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Pre-commissioning Execution (Mechanical Completion)

Major activities:

  • Conformity checks of equipment items – Mechanical completion / Punch clearance
  • Static/de-energized tests of equipment items
  • Mechanical/Piping: Alignment of all equipment and flushing and cleaning of the pipes and vessels
  • Instrument: Calibration and cable continuity tests
  • Electrical: Insulation and continuity tests
  • Functional tests and operational tests
  • Issue the pre-commissioning, commissioning weekly progress report based on PCS data

Activities detailed by discipline:

Operational systems

Discipline Activities
  • Visual inspection for complete and correct installation
  • Internal inspection of tanks and vessels
  • Alignment
  • Load testing of lifting & rotating equipment
  • Hot oil flushing
  • Bolt tensioning
  • Dimension control
  • Preservation
  • Visual inspection for complete and correct installation
  • Insulation and continuity testing of cables
  • Insulation testing of generator, transformers and motors, panels, distribution board etc
  • Earthing checks
  • Static check of switches and control devices
  • Battery preparations
  • Lighting and socket outlet checks
  • Area completion
  • Heat tracing
  • Preservation
Instrument / Telecommunication
  • Calibration and testing of instruments prior to installation
  • Visual inspection for complete and correct installation
  • Insulation and continuity testing of cables
  • Cleaning, flushing, pressure and leak testing of pneumatic and hydraulic tubing
  • Adjustment of control, alarm and shutdown settings
  • Loop testing
  • Function testing of control systems
  • Function testing of field instruments
  • Hot oil flushing of instrument tubing
  • Area completion
  • Preservation
  • NDE carried out
  • Welding procedure specification
  • Removal of all items subject to damage during flushing, cleaning and pressure testing
  • Flushing of pipework
  • Chemical cleaning and testing of pipework
  • Drying of tested pipework
  • Preservation of tested pipework
  • Reinstatement of all items after testing
  • Final inspection of pipework
  • Test ISO's and P&ID's showing the extent of each pressure test
  • Pneumatic and hydraulic tubing
  • Hot oil flushing of pipework
  • Bolt tensioning - Flange Management System (FMS)
  • Insulation
  • Flow coding
  • On-line chemical compound leak sealing
  • On-line safety valve testing(TREVI test)
  • On-site machining
  • Valve reconditioning & overhaul
  • Visual inspection for complete and correct installation
  • Cleaning of ductwork
  • Leak testing of ductwork
  • Alignment checks
  • Mechanical functions checks of equipment
  • Preservation
  • Flow coding
  • Safety
  • Visual inspection for complete and correct installation
  • Preservation
  • Area completion


Non-operational systems

Discipline Activities
  • Visual inspection for complete and correct installation
  • QC documentation
  • NDE carried out
  • Welding
  • Load testing of lifting lugs and monorails
Surface protection, insulation and fire proofing
  • Visual inspection for complete and correct application
  • Thickness checks carried out
  • Adhesion checks carried out
  • Preservation
  • Insulation
  • Painting
  • Fire proofing
  • Visual inspection for complete and correct installation
  • Preservation
  • Doors

Commissioning Execution

Major activities:

  • Pre-commissioning witnessing
  • Preliminary checks
  • Functional tests
  • Piping and vessels preparations
  • Operational tests
  • Support activities
  • Documentation tasks

A. Pre-commissioning witnessing

There is no specific witnessing procedure : The above tests will be attended by a suitably qualified commissioning engineer and the relevant pre-commissioning test sheets countersigned, on the successful completion of the tests.

The commissioning will perform witnessing of critical pre-commissioning activities, listed below.

  • Setting of PSV's
  • Piping flushing and cleaning
  • Gross leak test
  • Machinery cold alignments
  • Electrical protection relays setting
  • 20% of instrument calibrations, at random

B. Preliminary checks

The preliminary checks, first task of site commissioning activities, are the cross-verification by the commissioning that the construction contractor has achieved his full Pre-commissioning scope of work.

These checks are carried-out on a subsystem basis.

B.1. Mechanical preliminary checks

B.1.1. Review of documentation

The commissioning mechanical specialists will review the mechanical pre-commissioning operations reported in the pre-commissioning dossier and make sure that:

  • All rotating equipment has been cold aligned and that alignment records are available
  • Couplings have been installed
  • Suction and discharge piping have been correctly installed and freed of stresses according to vendor's requirements or recommendations
  • Suction strainers have been installed
  • Fans and drivers have been correctly aligned and that fans pitch and clearance have been set
  • All relevant check lists have been filled-in and signed
  • All as-built installation drawings are available.

B.1.2. Review of facilities

The commissioning mechanical engineers in charge of the preliminary checks will thoroughly inspect visually all mechanical equipment. This inspection will be based on the following reference documents:

  • Installation drawings
  • P&IDs
  • Vendor's drawings and manuals
  • Data sheets

The following is a list of points that will be systematically addressed during the site survey:

  • Name plates
  • External damage - painting - insulation
  • Conformity to project standards and codes, vendor drawings, vendor recommendations, safety rules and good practice
  • Ancillary equipment: condition, quality of installation
  • Availability of lubricating and seal oil fluids in quantity and quality
  • Free rotation of rotating equipment
  • Connection of suction/discharge piping
  • Piping supports in the vicinity of the equipment
  • Safety protections installation and setting
  • Coolant means installation and condition
  • Seals, packings installation
  • Removal of transport/shipping supports, bracings, and stops
  • Removal of all rust preventives, oil, grease, etc., used to preserve the equipment during the construction phase.

B.2. Electrical preliminary checks

B.2.1. Review of documentation

  • All relevant check list and test sheet (filled-in and signed).
  • All relevant check list and test sheet (filled-in and signed).
  • FAT reports.
  • All as-built drawings.

B.2.2. Review of facilities

The commissioning electrical engineers and supervisors shall carry-out a thorough visual inspection of the electrical equipment.

B.3. Instrument preliminary checks

B.3.1. Review of documentation

  • Calibration test sheets
  • All relevant check lists and test sheet (filled-in and signed) including those dedicated to instrument cables and to junction boxes.
  • Pre-commissioning punch lists.
  • All as-built drawings

B.3.2. Review of facilities

The commissioning instrument engineers and supervisors will carry-out thorough visual inspection of the instrument equipment, the following points being systematically addressed during the site survey.

  • ­ESD valves control panel
  • ­Automatic valves
  • ­Flow measurement devices
  • ­Other equipment (pressure transmitter, magnetrons, thermocouples, etc.)

C. Functional tests

The functional tests are the dynamic checking that each elementary electrical, instrument, and telecommunication function included in the plant design performs properly. The purpose of this commissioning specification is to provide commissioning personnel with all the information required to conduct the functional testing activities in a planned, safe and logical manner.

C.1. Functional testing

A “Functional Test” is the live test applied to a given basic function, hence it is a single discipline activity.
The present specification defines for each type of basic function, the scope of work of the functional test that will be applied to this basic function.
Every basic function of the plant, in the three above disciplines, will be subject to a functional test, be it part of field or package equipment.

C.2. Tests reporting

Functional tests results will be reported on “Functional Test Sheets”, which are available in this specification for every type of basic function.
There will be one functional test sheet by test, i.e. by basic function. The functional test sheets will be grouped by discipline and subsystems in the commissioning dossiers.

C.3. Technical database

All basic functions, grouped by subsystem, discipline and type of basic function, are listed in the technical database.
The database indicates, for each basic function, the type of commissioning operation required, by reference to the task report form of this operation, and it also gives other relevant information (set points, drawings no., etc.).
The completion date of each activity is also recorded, so that it is a working document used to follow up the commissioning progress.
The database will be used during the functional testing of the plant as a follow-up and reporting tool.

C.4. Reference documents

For each subsystem the following documents, transmitted from pre-commissioning, will be needed to allow functional testing to take place:

  • Data sheets
  • Pre-commissioning punch lists
  • Pre-commissioning check lists
  • Pre-commissioning test sheets
  • Status index
  • As-built drawings (marked up)
  • As-built electrical cable schedule
  • Marked-up TSLD's
  • Instrument calibration sheets
  • Test certificates for
    - Air piping
    - Air tubing
    - Hydraulic tubing
  • Vendor documentation

D. Piping and vessels preparations

Before undertaking introducing the feed into the plant, a number of specific process operations must be carried out on the pipework and vessels, which are grouped under the generic terminology of "Piping and Vessels Preparations". These operations, the preparation and execution of which are an integral part of the commissioning activities, are the following:

D.1. Leak tests

General subsystems or circuits pressure tests carried out at the pipework maximum operating pressure, just before oil or gas-in.
Leak tests are systematically performed on any subsystem including pipework.

D.2. Dry-out

Removal of liquid water from facilities and achievement of a given water dew-point.
Drying-out is performed on all equipment internally protected by refractories and plant section designed to run at low temperatures, to avoid hydrates formation during the start-up phase.

D.3. Chemical loading

Filling-up certain types of vessels with their packing.

D.4. Inerting

Removal of oxygen from all pipework and vessels due to hydrocarbons.

E. Operational tests

  • ­The test preparation
    - Mechanical preparation
    - Subsystem preparation
  • ­The start-up and tuning
  • The demonstration

F. Support activities

  • Logistics: Housing, catering, offices, transportation means
  • Material: Spares, consumables, test equipment, temporary equipment, documentation
  • Execution personnel: Mobilization, administration, organization
  • Vendors: Mobilization, assistance
  • Planning: Forecast, program, histograms, man-hours
  • Punch lists: Follow-up, clearance

G. Documentation tasks


G.1. Database

During the execution phase, the database will be used by the commissioning as a working document, by recording the completion dates of each functional test and of all other commissioning activities listed in the database.

G.2. Drawings update

  • PID's
  • TSLD's
  • Single line diagrams
  • Interconnecting diagrams
  • Interlock logic diagrams
  • ESD/F and G matrixes

Commissioning dossier

  • Ready for start-up certificate
  • Subsystem definition drawings
  • Data base print-out
  • Commissioning reports
    - Preliminary checks reports
    - Functional test sheets
    - Piping and vessels preparations reports
    - Operational test procedure
    - Mechanical reports
    - Vendors reports
  • Punch list (final status at the end of the commissioning)
  • As-built drawings
  • List of modifications