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