Professional Documents
Culture Documents
and Commissioning
Plant Start-up and Commissioning
Financial viability
Mechanical completion
Provisional acceptance
Construction Acceptance
Pre-
commissioning,
Inspection and Start up and
Operational Performance Post
Testing testing commissioning
Construction and Commissioning
How it happens …..
Mechanical completion
Progressive provisional acceptance
Construction Progressive acceptance
Pre-commissioning,
Inspection and Start up and
Operational Testing Performance Post commissioning
testing
Commissioning in practice
Isolation
Testing
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
Performance and
Acceptance testing
Post Commissioning
The Commissioning Process Detail - 1
Appointment of Commissioning
Preparation and planning
Manager or Lead Commissioning
Engineer;
Mechanical Completion
and Integrity checking
Appointment of Commissioning
Team Members and Support Staff;
Pre-commissioning & Training;
Operational Testing Information Compilation;
Start Up & Initial Safety and Risk Assessment;
Operation Commissioning Strategy
Performance and
Development;
Acceptance testing Procedures and Checklist
Development;
Post Commissioning Detailed Plan and Budget Preparation;
The Commissioning Process Detail - 2
Preparation and planning
Inspection
Mechanical Completion
and Integrity checking
Pressure testing
Cleaning and Flushing
Pre-commissioning &
Operational Testing Machinery checkout
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
The Commissioning Process Detail - 3
Preparation and planning
Mechanical Completion
and Integrity checking
Steam and other utilities
Pre-commissioning & introduced;
Operational Testing
Dry running trials;
Start Up & Initial
Operation
Hot running trials;
Safe-fluid dynamic testing;
Performance and
Acceptance testing
Solvent dynamic testing;
Process fluid tests.
Post Commissioning
The Commissioning Process Detail - 4
Preparation and planning
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
The Process
Conditioning and Special Equipment
Starting Procedures
Shutdown Procedures
Maintenance Responsibilities
Publish work and safety procedures;
Specify maintenance activities
Select and purchase maintenance supplies and spare parts;
Negotiate with vendors and contractors;
Keep up maintenance records;
Make detailed designs of any changes and additions made
during commissioning;
Storage of spare parts and supplies;
Schedule routine daily work and that for planned shutdowns.
Safety in Maintenance - 1
Detailed procedures for maintenance work and work to be
done when executing the commissioning procedure
Need to cover each major piece of equipment & system
take into account all possible hazards
Include:
Instructions for isolating (blinding, draining, venting,
1. Centrifugal compressors
2. Steam turbines
3. Large gear speed increaser units
4. Electric motors in size categories above 1000 HP
5. Reciprocating compressors
6. Gas turbines
7. Gas expanders
Commissioning Team Information Requirements
Project design file
Process file
Operating instructions
Analytical procedures
and personnel;
Costs for unexpected changes and additions;
Startup Costs
Cost = 100 (0.10 -0.02 -0.03 + 0.04 +1*0.02)
= 8 * 0.38 = 3 Months