DKK2462 PCSU

Chapter Two
Construction and installation
Pre-Commissioning Period
Introduction to Pre-Commissioning

• The initial start-up of any plant, irrespective of

size, type of industry, is a unique occurrence.
• Therefore, start-up poses some special
problems.
• Lack of experience in dealing with these
problems has frequently resulted in prolonged
and costly start-ups.
• This topic will provide guidelines for all those
involved in the execution of a project on how to
achieve a successful plant commissioning &
start-up.
• The requirements for start-up oriented thinking at all
stages of the project, from engineering to
commissioning, will be demonstrated.
• Emphasis is on effective planning and use of available
resources, both material and manpower.
• Troubleshooting performed during the actual start-up can
be very expensive and must be done as effectively as
possible.
• Effective troubleshooting can minimize the time and cost
of going from the initial start-up to full production.
 Aims of Pre-Commissioning
• Ensure the Plant is constructed as designed.
• Ensure the Plant is clean.
• Ensure all the instrumentation, safety systems
and machinery are fully functional.
• Ensure all vessel internals is installed correctly.
• Ensure the Plant is leak tight.
 Overview of
Pre-Commissioning Activities
Construction & Hydrotest Encourage the construction group
to leave the plant as clean as
possible
Initial Plant Inspection to provisional
Punch list & safety of construction
mechanical completion review

Mechanical, air/steam blow or

Plant Cleaning Method blast, water flush, chemicals,
etc.

Remove any fragile equipment,

Rig Out the Plant for Cleaning e.g. instruments.

Ensure blow points are safe

Clean & Inspect the Plant The time and effort to prepare for
cleaning is mush greater than
the cleaning time. One more
blow than necessary is easy and
should be done.
 Overview of
Pre-Commissioning Activities
Reconstruct & Purge Put back instrumentation,
internals, load catalyst,
etc.

Final Punch List This is the last chance to

get what you want

Instrument Testing Do not underestimate how

long this can take

Leak Testing It’s much easier and safer

to fix a leak before the
introduction of organics

Trip Testing Trip test once all systems

are complete

Start-Up
 Key to Effective Pre-Commissioning

• Planning and Preparation-milestone &

progress report
• Work closely with the Construction Group
• Divide the Plant into small sections and
pre-commission each one as it becomes
available.
• Hold regular pre-commissioning meetings
to check progress and to keep all parties
informed.
 Typical List of Systems
• Electricity
• Portable/Cooling water
• Nitrogen
• Fuel – gas/liquid
• Plant/Instrument air
• Hot oil/Steam system
• Other utility systems (AHU : Air Handling Unit)
• Tankage Area
• Security system
 Planning & Preparation
• Master drawings for cleaning.
• Master drawings for instrument checks.
• Identify needs for vendor representatives
and outside contractors.
• Ensure sufficient labour is available.
• Ensure sufficient materials are available.
 Planning & Preparation
• Prepare systems breakdown and mark-up
on a master P&ID.
• Agree systems with construction.
• Agree timing for hand over of each system
(installation-commissioning-training).
• Prepare pre-commissioning plan for each
system.
 Pre-commissioning Plan
• Marked-up P&ID showing cleaning points,
instruments to be removed, etc.
• Description of system plan.
• Schedule for activities.
• List of consumables required.
• Requirement for vendor representative.
• Special safety activities.
 Mechanical Completion &
Pre-Commissioning
• The registers for pressure vessels, piping systems, and
protective devices should be established before
commissioning.
• (PMT/PMA/PMD submit to JKKP)
• Mechanical completion ensures that the installed
equipment is ready for commissioning and involves
checking it is installed correctly.
• The component parts operate as specified.
• The plant layout should be checked with respect to features
such as: means of access & escape routes, floor stairs and
handrails, lighting, fire equipment and safety equipment.
 Pre-Commissioning Documentation

• The documentation available at the

Pre-commissioning stage should include:
1. Operating manual
2. Operating instructions
3. Safety instructions
4. Permit system documents
5. Pressure vessel register
6. Pressure piping systems register
7. Protective device register
8. Maintenance systems and documents
9. Checklists
 Some Checks and Tests Carried Out On Process
Equipment and Machinery During Plant Commissioning

• Pre-installation inspection, checking and testing of:

-pressure vessel & process machinery
• Plant checking against piping & instrument diagram (P&ID)
• Checks on materials of construction
• Pressure vessel and system tests:
-inspection, pressure tests, leak tests & protective devices tests
• Process machinery tests:
-inspection, dry runs, load runs & performance runs
• Subsystem and system test:
-dynamic safe fluid test (water test)
-dynamic process fluid test
• Also tests on:
-utilities, instrumentation, unit operation & simulated faults.
 Some Elements of the Checking and Testing of
Process Machinery

• Field disassembly and reassembly

• Lubrication systems: cleaning and checking on circulation (flow &
temp)
• Cooling water system: cleaning and check on circulation (flow &
temp)
• Pre-commissioning of instruments
• Check on free and unhindered rotation
• Check on anchor bolts
• Disconnection of piping to check that it does not stress equipment
• Check on alignment
• Check on vent system
• Check on seal system
• Dry run: check on vibrations and overheating of bearings
• Load run & performance run
Some Elements of the Checking and Testing
of Instruments

• Instrument checking against drawings and

manufacturer’s requirement
• Removal of shipping restrictions
• Calibration
• Continuity check
• Movement check
• Alarms check
• Interlocks check
• Analysers check
Examples of Process Machinery

Spray
Dryer
Reactor Vessel
Membrane System

Mixing System
Examples of Instrument & Device

Solid Level
Detector
Foam Level
Detector

Liquid Level
Detector
Gas Detector
AHU (Air Handling Unit)

regulate and circulate air

An air handling unit; air flow is

from the right to left in this
case. Some AHU components
shown are
1 – Supply duct
2 – Fan compartment
3 – Vibration isolator ('flex
joint')
4 – Heating and/or cooling coil
5 – Filter compartment
6 – Mixed (recirculated +
outside) air duct
Boiler