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2.

0 PRE COMMISSIONING

2.1 Pre Commissioning Activities

Pre-commissioning activities undertaken after mechanical completion, but prior to


commissioning, are to prove and validate the functioning of equipment. The activities may
involve the introduction of fluids into systems, but not hydrocarbons.

Typically, pre-commissioning activities will verify the documentation to support mechanical


completion is in place, and not repeat work carried out to achieve mechanical completion. Such
activities are carried out on a single discipline basis, by system or subsystem, and require
equipment or systems to be energised, but do not require the introduction of process fluids.
Activities include instrument loop checks, panel function tests, energising electrical equipment
and running motors without loads. They are documented on checksheets, which will also be
generated and managed by the Project Certifications and Commissioning Management System
(CCMS) to ensure that asset integrity can be verified and demonstrated.

At the start of pre-commissioning the Completions Management System (CMS) needs to be


ready, operational and maintained up to date and the commissioning Permit to Work (PTW)
System activated.

2.2 Plant inspection

Before pre-commissioning operations begin, it is important that all equipment and pipes been
thoroughly checked to ensure that they met the detailed P&IDs and the project specifications.
Through this, mistakes committed during construction can be found and rectified. Inspection of
the plant can be basically divided into the following areas:

Personnel and safety


Vessels and heat exchangers
Reactors and columns
Machinery
Piping
Electrical and instrumentation

For each of these areas, a checklist of the essentials should be provided. This checklist can be
used as a to do list before commencing preparations for startup.
NO Personnel Safety Vessels/Heat Exchangers Columns/Reactors
1 Medical checkup for all site General cleanliness. General cleanliness.
personnel prior to
commencement of work.
2 Copies of accident prevention Internal baffles : type, Column trays level.
regulations are available. orientation, levelness.
3 First aid kits are available. Dip pipes correctly installed. All internals proper fit.
4 Emergency telephone number Vortex breakers as per Trays liquid tight.
for accidents, fire are displayed specifications.
at important places.
5 Fire extinguishers available. Demisters correctly installed. Type and height of
packings correct.
6 Necessary safety clothing used Location and orientation of All bottlings and clips
by all personnel at site. instrument nozzles verified. tight.
7 All necessary safety equipment Insides of tubes inspected to Catalyst bed correct
available. check possible fouling. height.
8 Guidelines for handling of Motor switches located near Feed pipe or distributor
dangerous materials are exchangers for air coolers. direction/orientation
available. correct.
9 Procedure for issue of work Proper motor rotation. Type and size of vortex
permits agreed with owner. breakers correct.
10 Make spark-free tools available Tube fin surfaces in good Distributor trays leak
at site. condition with no tested.
construction debris.
11 Gas and fire alarm systems For water-cooled Support plates securely
functioning properly. exchangers, checked for fastened.
location of thermal-relief
valve, vent and drain inside
the outlet block valve.
12 Area demarcated for Instrumentation easily Valve caps and other
precommissioning and accessible from grade. contact devices move
commissioning cordoned off. freely.
13 Safety and eye wash showers Drains connected to safe Instrumentation easily
functioning properly. location. accessible from grade.
14 All gratings firmly anchored. Relief valves bench tested Drains connected to safe
and correctly installed. location.
15 All construction debris Insulation provided as Relief valves bench
removed from site. specified. tested and installed
correctly.
Piping Machinery Electrical/Instrumentation
Correct gasket types installed. NPSH requirements met. Control system
configuration correct.
Insulation provided as specified Discharge-pressure gauge Instruments correctly
readable from discharge- located.
block valve.
Steam/electrical tracing Suction strainer easily Flow instruments and
provided as specified. removable for cleaning. control valves correctly
installed.
Check valves installed in Minimum flow bypass Measuring ranges and
correct flow direction. provided if required. scales correct.
Slopes provided as per Check valves installed in Temperature sensors have
requirements. correct direction. correct length.
Requirement of no pockets Venting and draining the Orifice plates have correct
adhered to as specified. pump causing adequate. bore diameter and installed
in correct direction.
Insulation provided as per All drains and vents routed Interlock systems checked.
specification. to safe location.
Field instruments visible from Pulsation dampeners Emergency shutdown
grade. provided for reciprocating systems.
pumps.
Valves to be operated Relief valves provided for Functional checks carried
accessible from grade. reciprocating pumps. out.
Pressure relief valves bench Warm-up lined provided Analysers calibrated.
tested and correctly mounted. across discharge check valve
when pumping hot liquids.
Vents and drains properly Suction/discharge valves and Emergency and redundant
located. auxillary piping and controls power supplies checked.
easily accessible and
operable.
Insulation provided wherever Pumps and drivers correctly Insulation, screening,
required. aligned. earthing of power lines
checked.
Piping requirement for special Cooling water to mechanical Switching devices, motor
procedures correctly done. seal provided with sight flow controls, setting of
indicators. protection relays checked.
Spectable blinds installed in the Reciprocating pumps Direction of rotation of all
correct position. calibrated. electrical drives checked.
Locked open/closed valves Alignment properly Lightening protection and
locked in proper position. performed. grounding systems checked.

Table 1 : Check list for plant inspection


The pre-commissioning and operations personnel should be in touch with the construction staff
at an early stage of piping erection in order to establish priorities for mechanical completion.
Ideally, when construction activities have achieved about 75% completion, the construction team
should be refocused according to the needs of the pre-commissioning team. The plant should be
divided into various sections in the order in which mechanical completion is desired.

For example, process gas compressor if any, may have to be test run at a fairly early stage in
order to rectify possible problems. Therefore, all process lines and equipment falling in the
compressor loop will have to be pre-commissioned on a priority basis. Similarly, reactors, which
ordinarily have to be filled with catalyst, must normally undergo a drying cycle involving fired
heaters. Therefore, equipment and piping included in the catalyst and fired-heater loop also need
to be pre-commissioned at an early stage. Refrigeration systems, which are used to chill a
process stream or product, also fall under this priority category and need to be test-run at an early
stage. It is therefore essential that a schedule be prepared, well before the commencement of
startup activities. The schedule should take into account those activities that fall on the time-
critical path.

2.3 Pre Commissioning Planning

Pre-Commissioning planning is very important stages of any project as it comes to an end of


various phases of engineering. Pre-Commissioning planning is an important interface between
construction and commissioning. A planned systematic Pre-Commissioning will form good base
for plant commissioning.

The experts who have carried out complicated plant Pre-Commissioning use their experience to
develop the key documents like plans and procedures. Based on the requirements main systems
are divided into sub-systems or sub-sub-systems. Detail plans e.g. flushing plan, blowing plan
and purging &inertizing procedures are developed.
Many companies continues to lead the way as the premier provider of pre-commissioning
services in the industry. Pre-commissioning planning allow facility owners to rest assured that
the start-up and future operations of their facilities will run smoothly. As the most critical link in
a projects life cycle, properly planning and executing the pre-commissioning planning is
imperative to the projects success and will save you both schedule days and money.

Project drawings are used to mark these plans based on availability, application and requirement.
It also estimate the requirement of important utilities like Nitrogen, Air, Water, temporary
routings etc. Heading Section Subsection Description Responsibilities that provide a description
of the Pre- Commissioning tests, tasks, deliverables, and responsibilities.

Pre-Commissioning Tests

Since these tests shall already be developed and included in the Specifications, this section shall
provide a description of any specialized tests requiring extensive design development (i.e.
complex subsystem PLC factory test that requires simulated outputs, mixer dye testing, large
tank leakage test, etc.) Acceptance criteria for a successful test shall also be provided.

2.4 Importance of Pre Commissioning Planning

Pre-commissioning activities ensure that all parts of a plant are in a suitable state of cleanliness
and readiness prior to the commissioning and future operations of a plant. Sounds simple enough
right? Yet, if the pre-commissioning process is not planned for thoroughly from the beginning
stages of a project, it could cost a company upwards of one million dollars. This is why taking
into consideration all the components of pre-commissioning is so crucial to a projects success. If
underestimated, the process will only cost a company more in the long run. When planned
correctly though, a smooth pre-commissioning process can be expected and will allow for
effective transitions through the remaining phases of the project, providing value to the overall
construction and improve project safety.
Pre-commissioning activities can consist of a variety of processes. It offers engineered pre-
commissioning cleaning services using our specialized equipment, including Aqua Lazing,
chemical cleaning, steam blowing, air blowing and pulse flushing. But, from the development of
a pre-commissioning cleaning plan to managing and executing all of these cleaning services, for
pre-commissioning to truly be effective, each service must be predetermine before the start of a
project. The key to a successful pre-commissioning is to become proactive instead of reactive
and thorough planning is the only true way to achieve this.

Each of the teams experienced professionals has the expertise required to effectively evaluate
every facet of a project and make the decisions necessary to ensure the project launches without
a hitch. Pre-commissioning is the most important phase in any project, and professionals can be
trusted to handle even the most complex projects with precision and care, in order to deliver
outstanding results at unmatched value.