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Pre-Commissioning and Commissioning
Pre-Commissioning and Commissioning
INTRODUCTION
AEI is well experienced in Pre-Commissioning and Commissioning activities and can provide
the in-deph experience, guidance and qualified personnel necessary to deliver a
unit Safely prepared and ready to achieve a successful Start-up.
The senior technicians and the engineers who make up our staff have been all chosen on the
basis of the professionalism, versatility and ability to adapt themselves to the different
environment and industrial culture of our customers covering both “Home-Office” and “Site”
phases providing specific services as well as the implementation of fully integrated projects
2.0
Pre-Commissioning
Pre-Commissioning activities start when the plant, or system, achieves Mechanical Completion.
Frequently however, Pre-Commissioning activities overlap Mechanical Completionactivities and
for this reason the plant should be separated into easilymanageable system package, each
system package will be Pre-Commissioned as awhole and isolations at the boundaries of the
system package will be maintained untilthe completion of Pre-Commissioning activities.Pre-
Commissioning activities include: checking for design conformity, checking the statusof
electrical, mechanical and instrument installations, running-in of equipment, flushingand
cleaning activities, drying etc.
Commissioning
Commissioning is the phase in a project when design process fluids are introduced to
the process. Note that for hydrocarbon systems the commissioning activities commence
with inerting operations. Commissioning activities normally consist of activities associated with
running or operating the plant and include operating adjustments necessary for satisfactory
operation of the plant or part thereof. Also included are “Functional checks” which are methods
used to prove that an item of mechanical equipment or control system functions correctly.
Start-up
Start-up is the point in a project where process fluids and conditions are established with the
intent of making products.
System A section of the plant or facility that can be Pre-Commissioned and commissioned
independently, but in parallel, with other sections of the plant or facility under construction.
This is the point in a project where all utilities are commissioned and operational and the unit is
ready to accept the introduction of hydrocarbons.
This is the point in a project where the unit is ready to establish process conditions with the
intent of making product.
2.1
• Site Phase
• Pre-Commissioning
• Performance Tests
2.2
During this phase the preparation of Tool for measurement and reporting of Pre Commissioning
& Commissioning activities Progress, project detailed plan, project detailed and operative
deployment plan, preparation of detailed “procedures”, etc. take place.
During this phase the following activities will be carried out, but not limited to:
a. System/Subsystem definition
• Organization Chart
• P&ID Review
• HazOp Reviews
b. Quality Manual
• System Turnover
a. Handover: The Turnover Management System for Commissioning Tool implementation and
configuration.
2.2.1
PRE-COMMISSIONING ENGINEERING
• System/Subsystem Definition
• Units separated into a large number of systems have high manpower expenditure for the pre-
commissioning phase.
• Units separated into a low number of systems have an uneven workload pattern throughout
the pre-commissioning phase.
Systems should be defined by colour coding a set of A3 P&IDs. System boundaries should be
“flagged” in RED and system numbers should be clearly marked at regular intervals on the
respective line-work and equipment. System summary sheets should be prepared which list the
system content by line and equipment numbers.
A plan is developed that identifies all of the major pre-commissioning activities by system. The
plan will be developed in reverse and will clearly identify “system ready for pre-commissioning”
milestones. Commencement of system turnover from construction to commissioning should
ideally commence at approximately 70% erection completion. From this point handover of
systems should be made on a regular basis. Safety is impaired
When there is a period of low activity followed by a period of high activity to achieve target pre-
commissioning progress. A method of pre-commissioning progress monitoring
• Vendor Schedule
A vendor schedule will be developed that identifies vendor requirements for each item of
equipment .Supporting documentation will provide information on required vendor activities,
support required and approximate duration of each major activity.
Generic method statements is developed for each activity type (Cleaning, Leak Test Inerting ,
…). Each statement will form the basis for the development of safe and efficient detailed
procedures. The method statements will contain information on the methodology, acceptance
criteria and HSE implications.
A network is developed those indexes and identifies all start up activities. Parallel and
consecutive activities will be identified. Each activity will have an expected duration and will
logically link into the next related activity. Each activity will have a summary sheet to identify in
checklist format the necessary actions to be undertaken to achieve the completion of the
activity. A strategy will be developed to achieve the following requirements within the agreed
contractual milestones
The Commissioning Organisation will consist of an integrated Company, PMC and EPC team.
The organisation will change as commissioning progresses from design, through Pre-
Commissioning and start-up activities. This evolution will be managed through regular reviews
of the relevance of the commissioning organisation structure to that stage of progress.
Will be incorporated into this system. The system will be able to allow categorisation of punch-
list items as follows:
Category C Commissioning Items.
The system will be able to track outstanding items by system, category and discipline.
• All phases of the initial start-up (Including oneoff special procedures) are adequately covered
in the design specifically including definition of systems and system turnover sequence
• To achieve this commissioning group representative will attend and provide input at P&ID
reviews, HAZOP Reviews and Model Reviews: They will also review cause and effect diagrams
and spare parts orders.
consumables will be generated to allow preparation and reinstatement of all systems. Particular
attention will be paid to spool, dummy spool and gasket requirements.
Stream sample and testing schedules will be developed which addressed licensor and Client
requirements. One schedule will be developed to cover the initial start-up phase, one to cover
the test run period and one to cover normal on-going operation of all
2.2.2
2.2.2.1
• Mechanical Preparation
• Mechanical Restoration
• Machinery Run in
• Tightness test
• Loading of chemicals
• Loading of catalyst
• Heaters drying
2.2.2.2
1. INTRODUCTION
1.1 General
2. BASIS OF DESIGN
3. PROCESS DESCRIPTION
4.1 General
6. NORMAL OPERATION
9. ANALYTICAL REQUIREMENTS
10. ATTACHMENTS
Note:
Start-up and shut-down procedure will include detailed equipment procedure. Systems will be
divided into “main equipment”, such as turbines, special motors, etc., and “common equipment”.
For each Main Equipment will be developed a specific “TAG” procedure while for the “common
equipment”, such a centrifugal pumps, exchangers, etc, will be developed a
2.2.2.3
The index consist of section titles (one digit numbering) and paragraph titles (two digits
numbering). Sub paragraph titles exceeding two digits do not appear in the general index. A
detailed section index listing all subparagraphs titles is given before each section of the manual
1. INTRODUCTION
1.1 General
7.2 Lockout/Tagging
7.3 General
8. SAFETY CONCEPTS
8.1 General
8.2 Codes and Standards
9. GENERAL INFORMATION
2.3
During this phase an integrated organisation performs all of the activities addressed in Home
Office phase. The activities will be monitored and witnessed as necessary by relevant parties.
All activities and reporting should be system based and fulfil the requirements of the respective
acceptance criteria. The site phase can further be separated into the main periods:
• Plant cleaning
• Punch-Listing
• Leak testing
• Inerting
• Pre-Commissioning complete
• Start-up procedure
• Licensor/Vendor support
• Conduct and supervise all activities during the Introduction of feedstock to the Units
2.3.1
Engineers (from relevant disciplines). When all “A” type items have been cleared and a small
but manageable amount of “B” type items are left, a handover can be progressed from the
construction to the commissioning group. Since mechanical completion has been achieved with
agreed exception items, it is classed as an interim handover to permit construction completion
and Pre-Commissioning activities simultaneously. Control and responsibility of work on the
system rest with the commissioning group. Any construction work will require written permission
from the Lead-commissioning Engineer of the particular Process Unit. Permission will be
granted on a job by job basis. This would involve a line-by-line detailed check of the actual
physical installation against the latest P&I diagrams issue, job specifications, piping hanger and
support drawings, vendor drawing, etc., for erection of the unit in accordance with all drawings
and applicable specification. The systems would also be checked from an operating viewpoint
for proper location and orientation of valves, vents, drains, steam tracing and traps, sample
connections, etc. Punch lists of deviations,
Installation errors, missing items, etc., shall be prepared and given to the appropriate
construction department for correction or completion. Also included in this inspection and check-
out would be:
• Vessel Internals - This would include going through each tower and vessel to check the
installation of trays, baffles, demisters, spargers, etc., and verifying that the dimensions of all
weirs, downcomers, distributors, thermowells, etc., are within specification and are properly
oriented, as well assuring the internal cleanliness of each vessel prior to final closure.
• Non-operating Adjustments - All non-operating adjustments, packing of pumps and valves and
cold alignment of equipment performed by the construction subcontractors should be spot
checked, witnessed or periodically inspected to ensure proper records are being kept and
recorded for turnover.
• Piping - Check lists would be prepared on each hydrostatic test system before the system is
released for hydrostatic testing. Completion of this punch lists by the construction contractor
would be required before the test system is released for testing. Post-hydro punch lists would be
prepared and followed through on to ensure that the systems were fully completed and ready for
pre-commissioning.
• Electrical Installation - Each electrical circuit and motor installation and their electrical polarity
check and insulation resistance measurement would be demonstrated by electrical
subcontractor to the Commissioning Subcontractor Team.
• System Pressure Testing - Although the construction contractor is responsible for the actual
pressure testing of each system prior to mechanical completion, the Commissioning
Subcontractor Team would review the test program and the methods used to ensure
satisfactory tightens.
2.3.2
PRE-COMMISSIONING PERIOD
The site phase of the project will commence at approximately 60% construction completion and
activities will be mainly centred on:
• Progression of all of the procedures developed during the Home office phase of the project
Punch-Listing
Punch-List and aimed at checking the system over before introducing hydrocarbons
Utilisation of the Pre-Commissioning check sheets will assist in completing a full range of
required checks. Punch-Listing progress will be recorded on an A3 set of P&IDs.
System Cleaning
This would include directing the cleaning of systems either by flushing, blowing or chemical
cleaning by issuing directives for the necessary temporary connections, utilities and proper line
up of the system to be cleaned. When the services of a chemical cleaning subcontractor are
required, the Commissioning Team will monitor his performance to ensure a satisfactory
cleaning job. Before each system is closed for operating, the lines and equipment would be
inspected for cleanliness. Cleaning progress will be recorded on an A3 set of P&IDs.
Equipment Run-In
This would include planning and co-ordinating Vendor representatives for the running in of the
equipment and obtaining the necessary utilities to accomplish the run-in for equipment such as
blowers, pumps, compressor, motors, turbines, and other machinery or mechanical equipment
without process fluids before start-up.
Vessel Loading
This phase would ensure that all catalysts, packing, resins and desiccant loading is performed
in a proper manner and accurate records and samples of each material loaded are retained.
When all the activities foreseen in the Pre-Commissioning phase (the Process
Units will be ready to receive hydrocarbons, most of the utility systems will be live to the
respective units and all of the hydrocarbon lines will be positively isolated at the unit battery
limits) have been performed successfully a Ready for Commissioning Certificate will be issued
and so Commissioning activities can start.
2.3.3
Once the unit is pre-commissioned, the Commissioning Team will conduct the following main
activities:
• Purging
•…
to start with initial Start-up operations assuring that every activity is accomplished smoothly and
safely. The Commissioning Subcontractor Team would take care in troubleshooting any
operating or process problems, should they arise, and would investigate any operating
deviations as they occur. Team will:
a. Develop and Review Specific Operating Instruction
Normally, the procedures and practices outlined in each unit’s operating manual will be
followed. However, as these manuals cannot cover every conceivable operating situation, it will
be necessary to develop specific operating instructions to cover critical areas of operating as
they arise. Any additional operating procedures and practices to operate or control the units will
be given either in writing, if time permits, or verbally, if immediate action is required, to operating
supervisors. An operating logbook will be kept in order to record the instructions and relevant
changes in the operating conditions.
b. Conduct and supervise all activities during the Introduction of Feedstock to the Units
Licensor’s process and operation specialists (if required) will be present for providing advice
during the critical first start-up from a technical point of view and will help troubleshoot any
problems that arise or investigate any deviations that occur.
The Commissioning team will monitor the plant operations and make any operating changes for
stable, efficient operation.
The Commissioning Team will provide to work with process licensors (if required) on how to
bring the units on stream and up to design rate. Control variables and flow rates will be specified
to stabilize the unit at design rate in preparation for the acceptance test and during the
performance test.
The Commissioning Team will pompon the procedures guarantee and documentation and
witnesses the instrument calibration. During the execution of Performance Test the Initial
Operation Team will conduct the plant according to the procedure already agreed between
the AEI and the Client.
2.4
System Handling
A Systems Co-ordinator will provide the necessary link between construction and
commissioning. The co-ordinator will be responsible for developing system completion
strategies on a daily basis to ensure a smooth handover process. Each system will have a
turnover package of commissioning dossier associated with it. A co-ordination procedure will be
utilised for the “offering” or “receiving” of systems. At the schedule date for system turnover, the
construction group will compile diagrams, equipment list, instrument lists, exception lists,
inspection reports and other QA/QC documentation
for that system. The routing of each system will be from the construction group to the
commissioning group. The commissioning group will have an internal handover mechanism to
recognise the importance of introducing hydrocarbons to a process unit for the first time.
Pre-Commissioning Complete
When the Pre-Commissioning work on each utility system is complete it can then be
commissioned providing it is safe to do so. For non-utility systems the point at which the
process Unit is considered to be “ready for Start-up” is when all non-hydrocarbon systems have
been pre-commissioned. At this stage the Unit is presented as “Ready
Commissioning Complete
When all commissioning for a process unit is completed the unit is declared “Ready to Start-up”.
At this point normal conditions are established to produce the designed products.
3.0
DEDICATED TOOL
In order to control the commissioning activities that should be integrated with the construction
activities,AEI has been developed an In-House software: PMS® (Project Management System
for Commissioning).
The purpose of the Plant turnover Management System is to provide the appropriate tool to
follow the AEIpolicies, procedures and quality (QA/QC) checks, in order to administrate all the
documentation and to control the Turnover of the facilities from AEI to its Client / the
Owner. AEI has developed the above mentioned tool that allows the turnover engineer to follow
construction, Pre-Commissioning and commissioning activities from the plant’s area definition
up to the final hand-over of the plant reducing time and costs related to this kind of activities
given a time by
time progress. The PMS® is a fully web-based, modular and tailored tool in the cloud that allows
more than 200 concurrent users to access together into the system for on-line up-date and view
using a normal TCP/IP network. It shall be the direct link between Construction and
Commissioning activities.
5.0
6.0