"corePageComponentUseShareaholicInsteadOfAddThis": true, Use shall be made of the standard test forms. h) Disconnect the test equipment. While nitrogen testing might eliminate the need for pipeline drying, most other integrity tests still require this important next step. 4.2.7.5 Testing of Motor Protection Relay o o o As per the recommended procedure of the relay manufacturer, this relay shall first be tested for the current settings. High voltage testing shall be done either by applying AC (power frequency) or DC voltage at a level above the normal operating voltage. If designed, installed, and commissioned well, the assets should last for many years into the future. Each item of equipment shall be inspected upon arrival at site. Tag number. The inline instruments, susceptible to damage by air blowing, shall be removed or isolated from the air blowing operation. I (1) Multimeter (2) Clamp on Ammeter (3) Ductor tester (4) 500 - 5000 V megger (5) Phase rotation indicator (6) Primary injection test set (7) Secondary injection test set (8) Grounding resistance test set (9) Any special test device required to perform any recommended test by the equipment vendor. System Definition System: A system is a major subdivision of an installation or facility, either process or utility, that performs a major operational function of the plant. Air Blowing / drying The pipe lines are dried by air blowing. b) Check for correct Tagging and the label is visible. Check all piping/fittings meet the specification as per P&ID. 4.3.2 Isolation Test Ensure all main switches, circuit breakers, PLC power supplies, Interface cards, cables from direct connected devices are disconnected Check impedance between all power distribution circuits and ensure it approaches infinity 4.3.3 Check the continuity of all the earthing systems. 3.1 Pre-commissioning Inspection 3.2 Preparation of Firing 3.3 Performance Tests 3.4 Record of Tests 3.5 Comment . Type. Date 28 of 45 0 16-11-2016 installation. Telephone: 810-664-1801. 2. h) Ensure that all covers and protective devices are replaced and secure. SYSTEM APPROACH 11 C . Doing so will also improve the accuracy of any tests run in the pipeline. Before engaging the interface card, ensure that the power supply is turned off. More details on what they are and what they mean here. 7. Steam Blowing Procedure. This test should not be confused with other less severe tests generally carried out before a start-up to check tightness of connections. This pump commissioning checklist includes inspection items such asIs the pump/engine rotating direction correctly?andAre oil coolers, oil pipes, and cooling water pipelines installed properly as per Piping and Instrumentation Diagram (P&ID) and General Arrangement (GA)?. Sample 1 Sample 2 Sample 3. Methods to gather test results need to be determined, either as data logging systems or manually recorded. 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. When a system is ready for Pre-commissioning, Company shall be informed in writing of the intent to carry out Pre-commissioning activities. Date C ELECTRICAL 27 D INSTRUMENTATION 36 E MISCELLANEOUS MECHANICAL EQUIPMENT 43 F PRE-COMMISSIONING FORMS 43 G PUNCH LIST CATEGORIZATION TABLE 44 3 of 45 0 16-11-2016 SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. The next phase of pre-commissioning procedures begins with preparing the pipeline for testing. A plumbing commissioning checklist is used to carefully examine the piping system in a facility and prove it works according to its design. Should the system operation be interrupted, the trial period starts over. All the pipelines which will handle hydrocarbons will be inerted with nitrogen and a positive pressure will be maintained in the lines. The pressure generator and the high and low sections of the pipe loop to be tested are provided with separate pressure gauges. ), if not previously included. The Consultant SME and Owner reps are present to verify correct operation of the plant process. Check for proper installation of the boards as per vendor recommendations. Ratio test shall be done by applying low voltage on high tension side and measuring on low tension side of the transformer. If this is a first new system for the owner, an asset management system may be a new system being established. Unlimited reports and storage, integrations, and real-time analytics for premium accounts. A soft handover approach is best to prepare operators as opposed to waiting to the end of the project, passing a bunch of new information to operators, and the project team leaving site. 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. A caliper pig tool is a unique pig that is designed with mechanical sensors or arms on the pigs body. Note: The flushing and blowing of process lines can be done before or after hydrostatic testing. The station piping, pumps or compressors, electricals, instrumentation, and control systems and safety systems have to be ready for operation before the pipeline can be commissioned. There are several activities that take place off-site prior to the commissioning team mobilizing to site during the design and construction phases of a project. Steam usually represents the first "hazardous" fluid. (3) Travel direction indicator installation. 2. The utility system is operational during commissioning phase and utility streams are available at the required specifications [for example, Instrument Air (IA) with required dew point]. Hostname: page-component-7ff947fb49-pwt9n 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). Doc. 6. Keep reading to learn what each of these steps is used for, the tools it might require, and more. is added to your Approved Personal Document E-mail List under your Personal Document Settings The cleanliness of the lines must be witnessed by all the concerned parties and relevant quality documents will be maintained. The final setting of the relay shall be checked and the data shall be recorded. Make up required water level in the Utility Water System as soon as it is pre-commissioned. We use cookies to provide necessary website functionality and improve your experience. A chiller commissioning checklist is used to thoroughly record observations before and after the start-up of chiller systems. This chapter will treat the subject accordingly. This manual will be used by the Pre-commissioning Team to verify and document that all equipment and systems have been checked out and are ready for commissioning. All Pneumatic Control tubing is to be leak tested with a bubbler apparatus. Provide standardized documentation and indices for all certification completion aspects of the project. The same pig used to fill the pipeline prior to hydrostatic testing is run back through the pipeline. Date 45 of 45 0 16-11-2016 Installation and Control and Logic Fully There shoud no C Continuity Checks Functional items allowed for control systems Solenoids and Trip Installation and Circuits Continuity Checks Fully Functional There shoud no C items allowed for control systems Buildings Structural Components Building Utilities including Fire and Gas Minor Repairs and paint. 4. An air conditioning commissioning checklist is used to validate that packaged air conditioning units still conform with design specifications after installation onsite. This piping pre-commissioning checklist can be used by pipeline engineers to perform flooding spread set-up (dry commissioning), pipeline pig valve launching sequence (wet commissioning), and pipeline flooding, pigging, gauging, and chemical injection (commissioning). Pipeline preservation, in case gas-initiation of the pipeline is performed later than six months after the installations are completed the pipeline is preserved. Date 5 of 45 0 16-11-2016 The completion of Pre-commissioning activities marks the end of the Mechanical Completion. PRE-COMMISSIONING PROCEDURES A. Vendor-supplied equipment design specifications, installation drawings, and operation and maintenance manuals. ), Find out more about saving to your Kindle, Chapter DOI: https://doi.org/10.1017/9789382993261.005. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Title Pre-commissioning Manual Document Number Page Rev. These can be cleaned by sending a man down the line with a brush to sweep the sand / debris out. The following points shall be verified: (b) (1) Valve connection size and type. Commissioning documentation is defined and prepared in advance of the commissioning phase. Pipeline integrity testing is a proactive process used to detect any leaks or pipeline anomalies before they get worse. Date 16 of 45 0 16-11-2016 PRE-COMMISSIONING GUIDELINES The following guidelines summarize all activities required to be completed during the precommissioning phase of the project. More details Words: 9,289 Pages: 50 Preview Full text b) The mechanical runs, the actual running and on-line tests for a significant period of the plant utilities, and wherever applicable, of the main process equipment in closed loop c) A number of activities related to preparation of the plant for feed Hydrocarbon introduction, such as loading of various chemicals, catalysts, molecular sieves, activated carbon, etc., d) Hydrocarbon Introduction and Performance Test. Vessels and tanks are to be cleaned internally before man ways are closed and bolted. 6. Since it will not be practical to pressure test all equipment in the plant simultaneously, the plant should be divided into sections (namely Test packs) as governed by the test pressure for each section. Certificates shall be examined to ensure that the installation is in compliance with the certification requirements. A commissioning inspection is performed to verify that the end result of a commissioning process is done according to the projects specifications and based on the requirements of the client. The wiring shall be checked point to point for continuity, ground faults, and termination correctness. Date 7 of 45 0 16-11-2016 B. DEFINITIONS BASIC FUNCTION: group of items of equipment that performs an elementary function of the plant / process. Temporary electric power supply will be available for pre-commissioning. 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. This project commissioning checklist can be used by commissioning teams during the planning, designing, construction, and post-construction phases of a project to achieve desired outcomes. Pre-commissioning checklists are completed for each piece of equipment, and may be witnessed by consultant SME to verify tasks are being completed. Here is a run-down of what needs to be done during pre-commissioning and commissioning, respectively: PSSR is a thorough safety inspection of a new or modified facility to be conducted before commissioning. All rights reserved. Verify that vent and drain valves are installed on all pumps and they are free to operate. Loop check from field instruments and other instrument loops. Warning signs are displayed to restrict the entry of unauthorized personnel into the testing area. All necessary tags, warning tapes, barricade tapes and safety gears supply shall be available at the site. Mechanical process are slowly started, and piping is configured for the initial operating scenarios. by Paul Turner | Jun 15, 2020 | CSU | 12 comments, Commissioning process helps to achieve the project goals. 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). Welding sockets shall be energized and phasing, earthing and output voltage shall be checked. Verify that mist extractors, weirs, baffles, sand jets, anodes, ladders, float guides, floats, Vortex breakers and all internals have been installed as per approved drawings for construction. The Stability Test for the differential protection of the transformer shall be done. The commission procedure may be incorporated into the vendor's startup procedure, but activity will be supervised by CA. c) Note the positioner output pressure and the input whenever the valve begins to move. All the instruments and control valves must be isolated and removed. Our partners will collect data and use cookies for ad targeting and measurement. PIPELINE PRE-COMMISSIONING PRE-, Pre-commissioning & Commissioning Male / female contacts mating for both power & control circuitry shall be checked for proper operation. PRECOMMISSIONING CHECK LIST: definition of the scope of work conformity checks to be performed on elementary items of equipment. Check all piping specification breaks are as shown in P&ID. 4. Refer to vendor data books. After the above test & setting, current injection 2 times the set current and then current injection 5 times the set current shall be done. Reinstatement of the System The system shall be reinstated, as per construction drawings, after the testing. However, the overall process to plan, commission, and startup a project is similar in each case. The facility will be checked for provision of all the instruments/equipments, their operability / maintainability issues, correct installation etc. I worked as a commissioning engineer for several projects, including an offshore platform, a few petrochemical plants, and an LNG terminal. In Chapter 3 we have observed that pipeline construction is considered to be complete only after the pipeline has been subjected to a hydrostatic test. The valve shall be stroked the entire length and the actuator spring compression shall be adjusted if necessary. Witness or conduct and record all ground/earthing tests for all wiring. Phase 2 development will include, but not be limited to, installation and tie-in of the Train # 2 of the Gas Processing Plant and ancillary units. The warranty period begins once each piece of equipment is placed in service, or at issuance of PAC, dependent on the contract requirements. i) All systems shall be checked for correct fail-safe operation including burn-out features of thermocouple systems. One type of test that is used for newly constructed pipelines is hydrostatic testing. Control Valves /PSV cleaning prior to reinstatement: The control valves /PSVs will be brushed out with soft brush and then air blown with hand held air hose or blower. 05 September 2013. A substation commissioning checklist is used by commissioning engineers to test and evaluate the safety and operation of high voltage electrical systems. Check for visible damage. The process lines to and from the vessels, however, must be cleaned by water flushing or air blowing. Check that the right types of internals for the equipments (e.g. Check the compliance for the notes given in the P&IDs. A low pressure air test may be used in place of hydrostatic test for low design pressure, flare lines. e) Switch controller to Manual operation and check the valve stroke correctly. b) Set the communication parameters (Baud rate, parity, address etc.) e) Check the orifice size against the Instrument Specification Sheet and verify that the orifice plate is installed with the square edge upstream. Should a problem exist, it shall be noted on the checklist. 2. The detail procedures for testing of equipment and lines and other pre-commissioning steps are not included in this Standard and shall be prepared in accordance with the Company's Engineering Standards by the Contractor and submitted to the Company for approval. f) With set-point, measured variable and control output all at 50% check for bumpless auto/manual change over where applicable and adjust if necessary according to manufacturers instructions. 2. If damage is observed, corrective action shall be initiated. Accurately read the transmitter output as specified on the instrument checklist. Starters & switch fuse units shall be checked & tested as per the LV Starter / Switch Fuse Unit Test Sheet and the results shall be recorded. b. hasContentIssue false, A Handbook for Onshore Oil and Gas Pipelines, Introduction: Some Basic Facts about Pipelines, Pre-commissioning and Commissioning of Pipelines, Operation and Maintenance of Cross-country Pipelines, https://doi.org/10.1017/9789382993261.005, Get access to the full version of this content by using one of the access options below. 4.2 HV Switchgear Testing 4.2.1 The type, model and rating of the switchgear shall be identified. Accurately capture suction, discharge, oil, and brine temperatures usingSafetyCulture temperature sensors. Find out more about saving to your Kindle. c) Manually, or with applied input signal, transmitter output signals of 0%, 50% and 100% shall be generated to check the response of all other instruments and control valves in the loop. Date 29 of 45 0 16-11-2016 Should flash over occur during high voltage testing then the test shall be deemed to have failed. Introduction to Project Life Cycle WithSafetyCulture analytics, you can view real-time data about inspections with most failed responses, total inspections conducted, their performance, and the unique people conducting them, and more. Regards, Once the performance guarantee period is complete and commercial impacts have been determined, the Final Acceptance Certificate (FAC) is issued to the contractor. Process tubing that has not received a hydrostatic test shall be pressurized to the maximum working pressure of the connected instrument with water or, in exceptional cases, nitrogen gas. Pre-commissioning and Commissioning Procedures Uploaded by Saheb Yadav Copyright: All Rights Reserved Available Formats Download as PDF, TXT or read online from Scribd Flag for inappropriate content Download now of 34 THERMAX LIMITED BOILER & HEATER GROUP Document No. Each item on the installation / pre-commissioning check lists shall be completed or checked, signed and dated by the pre-commissioning representative from PETROJET. Contents 1.0 INTRODUCTION 2.0 SCOPE 4.3.5 Control logics Hardware check. 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 Of Pipelines This procedure gives minimum requirements for dewatering, cleaning, drying & preservation of pipelines. All test data of the above shall be recorded in the format for inverse time over current relay test sheet. 9. Pre-commissioning / installation check lists, punch lists, mechanical completion certificate) shall be maintained system wise in WinPCS. 10. Pre-commissioning is assembling the equipment, systems, and sub-systems, as well as testing and checking individual units to ensure they are installed correctly and able to perform as required. For additional information, you can also check this article out to help you set your projects up on successProject Mindset Lifecycle. Date 15 of 45 0 16-11-2016 Report completion status throughout all project completion stages. Pneumatic transmission lines are to be disconnected from all receiving instruments (I/Ps, switches etc.) ISS International Standard Pre-Commissioning,Commissioning and Start-up Methodology is organizedconsidering the entire project frame and having in mindthe following objective: TO CONDUCT THE PLANT IN OPERATION. Detailed procedures for these activities are provided in the next section of the manual. All solenoid valves should be bypassed during this cleaning blow down. Find out more about saving content to Google Drive. VESSELS AND TANKS Review all vessels and tanks for compliance with specifications as follows: 1. The Company approval shall be obtained for completion of pre-commissioning. Flushing (or air blowing), cleaning, drying and inerting of the piping and equipment Leak tests (For lines, vendor packages etc) Purging for commissioning (If applicable) D. PRE-COMMISSIONING SYSTEM LIST SIBA FIELD DEVELOPMENT PROJECT System and Sub-System Lists System Area code Subarea code Subsystem System Number System Defination Process 020 000X XX 01 SYS-020-01 DIESEL STORAGE AND SUPPLY SYSTEM 020 000X XX 02 SYS-020-02 AIR COMPRESSOR AND DRYER; AIR AND NITROGEN 020 000X XX 03 SYS-020-03 RAW WATER SYSTEM 020 000X XX 04 SYS-020-04 POTABLE WATER SYSTEM 020 020 020 020 020 020 020 020 020 020 000X 000X 000X 000X 000X 000X 000X 000X 000X 000X XX XX XX XX XX XX XX XX XX XX 05 06 07 08 09 10 11 12 13 14 SYS-020-05 SYS-020-06 SYS-020-07 SYS-020-08 SYS-020-09 SYS-020-10 SYS-020-11 SYS-020-12 SYS-020-13 SYS-020-14 FIRE WATER SYSTEM GAS TURBINES DEMIN WATER SYSTEM OILY WATER SYSTEM COOLING WATER SYSTEM CLOSED DRAIN SYSTEM HP/LP FLARE SYSTEM AMINE STORAGE FUEL GAS SYSTEM GAS INTAKE SYSTEM SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Title Pre-commissioning Manual Document Number 020 020 020 000X 000X 000X XX XX XX 020 000X 070 Rev. Close this message to accept cookies or find out how to manage your cookie settings. Commissioning managers can type or dictate additional recommendations within the SafetyCulture mobile app. Loop schematics shall be used to carry out the checking. Remove the instruments which are susceptible for damage, like flow meter, during flushing. To ensure that your pipeline operates correctly, the pre-commissioning process must be completed properly. A checklist shall be completed for each instrument that was inspected. j) For displacer type level transmitters use water as the process fluid and ensure that associated vessel block valves are closed during the test. Other members of the commissioning team are the electrical/mechanical/automation key discipline leads, consultant subject matter experts (SME), contractors, vendor reps, and owners reps. These check sheets will be stored in the WinPCS and used during the Pre-commissioning and Commissioning activities. Verify that all safety relief valves and pressure / vacuum relief valves, flame arrestors, emergency hatches are installed as per issued P&ID for construction (IFC). each project is unique and has different problems to face and to be solved. Commissioning activities can only be carried out after pipelines have been duly pre . The preparation for air blowing shall include following: Preparation of detailed procedure outlining the proposed methods and loop covered, supported by marked up P&IDs. The wiring check shall be made utilizing a Volt/ohm meter with the resistance scale set at 10 ohms. Remove test connections, and reconnect field wiring and process inputs. Test Air compressor - General instrument checkout All instruments and accessories shall be visually inspected for damage after installation. After the dewatering process is complete, the drying process can commence. 0 As construction is completed and equipment installation is complete, the construction and commissioning teams will perform a walkthrough to identify any contract deviations or deficiencies, and list all items on a deficiency tracking list. Verify that all spectacle blinds are installed in the proper position in accordance with the issued P&IDs for construction (IFC). If this is specified in the contract, then this must be done before the equipment leaves the factory. Verify that all blinds, temporary spools, valves and fittings used for hydro testing have been removed. 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. It should be remembered that in pressure testing of vessels and towers that the test gauge should be placed at the bottom of the vessel so that the liquid head will be taken into account. Date 4 of 45 0 16-11-2016 I. D.C. supply voltage shall then be checked and a trip test shall be carried out. The first phase to undertake in pre-commissioning procedures is cleaning out the pipeline. c) Connect a 5.5 bar(g) air supply to the shutdown valve actuator supply. This is what exacrly we follow in our projects. AC high voltage test equipment shall be used for HV switchgear and generators. Commissioning is considered complete, after completion of Performance Test Run. A dedicated mobile compressor may be used for this air blowing / drying operation. When project managers useSafetyCultures scheduling feature, key personnel automatically receives scheduled inspection notifications via SafetyCulture mobile app, email, or text messages (SMS). h) Trips and alarms not covered by the above tests i.e. 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. Percentage bias current test shall be carried out. Check that the pipework installation is in line with the manufacturers information. In fact, it is best to have the owners operations staff involved in the commissioning process, as this is a great time for them to learn about the new systems and ask the experts who are on-site testing the systems any questions that they have. Pipe work to be tested is generally divided into groups (hydrotest packs) of similar test pressures and isolated from other sections by installing suitable blinds or disconnection. Each project is different and must have a unique plan to achieve the desired outcome. C, Commissioning Plan Preparation Guide Sacramento Regional County Sanitation District 4.2.3.2 The alignment of the circuit breaker truck in the panel for free movement, and engagement of mating contacts shall be checked for all panels. SYSTEM APPROACH 12 D . Internals such as level ball floats, which are not designed for the test pressure, must be removed before the testing. Vendor representatives shall be involved in the pre-commissioning of the package. Ensure that the debris is removed and the work place is clean. Date Date 20 of 45 0 16-11-2016 c) Verify that driver, coupling and driven equipment is properly aligned. For resistance values for respective systems refer Electrical Design Basis and approved Earthing Calculations. f) Verify that recommended quantities of spare parts, materials and lubricants are on hand. Items, such as vessels connected to piping under test, which are not capable of withstanding the test pressure, must be isolated by blinding. Loop check from the field the fire detection and protection system. SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. The intention is to ensure that the pipeline are clean up to the equipment throat. In order to be considered you must submit a resume and application to: Lapeer County Sheriff's Office Recruiting Team. During the design and procurement phase of the project, a critical step prior to equipment delivery to site is Factory Acceptance Testing (FAT). Date 8 of 45 0 16-11-2016 TECHNICAL DATA BASE: list of basic functions constituting a subsystem, i.e. Verify that process and utility systems have been flushed properly by water. Leak Test Checklist and Procedures ; 12. (Note: In this case utmost care should be taken and this activity should be reviewed with site HSE personnel to decide whether this is a confined space entry) 6. Each item on the installation/pre-commissioning checklists shall be completed or checked, signed and dated by the Pre-commissioning Representative from PETROJET SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REVCPF EPC Document Number Document Title Pre-commissioning Manual Page Rev. And last but not least, safety management systems need to be established prior to commencing any commissioning activities, learn more about safety hereSafety During Commissioning.
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