems

 Usually managed by commissioning manager

 Client commissioning teamA

 Contractor commissioning team

 Licensor

Ready For Start-Up (RFSU)

 API Recommended Practice 1FSC

Signifies that system construction, pre-commissioning and commissioning work

are complete and the required safety verification is ready to commence start-up.

 Has to be put down in a protocol.

 START-UP

 The phase in a project where the entire plant (all systems and sub-systems) are

taken into operation. Process fluids are introduced and process conditions are

established with the intent of making products.

Ready For Start-Up

 Signifies that system construction, pre-commissioning and commissioning work

are complete and the required safety verification is ready to commence start-up.

 Has to be put down in a protocol.

Shift Works:

 Client  Vendors

 Contractor  Licensor
Shift log book

 Who

 How

 What

 Paper or electronically

 Client and/or contactor

Pre-Start-Up Safety Review

 Usually by systems

 Usually managed by commissioning manager

 Client commissioning team

 Contractor commissioning team

 Licensor


Pre-Start-Up Checks (What is required to be in place before start-up

 Utilities

 Feed

 Product Storage
Start-Up Procedures Examples:
 Pipe & equipment purging

 Pipe & equipment evacuation

 Initial introduction of feed & chemicals

 Initial heating or cooling

 To put a catalyst or other media into initial condition

 Valve positions for start-up

 Start-up sequence

 Holding steps

 Detailed procedures how the systems and the whole plant is brought into

operation

 “Normal” operation including data

 Shut down

 Emergency shut down

Interfaces Examples:
 Operations and Maintenance (by company)

Hands-on activities

 Product Quality Control (by company)

Product quality control laboratory analysis

 Production Planning (by company & contractor)

 Emergency Response, Security, Safety (by company & contractor)

 Maintenance Support (by company)

Hands-on duties & technical support

 Vendors (by contractor)

 Licensor

Where necessary, the process licensor may supervise the start-up of relevant

systems and provide technical assistance.

Process operating parameters and conditions will be advised by process

licensor’s process engineers.

 INITIAL OPERATION

 The entire plant is running in continuous operation, fine-tuned and prepared for the

performance test.

Shift Works
 Client  Vendors

 Contractor  Licensor

Shift Log Book (Hopefully already set-up during star-up phase

 Who  Paper or electronically

 How  Client and/or contractor

 What
Activities

 Fine tuning of control loops

 Tuning of process

 Testing of operational limits (emergency shut-down?)

 Preparation of performance test

 Data collection

 Equipment data

 Process data

 Performance data

Interfaces Examples:

 Operations and Maintenance (by company)

Hands-on activities

 Product Quality Control (by company)

Product quality control laboratory analysis

 Production Planning (by company & contractor)

 Emergency Response, Security, Safety (by company & contractor)

 Maintenance Support (by company)

Hands-on duties & technical support

 Vendors (by contractor)

  Licensor

Where necessary, the process licensor may supervise the start-up of relevant

systems and provide technical assistance.

Process operating parameters and conditions will be advised by process

licensor’s process engineers.

PERFORMANCE TESTING

 Mutual agreement between client, contractor and licensor

 To check if the plant is operating according to design

 API Recommended Practice 1FSC

Performance testing involves operating the facility and carrying out a series of

defined tasks, demonstrations and tests to measure the new plant and equipment

against the contract, design and nameplate parameters.

Duration

 Varies from plant to plant and industry to industry

Examples:

 Simple Water Treatment Plant (24-72 hours)

 Sulphuric Acid Plant 3x4500 tons per day (4x5 consecutive days)

 800 MW Coal Fired Power Station (Several months)

Shift Works

 Client  Vendors

 Contractor  Licensor

Shift Log Book (Hopefully already set-up during star-up phase

 Who  Paper or electronically

 How  Client and/or contractor

 What
Mutual Agreement

 Company and contractor mutually agree on performance test procedures, test,

sequences, schedules and other conditions for carrying out the performance

testing.
Interfaces Examples:
 Operations and Maintenance (by company)

Hands-on activities

 Product Quality Control (by company)

Product quality control laboratory analysis

 Production Planning (by company & contractor)

 Emergency Response, Security, Safety (by company & contractor)

 Maintenance Support (by company)

Hands-on duties & technical support

 Vendors (by contractor)

 Licensor

Where necessary, the process licensor may supervise the start-up of relevant

systems and provide technical assistance.

Process operating parameters and conditions will be advised by process

licensor’s process engineers.

Don’t Forget

 Are you able to take all necessary readings?

 Does everybody involved knows where to take the readings

 Does everybody knows what can be touched and what should not be touched

during performance testing?

 Is the laboratory ready?

 Do you have enough sample bottles?

 Does everybody know when and how to take samples?

 Does everybody know where and how to store samples?

Final Acceptance (FAC)

 After successful performance test

 Care and custody transferred from contractor to client

 Handover
 POST COMMISSIONING

 The phase starting after handing over the plant to the client (FAC) – until operations

assistance is not needed anymore and the outstanding punch points are solved.

Activities:

 Adjustments, modifications and fault correction

 Completion of outstanding punchlist items

 The first routine maintenance checks are performed, findings evaluated and

reported

 Process equipment and items covered by warranty are observed for possible

problems

 Operating data is collected and evaluated to ensure consistent plant operations

are maintained

Interfaces Examples:

 Contractor

Solving of outstanding punch points

Usually, at the beginning a few experienced commissioning engineers from

the “old” crew

Later usually just one

He or she is the first contact person for the client in the daily routine

Usually, just in day shift

 Company

Production Planning

Operations

Maintenance

Product Quality Control

Emergency Response, Security, Safety

  Vendors (by company)

For repair works

 Licensor

Where necessary, the process licensor may supervise the operation of

relevant systems and provide technical assistance

Duration

 Varies from plant to plant and industry to industry

 From a couple of months till years