Pre Commissioning

1.
Pre commissioning schedule

2. Plant inspection
Vessel and heat exchanger
Reactor and column
Machinery
Piping
Electrical
Instrumentation
3. Steam system
Steam tracing: Once steaming method
Process steam lines: Blowing cycle
Superheated steam line: Target plate method
4.Cooling water line flushing
5.Plant air line flushing
6.Instrument air line flushing
7.Fire water system fushing
8. Cleaning of pipelines ( Hydraulic flushing , pigging, air blowing, steam blowing, oil flushing, acid
cleaning, alkaline boiling and manual cleaning )
9. Calibration of level indicators against the tanks
10. Inspection and box up of vessels, column and heat exchanger
11. Run-in of rotating equipment
12. Air drying of process lines
13. Furnace drying
14. Catalyst loading
15. Technical audit by owner ( Punch list )
16. Pressure test
17.Service test
18.Vacuum hold test
1. Team selection
2. Proper written procedures before any pre commissioning
3. Proper emphasis on personnel safety.
Plant construction:
1. Basic Engg package

2. Detail Engg
3. Procurement
4. Construction
5. Operator training
6. Mechanical completion
7. Pre commissioning
8. Commissioning
9. Acceptance test run
Operator training
1.Start up procedures
2.Commissioning procedures
3.Specific P & ID review
4. Process control review
5. Reactor overview
6. Distillation over view
7.Plant specific process variables
8.Normal start up and shut down procedures
9.Emergency shut down procedures
10.Plant specific environmental concerns
( Concept : Train the trainer )
Mechanical completion Items Constructor Operations Advisors

Installation of piping and equipment Perform Witness
Integrity ( Hydrostatic/pneumatic) Perform Witness Witness
testing
Equipment inspection Perform Witness Witness
Develop Punch list Perform Witness
Cold alignment checks Perform Witness Witness
Point to point continuity check Perform Witness Witness
Removal of free water from systems Perform Witness
Preservation and maintenance Perform Witness
Punch list
Punch list is an integral part of mechanical completion and is a critical step to verifying the status of
system completion.
The category of punch list determines if a system is ready to move into the next phase of
commissioning.
Category A
Punch list items that must be repaired or completed prior to the issuance of mechanical completion
Category B
Punch list items that must be repaired or completed after mechanical completion but before pre
commissioning
Category C
Punch list items that must be repaired or completed prior to commissioning for safe start up and
continuing operations.
System turn over
The turn over procedure and schedule will define how the systems are turned over from construction to
commissioning; what work has to be completed and by whom, before the system can be turned over.
Utilities and OSBL are scheduled first and followed by ISBL.
SYSTEM DEFINITIONS
Detailed Design and Engineering Deliverable List

(Sample)
Process Design
 Basis of Design
 Process Flow Diagrams (PFDs), Utility Flow Diagrams (UFDs) and Heat &
Material Balances
 Process & Operational Control Description
 Process Equipment List
 Process Datasheets for Main Equipment (per Equipment List)
 Piping & Instrumentation Diagrams (P&ID’s)
 Line list
 Tie-in Schedule
 Cause & Effects Diagrams
 Process Data Sheets for instrumentation
 Process Alarm & Trip Schedule
 Effluent and Emission Summary
 Catalyst and Chemicals Summary
 Process Simulation Report (including Process Simulations files)
 Process Design Calculations
 Flare and Relief System Study/Sizing Calculations
 Distribution P&ID for the flare headers
 HAZOP Report
 Performance Guarantees Statement
 Performance Test Procedure
 Pre-commissioning and Commissioning Manual
 Operating & Maintenance Manual
Civil and Structural Design
 Earthworks Specifications defining procedures for excavation, filling and

compaction.
 Earthworks Grading Drawings Layouts
 Piling Specification
 Piling Layouts identifying capacities, locations and cut-off elevation of piles.
 Civil Design Criteria
 Structural Design Criteria
 Reinforced Concrete Specification
 Structural Steelwork Specification
 Design Calculations complete with index
 Fireproofing of Structural Steelwork Specification (If applicable)
 Civil Layouts
 Underground Services Specification
 Underground Services Layout
 Underground Service Design Details Drawings
 Foundation & Concrete Structure General Arrangement Drawings (GA’s)
 Drawings of platforms, ladders, handrails and stairs associated with
equipment and vessels
 Cable Trench Layouts
 Cable Trench Details
 Paving Plan and Details Drawings
 Foundation and Concrete Structure RC Details
 Road Layouts and Details
 Structural Steel Layout and Details for Pipe racks Structures and Pipe
Supports
 Requisitions for Structural Steelwork
Architectural Design
 Building layout drawings

 Building detail drawings
 Specifications for Buildings
 Schedules of Finishes (Buildings)
 Schedules of doors and windows
Piping & Layout
 Well flowline layout

 Overall Site Plot Plan
 Process Area Plot Plans
 Piping Material Specifications
 Special Piping (SP) Item Schedule and Data Sheets
 Standard Piping Details
 Fabrication and Installation of Pipe-work Specification
 Heat Tracing/Jacketing Specification and Schedules
 Piping General Arrangement Drawings
 Isometric drawings for 2" and above pipe-work above and below ground
 Material take-offs
 Key Plans of Piping General Arrangements.
 Stress Analysis Specification
 Stress Critical Line List
 Stress Sketches
 Final Stress Report
 Pipe Supports Design details
 Special Pipe Support Register
 Pipe Support Spring Register and Calculations
 Hydrostatic test diagrams
Electrical Design
 Area plans
 Hazardous area classification drawings
 Area key plans for Lighting, tray and grounding layouts
 Layout drawings
 Grounding layouts
 Plant cable tray and cable routing layouts
 Plant and buildings lighting layouts
 Substation layouts
 Switchgear building equipment layout
 U/G duct bank layout etc.
 One line diagrams showing interlocks, inter tripping, system capacity, Voltage
levels, currents, impedances, generation power levels etc.
 Key one line diagram
 138/4.16 kV one line diagram
 4,16 kV (MV) one line diagrams
 480V one line diagrams
 120 VAC UPS one line diagrams
 125 VDC UPS one line diagrams
 Emergency power one line diagrams etc.
 Schematics
 4 kV motor schematics
 460 V motor schematics
 MOV control schematics
 Lighting control schematics
 Heat tracing isometrics etc.
 Equipment drawings including vendor prints
 These drawings shall be supplied for all the major tagged equipment such as
Transformers, Switchgears, MCCs, UPS, Chargers, Generators, Power
supplies, PTs, CTs, Control panels, packaged equipments etc.
 Front and interior layout showing all the components
 Wiring drawings and terminal connections
 Installation details including manuals
 Component maintenance and instruction manuals
 Electronic equipment manuals and settings
 Fuse ratings and characteristic curves
 Equipment and component datasheets
 Weights and measurements
 Schematics
 Equipment specifications
 Motor datasheets
 Circuit breaker settings
 3 Line diagrams
 Battery details including amp-hour ratings
 Relay settings and relay discrimination curves
 Data sheets and environment limitations
 HVAC requirements
 Manufacturing data books
 Spare parts lists etc.
 Inter connection diagrams
 Inter connection drawings between panels
 Details
 Hazardous area classification details
 Installation details for Lighting, grounding, heat tracing etc.
 Duct bank details
 Lists and Schedules
 Cable routing schedules
 MCC schedules
 Lighting and Distribution panel schedules
 Heat tracing panel schedules
 Load lists
 Electric equipment list
 Bulk material lists and catalogue numbers
 Cable tray penetration details in to buildings
 Calculations
 Tray sizing calculations
 Heat tracing calculations
 Equipment sizing calculations
 Lighting level calculations
 Emergency power load requirements
 Studies and reports
 System studies showing fault levels, short circuit current, Minimum/
Maximum
 Load flow analysis, motor starting effects and system stability, voltage
levels
 Transformer tap settings
 Motor protection settings
 Relay setting schedules including setting curves
Instrumentation and Controls
 System Block Diagrams

 Specifications Defining functionality of systems and interfaces between
systems
 System Graphic Displays
 Control Logic Diagrams based upon ISA2
 Instrument Specifications for equipment and materials
 Instrument Data Sheets based on ISA S20 templates Data Sheets
 Instrument Index
 Relief and Safety Device Index
 Alarm and Trip Schedule
 Control Room and Control Building Layouts
 Instrument Location Drawings
 Instrument Cable Routing
 Panel and Rack Layouts
 Instrument and Control System Schematics
 Instrument Power and Utility Requirements
 Power Distribution One line
 Power Distribution Schedule
 Grounding Diagrams for instruments and control system
 Instrument Junction Box Schedules
 Instrument Cable Schedule
 Termination Schedule/Diagram
 Instrument Hook-Up Diagrams (Electric, Pneumatic, hydraulic and/or
Process)
 Air Distribution Diagram
 Instrument Junction Boxes and Panels Block Diagrams
 Interconnection Diagrams
 Loop Diagrams
 Requisitions for equipment and bulk materials
 Input/Output Schedules
 Instrument Design Data and Engineering Calculation
Fire Fighting and Safety
 Safety Design Philosophy

 P & ID for Fire Water Ring Main
 Fire Fighting Equipment Layout
 Fire Fighting Equipment List / Requisitions
 Fire & Gas Cause & Effects Matrix.
 Fire and Gas Detection Equipment Schedule
 Extinguishing Systems Design (Where/if applicable) of fixed fire extinguishing
systems (e.g. foam, carbon dioxide, clean agent, and/or dry powder systems)
 Mobile Fire Fighting Equipment Schedule
 Safety Equipment Schedule

Pre Commissioning

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Pre Commissioning

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What are the main steps involved in pre-commissioning?

What are the main steps involved in pre-commissioning?

What are the different categories of punch lists and their significance?

What are the different categories of punch lists and their significance?

1.

Pre commissioning schedule

Steam tracing: Once steaming method

Process steam lines: Blowing cycle

Superheated steam line: Target plate method

4.Cooling water line flushing

5.Plant air line flushing

6.Instrument air line flushing

7.Fire water system fushing

9. Calibration of level indicators against the tanks

10. Inspection and box up of vessels, column and heat exchanger

11. Run-in of rotating equipment

12. Air drying of process lines

13. Furnace drying

14. Catalyst loading

15. Technical audit by owner ( Punch list )

16. Pressure test

18.Vacuum hold test

1. Basic Engg package

3.Specific P & ID review

4. Process control review

6. Distillation over view

7.Plant specific process variables

8.Normal start up and shut down procedures

9.Emergency shut down procedures

10.Plant specific environmental concerns

( Concept : Train the trainer )

Mechanical completion Items Constructor Operations Advisors

System turn over

Utilities and OSBL are scheduled first and followed by ISBL.

Detailed Design and Engineering Deliverable List

Civil and Structural Design

 Earthworks Specifications defining procedures for excavation, filling and

 Building layout drawings

Piping & Layout

 Well flowline layout

Instrumentation and Controls

 System Block Diagrams

Fire Fighting and Safety

 Safety Design Philosophy

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