j) After the shutdown valve test is complete, disconnect temporary air supply, test equipment, and reconnect the valve to the field connections. d) Instrument zero settings and calibration adjustments shall be made as necessary, unless the instrument is of the SMART type. Mechanical Seals (1) Verify that seal flush lines and strainers are clean and will allow free flow of process fluid. Date 14 of 45 0 16-11-2016 SPRINKLER SYSTEM FIRE HYDRANT / MONITOR SYSTEM FIRE PUMP HOUSE NOVEC GAS BASED CLEAN AGENT SYSTEM CF3I GAS BASED RIM SEAL FIRE PROTECTION SYSTEM WATER FOAM TENDER VEHICLE FIRE FIGHTING AND SAFETY EQUIPMENTS PROJECT COMPLETION SYSTEM WinPCS The project will employ the WinPCS database. Warning signs are displayed to restrict the entry of unauthorized personnel into the testing area. The project team may be responsible to provide the information package containing all asset information to be loaded into the asset management system for continued use by the operating team. The body of the checklist can vary per project but the usual ones include a review of the following: Adhering to pre-commissioning and commissioning procedures can be challenging and drafting the commissioning report can be time-consuming. Find out more about saving content to Google Drive. Verify that all spectacle blinds are installed in the proper position in accordance with the issued P&IDs for construction (IFC). Some . Everything explained in brief manner. (3) Travel direction indicator installation. More details on what they are and what they mean here. For example, nitrogen pressure testing is useful for smaller pipelines, or in cases where weather adversely impacts a test using water. Instruments shall meet the manufacturer's specifications. demisters, inlet devices, filter element, bed support, etc.) Has data issue: false Date 27 of 45 0 16-11-2016 After leak test, inerting of the system will be carried out. Check the printout of the software output data. The Consultant SME and Owner reps are present to verify correct operation of the plant process. shall be identified and recorded in the pre-commissioning punch lists. Based on 14 documents. Contractor document deliverables are defined, such as O&M manuals and training plans, to be delivered during the commissioning phase. 4.2.5.2 Breakers shall be tested MANUALLY and ELECTRICALLY, both in TEST and SERVICE positions. Caution shall be exercised that no power is fed to the end equipment while performing the tests. 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. Thanks again for the commissioning process guidance that you share with us, its very interesting and I like it. An important group to ensure are part of the commissioning team is the Owners operations team, as commissioning activities are the best opportunity for the Ops team to learn about the systems and become familiar with the new operating requirements prior to taking over the systems. B.1.1 CHECKING AGAINST P&IDs The pre-commissioning team shall divide the plant area into systems and subsystems and shall check the system/subsystem against the relevant P&IDs approved for construction. Date 43 of 45 0 16-11-2016 13. i. Verify that insulating flange kits are installed as shown on the drawings. During the design and procurement phase of the project, a critical step prior to equipment delivery to site is Factory Acceptance Testing (FAT). 2. Draining a. To ensure that your pipeline operates correctly, the pre-commissioning process must be completed properly. (4) Any special features. This chapter will treat the subject accordingly. PRECOMMISSIONING CHECK LIST: definition of the scope of work conformity checks to be performed on elementary items of equipment. During the testing process, APS uses various monitoring equipment to determine your pipelines pressure levels. Date A OBJECTIVE 4 4 B DEFINITIONS 7 C DATA AND INFORMATION 8 D TOOLS AND EQUIPMENT 8 E SAFETY 9 II OVER VIEW OF THE PLANT 10 III SYSTEMS DESCRIPTION 10 A . All connections used for the leak testing are soap leak tested after the bubble test. Once FAC is issued, the project officially comes to a close. Proper pre-commissioning will ensure that the facilities can be made operable with the least number of problems. integrity test procedure, if this is the case commissioning need to create a list of 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. by Paul Turner | Jun 15, 2020 | CSU | 12 comments, Commissioning process helps to achieve the project goals. PRE-COMMISSIONING: corresponds to non-operating adjustments and cold checks performed at the end of the construction phase to verify that the installation conforms to plan, specifications, drawings, instructions and applicable codes and rules. Rating. 3.1.4 Interpretation of Results Should the reading obtained for IR or PI fall below the recommended minimum values as per IEC, then the equipment shall not be energized or subjected to high voltage testing. 4. : Your Doc Number Rev. F. PRE-COMMISSIONING FORMS Attached SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Title Pre-commissioning Manual Document Number 44 of 45 Page Rev. This includes the test plans and test procedures to be executed during commissioning, and checklists required, as well as drawings. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. Pre-commissioning / installation check lists, punch lists, mechanical completion certificate) shall be maintained system wise in WinPCS. Thank you for this a small trainig its helful thank you again sir. Each item on the installation / pre-commissioning check lists shall be completed or checked, signed and dated by the pre-commissioning representative from PETROJET. After the above test & setting, current injection 2 times the set current and then current injection 5 times the set current shall be done. 3.2 Conductivity and Earth Resistance Tests 3.2.1 Conductivity Test Conductivity tests shall be done on switchgear bus bar connections and switchgear earth system joints to establish their tightness and condition. A commissioning checklist is used to ensure the safety and functionality of new or modified systems in a facility. A checklist shall be completed for each instrument that was inspected. Following summarizes the activities and milestones of the pre-commissioning, commissioning phases. Address: Copyright 2023 VSIP.INFO. On completion of these documents, these will be stored system wise / sub-system wise in WinPCS. After completing the above tests, the relay shall be tested to check the accuracy of the timer settings. b) Equipment static/de-energized tests, to ensure critical components quality and condition. c) Connect a 5.5 bar(g) air supply to the shutdown valve actuator supply. 2.4 Commissioning and Training : 1. c) Check the pressure taps to ensure that the high and low pressure sides of the orifice are connected to the corresponding sides of the field instrument. b. Verify that all temporary blinds have been removed and that all spectacle blinds are in the correct position for operation, as shown in the P&IDs. The warranty period begins once each piece of equipment is placed in service, or at issuance of PAC, dependent on the contract requirements. Power on new DCS & new shutdown system and allow warm up time. 4.2 HV Switchgear Testing 4.2.1 The type, model and rating of the switchgear shall be identified. Use the permanent air supply, if operational; otherwise, connect a temporary supply to the branch from the air supply header. b) Check for correct Tagging and the label is visible. 11. Tubing shall be checked point to point for leaks and termination correctness. drying to normalize the figures. The contract may also specify a performance guarantee period, where the plant processes are expected to meet certain contractual criteria over a period of time. 7. Accurately read the transmitter output as specified on the instrument checklist. Commissioning process helps to achieve the project goals. All pressure gauges have valid calibration and calibration status for each gauge is available on it. The following signs in Arabic and English shall be posted at strategic locations before proceeding with the appropriate Pre-commissioning activities: Tags: - No smoking Danger, high voltage Do not enter beyond this point E. SAFETY The following safety gears (PPE) supply shall be available to all personnel involved in the pre commissioning: - Ear Protection Safety Glasses SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number - Document Title Pre-commissioning Manual Page Rev. It involves Pre-commissioning checks and Pre- commissioning activities. Date After carrying out the above test The current level to trip I inst the current level not to trip I inst. The tightness of all terminals shall be verified. INTRODUCTION A. Date 41 of 45 0 16-11-2016 Verify that the valve position matches for "fail open" or "fail close" operation. b) High voltage AC or DC testing for HV switchgear and HV cables. III. COMPLETION ACTIVITIES: pre-commissioning and commissioning operations HAND OVER DOSSIER: compilation of the construction, pre-commissioning, commissioning and performance test support documents of a subsystem / system. Test Equipment a) The following is a list of recommended test equipments as a minimum, required to perform the pre-commissioning test on the electrical equipment as per the Equipment Schedule. 5. It also proactively identifies any modifications needed through detailed assessment of the commissioning project. By Im glad you find the information helpful! It is critical that the construction team deliver an accurate set of red-line drawings to the commissioning team in order that the correct installed configuration of equipment in the field is accurately documented. Examples: 1. We use cookies to distinguish you from other users and to provide you with a better experience on our websites. To fill a pipeline, APS uses a specialty tool called a fill pig. A column of test water propels the fill pig through the pipeline. i) All systems shall be checked for correct fail-safe operation including burn-out features of thermocouple systems. Electrical motor drivers In addition to the procedure in this manual, specific electrical procedures shall be used as detailed in the specific vendor data books. Typical example of a system is: Compressed Air System Sub-System: A sub-system is a further division of a system that performs a given operational function with no or little interference from the other sub-systems. The intention is to ensure that the pipeline are clean up to the equipment throat. Step 1 - Planning. 3. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Title Pre-commissioning Manual Document Number Page Rev. After the dewatering process is complete, the drying process can commence. Pre-identified line will be chemically cleaned, viz. Pre-commissioning checklists are completed for each piece of equipment, and may be witnessed by consultant SME to verify tasks are being completed. Space heater rating, voltage and resistance. g) Check all associated alarm or trip functions by varying the transmitter signal and adjust switch level accordingly. It broadly covers following, but not limited to: Civil, Mechanical, Electrical and Instrumentation completion are Opening Date: 06/29/2023. Before draining water from vessels, make sure that a high point vent on the vessel is opened to prevent pulling vacuum on the vessel. A pre-commissioning representative shall inspect the inside and outside of the equipment enclosures. Prepare the WinPCS standard reports and other agreed status reports on daily basis and forward to construction and pre-commissioning authorities for their feedback during the Progress Review Meeting. Thanks, and good luck in your commissioning career! These can be cleaned by sending a man down the line with a brush to sweep the sand / debris out. After the test, reduce the pressure developed during the hydrostatic test very slowly and gradually. Auxiliary systems are brought online followed by major apparatus, and interfaces are verified for all equipment. Any deficiencies are noted and added to the deficiency list, with associated classification. Typical example of a subsystem is : Instrument Air At the pre-commissioning stage same system, sub-systems format will be used to check the completeness of the construction phase (Mechanical Completion). The contractor shall prepare a hydrotest report with supporting documentation. on the Manage Your Content and Devices page of your Amazon account. Verify that all instruments and tubing are correctly tagged, labeled, and installed at the correct location. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. D.C. supply voltage shall then be checked and a trip test shall be carried out. Special care must be taken in case of rotating equipment inlet lines, for the portion after the temporary strainers till the throat of the equipment. A pre-commissioning checklist aims to prepare a manufacturing plant for start-up, or when all new or modified systems are going live. 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. Her 5-year experience in one of the worlds leading business news organisations helps enrich the quality of the information in her work. 4.2.4 Ductor Test This test shall be carried out to ascertain the contact resistance of the circuit breaker and bus bar joints. d) Check for free access for operation and maintenance. Pneumatic transmission lines are to be disconnected from all receiving instruments (I/Ps, switches etc.) For resistance values for respective systems refer Electrical Design Basis and approved Earthing Calculations. Ready for Pre-Commissioning The works is ready for Pre-Commissioning when the Company has issued a certificate for Mechanical Completion and notification in writing that the Works is ready for Pre- Commissioning. Commissioning checklists are completed and witnessed by consultant SMEs. Every failed criterion triggers a push notification via the SafetyCulture mobile app, email, and/or text message (SMS). The general approach during pre-commissioning is described below: When the system is ready for Pre-commissioning, Company shall be informed in writing, the intent to start the installation checks / pre-commissioning activities. 4.5.2 Test for Circuit Breaker & Starter / Switch Fuse Units 4.6 4.6.1 Test on circuit breakers shall be carried out as detailed in LV Circuit Breaker Test Sheet. This will help and simplify the handling and status review of all documents. 2) Check valves, globe valves, and choke valves are installed in the correct flow direction. If required the motor stator windings shall be warmed up, to improve the polarization index. d) Check that all guards are firmly secured to protect personnel from rotating shafts, couplings, and belts. Jona Tarlengco is a content writer and researcher for SafetyCulture since 2018. Efficiently validate the performance of HVAC, pumping, piping, and lighting systems using this comprehensive checklist. each project is unique and has different problems to face and to be solved. Process piping After construction is completed, the piping and pipelines must be cleaned of all construction debris, hydrostatically pressure tested, dried and inerted, if required. Prior to beginning the instrument operational check and calibration, the following leak tests shall be performed: Pressurize the instrument air headers with clean filtered instrument air, and spray all screwed and flanged connections with a soapy solution (leak-test). Certificates shall be examined to ensure that the installation is in compliance with the certification requirements. 6. This is typically done by pigging the pipeline. A plumbing commissioning checklist is used to carefully examine the piping system in a facility and prove it works according to its design. Process Transmitters (Electronic) calibration-General Disconnect field wiring from transmitter and connect a receiver test instrument which will provide the required power to the transmitter. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number 4.5 Document Title Pre-commissioning Manual Page Rev. Ensure that all escape routes are clear of obstacles. Closing Date: 07/29/2023. and instrumentation (viz. 4.2. The construction team and commissioning team will perform a walkthrough to inspect the installation and confirm there are no deficiencies. Allowable tolerance is four or less bubbles per minutes. Temporary protective devices shall be removed prior to placing instruments in service. Instrument Check Sheet . Flows are started and monitored to ensure correct operation. 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. Use shall be made of the standard test forms. h) Trips and alarms not covered by the above tests i.e. m) Analyzers and other special systems should be fully checked and calibrated to manufacturers instructions with consent of the Supervising Engineer. When a system is ready for pre-commissioning, Company shall be informed in writing of the intent to start the installation/pre-commissioning activity / checks. 4.3.5 Control logics Hardware check. 19/12/2017 Flushing shall be carried out by introducing a calculated quantity of water through the system at a sufficient velocity. Date 40 of 45 0 16-11-2016 b) Check the upstream and downstream pipe lengths to verify that they are according to specifications. A low pressure air test can be performed on the sections of the unit prior to a hydrostatic test so that any open lines or flanges may be discovered and taken care of before water is admitted. (Note: Setting to Work is a potential fourth category, but may be included under Inspection or Testing as needed.) Check all electrical closures. The piping subjected to hydrotest shall be brought up to the pressure and shall be held under pressure for a period of approximately 1 hour for above ground (AG) pipes and 24 hours for underground (UG) pipes before a detailed inspection is started. Accurately capture, Before commissioning, the pre-startup safety review team (usually comprise the project manager, construction engineers, and contractor) use a PSSR checklist. Loop schematics shall be used to carry out the checking. In particular check the air supply pressures for control valves and in accordance with their specification. Check the tag number and range. Pipeline integrity testing is a proactive process used to detect any leaks or pipeline anomalies before they get worse. Mechanical commissioning consists of dry commissioning and wet commissioning. P&ID drawings are traced in the field to ensure all air/oil/water auxiliaries are available. Contractor shall pOGS Utilities with onsite rovide for new control training systems and equipment operation. : QF1461-7840-108 Rev: 00 Date: 28.02.2018 Pages :33 COMPANY has specified that the whole system from wellhead to export pipeline shall be capable of a peak production rate of 110 mmscfd (by the completion of Phase 2). The Pre-commissioning Team shall use the specifications, plans and detailed drawings for reference in checking all piping systems to determine that they have been properly fabricated, installed and tested. PRE-COMMISSIONING PROCEDURES A. Ronald F. Clayton 3. The facility will be checked for provision of all the instruments/equipments, their operability / maintainability issues, correct installation etc. The system / line shall be pressurized to the test pressure and maintained for sufficient time duration to enable Company inspection, if required. 2.1 List of Systems and Components to be Commissioned 2.2 Commissioning Status Check Sheets 2.3 OPR/BOD Requirements 2.4 Order and Timing List 2.5 Water Treatment/Flushing and Cleaning Reports 2.6 AHJ Approval Documentation 2.7 Commissioning Meeting Minutes 2.8 Commissioning Reports 2.9 Transmittal Records The Punch list items shall be categorized / marked A B and C as defined below A - Items are those activities that must be completed prior to Mechanical Completion. Note you can select to save to either the @free.kindle.com or @kindle.com variations. The construction milestones then define the required design milestones. Flushing shall be continued for a minimum time till flushing media becomes clear at the exit point. Typically commissioning packages (details of how the commissioning is to be carried out) are planned and completed. 3. Date 31 of 45 0 16-11-2016 Testing of Protection Relays 4.2.7.1 Testing General Relays shall be tested and commissioned in accordance with the manufacturers instructions. PIPELINE PRE-COMMISSIONINGPRE-QUALIFICATION DOCUMENT. 7. On installations which involve instrument seal pots or reference legs, the system shall be filled with the recommended fluid. Fire & Gas detection system a) Carry out wiring checks b) Simulate from field and check for the alarm / shutdown function as per C & E matrix. Validate performance and reduce risk of unplanned downtime, and conduct efficient installation, functional, and operational checks with a mobile app. direct process operated switches such as float switches, etc should be separately tested for correct operation. However, a hydrostatic test is necessary for final testing. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Title Pre-commissioning Manual Document Number 12 of 45 Page Rev. The process lines to and from the vessels, however, must be cleaned by water flushing or air blowing. b) Set the communication parameters (Baud rate, parity, address etc.) Date 0 16-11-2016 nitrogen is used, spray all fittings with a soapy solution. The Defining Point: Pre-Startup Safety Review (PSSR), The Ultimate Collection of Commissioning Checklists, Take/attach photos of compliance, detected failures, and more, Assign corrective actions with a due date and priority level, Sign off with digital signatures and auto-generate the commissioning report, Initial Operation, or the first production run, aims to determine if the production process manufactures output that meets design requirements. B - Items are those activities that must be completed prior to Hydrocarbon Introduction. It can be a complex initiative, but is the best part of the project as you get to see the original design come to life! This punch list (after categorization) and pre-commissioning checklists shall be transmitted to Company for review and approval. 2. These will be stored in WinPCS. 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. To save this book to your Kindle, first ensure coreplatform@cambridge.org 5. After elimination of the cause retesting shall be performed. 4.3.6 System I/O interface test. 0 f) Verify that recommended quantities of spare parts, materials and lubricants are on hand. This checklist has been designed to make it easier for inspectors to verify the installation, function, and documentation of pumping systems and the preliminary, secondary, and tertiary treatment process equipment. 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.
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pre commissioning procedure pdf
