THE 9 KEY ELEMENTS OF SUCCESSFUL PLANT

COMMISSIONING

August 28, 2018

Part 1: The 9 Key Elements of Successful Plant Commissioning
1. Planning
-Without proper planning, you will not be able to commission a plant safely and in time.
2. Mechanical Completion (MC)
-The commissioning team takes over the systems from the construction team.
3. P&ID Checking
-The commissioning engineers verify that everything is built according to its specifications.
4. Pre-Commissioning
-Includes cleaning of pipes by blowing and flushing, mechanical cleaning of vessel and tanks, no
load test runs of motors, and others.
5. Commissioning
-Includes, for example, introduction of utilities, dry running trials, hot running trials, safe fluid
dynamic testing, solvent dynamic testing, and process fluid test.
6. Start-Up
-This means the entire plant will be taken slowly to full operation.
7. Initial Operation
-This phase is necessary to prepare the performance test. During the initial operation, the entire
plant will be optimized.
8. Performance Testing
-The commissioning team will have to prove that the plant meets all specifications under normal
operating conditions.
9. Post Commissioning
-In this phase, a reduced commissioning staff will take care and solve open punch points.

Part 2: Planning
1. Risk Assessment
 Hazard and Operability Analysis (HAZOP)
2. System Definition
-The pre-commissioning and commissioning of the plant will be carried out on a system by system
and unit by unit basis. Therefore, each unit is divided into logical process and/or piping and
equipment systems or subsystems.
 P&ID Master Set
-Mark the different systems with different colors. Be sure that you are using the latest revision.
3. Completion Prioritization
-This means you have to think about the right order for commissioning of the systems.
 According Start-Up Sequence
4. Software
-You have to consider which software tools you will use to recall your commissioning progress and
to capture your test results.
  Integrated Commissioning & Progress Systems (ICAPS)
-Specialized software tool for commissioning. It has been developed by TOTAL. It manages
preparation, execution and monitoring of all pre-commissioning and commissioning activities
as per OPERCOM specifications.
5. Documents
-Should be prepared before the commissioning team will be on site.
 Time Schedule
 Organizational Chart
 Checklist
 Operating Manual
 Pre-commissioning Procedures
 Commissioning Procedures
 Safety Procedures
 Quality Control Procedures
 Security Procedures
 Emergency Response Procedures
 Status Progress Reporting
 Test Records
 Punch List Template
6. Manpower
-Includes:
 Pre-commissioning Team
 Commissioning Team
 Operating Team
 Maintenance Team
 Client’s Team
 Contractors
 Vendors
 Licensors
 Support from Office
7. Material
-It is important to plan the materials needed during pre-commissioning and commissioning in
advance. Includes, for example:
 Blinds
 Spool Pieces
 Hoses
 Additional Gaskets
 Sample Bottles
 8. Equipment
-It depends on the type of the plant you want to commission which additional equipment will be
needed. For example:
 Steam Blowing Equipment
9. Tools
 Tool Kits
10.OPERCOMTM
-This is a methodology developed by TOTAL and tailored to the oil and gas industry. The main
objectives of OPERCOM include safety, planning, confidence, efficiency, consistency and economy.

Part 3: Mechanical Completion

1. Definition: Checking and testing of equipment and construction to construction to confirm that the
installation is in accordance with drawings and specifications and ready for pre-commissioning or
commissioning in a safe manner and in compliance with project requirements.
2. Typical Task
 Mechanical
-Examples are:
 Visual inspection for complete and correct installation
 Verification of name plate details at tanks, vessels, rotating equipment and other
machines
 Internal inspection of tanks and vessels
 Hydrostatic test of vessels and tanks
 Vendor representative for large and/or complicated equipment
 Dimension control
 Bolt Tensioning
 Preservation
 Piping
 NDT done (nondestructive testing)
 Pipe supports completed
 Removal of all items subject to damage during flushing, cleaning and pressure testing
 Blowing
 Flushing
 Chemical cleaning
 Drying
 Preservation
 Reinstatement
 Bolt Tensioning
 Insulation
 Coding
  Structural
 Inspection of all supporting structures
 Electrical
 Inspection
o Cable trays
o Cable trays support
o Cable tray fill
o Cables
o Bend radius
o Wiring
o Termination
o Grounding
 Megger testing
 Instrumentation
 Inspection
o Cable trays
o Cable tray supports
o Cable tray fill
o Cables
o Band radius
o Wiring
o Termination
o Grounding
 Validation of instrumentation
 Validation of valves
 Loop checks
 Flushing of tubing
 Tightness test of tubing
3. What is included?
 As per contract
 Can vary from client to client and plant to plant

Part 4: P&ID Checking

1. Synonyms
-It can also be say as:
 System Check
 System Check for Construction & Engineering Errors
 Plant Inspection
  Punching
2. Who Checks?
-Usually this is done by:
 Commissioning Team (especially by Commissioning Engineers)
3. What to Check?
-The item that should be check are:
 Piping
 Equipment
 Instrumentation
 Point of View
 Safety
 Construction
 Operations
 Maintenance
4. Additional Task
-Includes:
 Temporary Identification Tags
 Temporary Signs for Various Lines, Valves and Equipment
 Temporary Signs for Medium and Flow Direction
-It is good idea to do additional task because:
 To assist subsequent commissioning & start-up activities
5. Which P&IDs?
 Use latest revisions
 Marked with system boundaries
6. Which other documents?
-Documents you need to perform P&ID check are:
 Plans
 Drawings
 Checklist
 Specifications
 Standards
 Hook Ups
 Vendor Documents
7. Punch List
 If you are unsure of the validity of any item, contact the lead unit process engineer
 Any punch item which changes any feature of the P&ID must be screened by the lead unit
Process engineer from a design and safety point of view before implementation
 Transmitted to:
 Construction
  Engineering
 QA/QC Department
8. Checking Method
1. Define which color has which meaning. Mark checked items with highlighter on the system
P&IDs.
2. Faulty items get a check number. Write this check number on the P&ID and enter this number
with a description of the fault into the punch list.
3. Make two copies of the marked system P&IDs and two copies of the system punch list. Attached
each punch list to its respective P&ID.
4. One copy is used as work / re-check copy.
5. The other copy is used as the commissioning team master copy and filled with the respective
system files.
6. The original punch list and marked up P&ID is the “System Master Punch List” and is sent to and
kept in the system punch list master files by QA/QC department. Punch items should be signed-off
by the respective “Originating Punch Team” or “Authority”.
7. Construction QA/QC control management through their respective punch list coordinator takes
care of execution, correction and signing-off of the original “System Master Punch List” through the
respective construction discipline punch list execution team.
8. After correction of punch items the respective construction punch list execution team will inform
the respective “Originating Punch Team” or “Authority” that the work is completed and will do a
combined re-check for immediate signing-off of the original system master punch list.
9. Remember
 Smooth start-up depends to a large degree on the thoroughness the unit is checked beforehand.

Part 5: Pre-Commissioning
1. What is Pre-Commissioning?
 The term pre-commissioning is used for activities after construction completion, such as
cleaning, catalyst loading, dry-runs and checks within the systems in order to prepare these
items/systems for the next step – commissioning.
 Pre-commissioning activities can be done after or as well before mechanical completion (MC).
 API Recommended Practice 1FSC
 “Group of energized and static test that constitute verification that the equipment or
component is fabricated, installed, cleaned, and tested in accordance with the design
and ready for commissioning”
 Also: “static commissioning”
2. Pre-Commissioning Activities
-Examples are:
 Flushing, Blowing and Drying Activities
 Chemical Cleaning
  Final Inspection and Closing of Vessels and Tanks
 Final reinstatement of System of Sub-systems
 Air Tightness “Leak” Testing of Systems
 Lubricants Application
 Pre-commissioning “Run-In” of Major Rotating Equipment and Electrical Motors
 Installation of Filters
 Packing of Distillation Columns
 Loading of catalyst and molecular sieve beds
 Refractory dry-out
 Vendor and Factory Acceptance Testing
 Instrument, Electrical and Motor Loop Testing
 Punch Listing
3. Pre-Commissioning Sequence
-Example:
1. Power and control system (electrical sub-stations)
2. Building power, HVAC, fire & gas protection
3. DCS and PLC systems and instrumentation
4. Raw water and firefighting systems
5. Waste water treatment system
6. Oily sewer / clean sewer systems and chemical sewer & neutralization pits
7. Service water / potable water / cooling water systems
8. Instrument air / plant air and regeneration air systems
9. Water treatment systems, demineralization units and boiler water system
10. Nitrogen System
11. Flare System
12. Plant safety equipment and fire & gas detection
13. Fuel gas and fuel oil system
14. Slop System
15. Flushing oil system
16. Boiler System with steam & condensate networks
17. Amine, aromatics and caustic drain system
18. Feed & product storage systems
19. Product feed system
20. Sour water treatment section and chemical handling treatment section
21. Amine treatment section
22. All process system in order of “priority”
4. Pre-Commissioning Procedures
-Example:
1. Spectacle blind installation checks (Note: All slip blinds or spectacle plates utilized must be given
a suitable tail or handle so immediate identification can be made in the field)
2. Non-return valve internals installation checks
3. Thermal refractory lining installation checks
4. Mechanical interlock checks
5. Fitting of all locks on the valves
6. Packing of a distillation or scrubbing column
7. Packing a reactor with catalyst
8. Installation of filter medium and cartridges
9. Air blowing
10. Steam blowing
11. Water flushing
12. Chemical cleaning
13. Tightness test
14. Cooling water passivation
15. Mechanical test run of pumps
5. Pre-Commissioning Checklists
 Many different checklists for different types of equipment
 To record the inspection and status of equipment items within the plant
 To conform readiness for commissioning
 Often to be witnessed by client, PMC & licensor
6. Pre-Commissioning Test Records
-Pre-commissioning activity test records are prepared to record the satisfactory completion of
various systems preparation task & activities. Like:
 Cleaning
 Chemical cleaning
 Drying
 Air tightness test
 Loading of catalysts
 Blinds list
 Performance indicators
-Includes:
 Construction QA/QC documentation
 System punch list (commissioning punch)
 Piping pre-commissioning activities
 Stationary equipment pre-commissioning activities
 Rotating equipment pre-commissioning activities
  Instrumentation pre-commissioning activities
 Tightness test
 Reporting (we can count the total, completed and remaining task which should have be
done)
7. Pre-Commissioning Additional Records
-Example:
 Request for mechanical completion acceptance
 Mechanical completion certificate
 Release for pre-commissioning notice
 Punch list report of outstanding punch points
8. Vendor Specialist
-Used in:
 For major items of rotating machinery, major utility systems and special electrical and
instrument control equipment
 Package units
9. Licensor
-Will do the:
 Final inspection of “critical” equipment installation
 Supervision of catalyst and chemical loading
10. Ready for Commissioning (RFC)
-This means:
 Pre-commissioning activities are completed, and the systems are ready to commence
commissioning
 According to API Recommended Practice 1FSC, “Minor milestone in project when pre-
commissioning activities for a discipline (electrical, instrumentation, mechanical, piping, etc.) are
essentially complete and ready to commence commissioning.”
 Protocol

Part 6: Commissioning
1. What is Commissioning?
 It is usually the phase in a project after pre-commissioning when design process fluids are
introduced to the systems and sub-systems. Sometimes commissioning means running the
systems with a safe fluid only.
 Commissioning moves the project from the “end of the construction” closed to the “commercial
operation” status.
 API Recommended Practice 1FSC
  “Group of energized and dynamic tests that constitute verification that each system or
sub-system is fabricated, installed, cleaned, and tested in accordance with design and
the systems are ready for start-up.”
 A complete, well-planned and accurately documented commissioning effort is one of
the key factors that contribute to a trouble-free start-up (the next step).
2. Grey Area
 Cold Commissioning
 Dry Commissioning
 Tests and procedures that are conducted without solvents or process fluids yet
introduced to the plant.
Sometimes already done during pre-commissioning
 Example activities
Interlock and emergency shut-down tests
Control system sequence checks
 Wet Commissioning
 Water or a solvent has been introduced into the systems or sub-systems.
Tests and procedures conducted with water or solvent.
 “Operating scenarios”
 Example activities
Running pumps with closed loops
Interlock and emergency shut-down tests
 Hot Commissioning
 Synonym “Live Commissioning
 Design process fluids are introduced to the systems and sub-systems
 Activities similar to “Wet Commissioning”
3. RFC
 Milestone “Ready For Commissioning”
 Pre-commissioning activities are completed and the systems are ready to commence
commissioning
 Protocol
 API Recommended Practice 1FSC
 “Minor milestone in project when pre-commissioning activities for a discipline
(electrical, instrumentation, mechanical, piping, etc.) are essentially complete and ready
to commence commissioning”
4. Safety
 PTW
 Permit to work system adequate?
 Security
 “Fencing” of facilities, access control, protection from on-going construction areas, etc.
  Emergency response
 These procedures must be in place, commissioning staff trained in their role in such
procedures and “practice drills” held to confirm effectiveness.
5. Common Activities
 Functional checks
 Operating adjustment
 Final leak testing
 Final drying
 Purging / inerting
 First fills
 Operation of systems and sub-systems
 Completion of system turnover and completion package
6. Sequence
 Commissioning of the facilities will be carried out on a “system-by-system” and “unit-by-unit”
basis.
 Utilize a “backwards” approach
 Control system, DCS, PLC
 Utilities (air, nitrogen, water, steam)
 Product storage, tank systems and loading
 Core process units (reaction, distillation)
 Raw materials feeds
 Raw materials storage
7. Commissioning Procedures
 Utilities and services
 Water or solvent commissioning – For each system
 Process fluid commissioning – For each system
8. Interfaces (“real” example)
 Operations and maintenance
 By company
 “Hands-on” activities for commissioning (and start-up, operation and
performance test) of the plant under the direction, advise and supervision of
the contractor’s commissioning staff, but directly coordinated/supervised by
company’s commissioning staff.
 Product Quality Control
 By Company
 Performing product quality control laboratory analysis for the new facilities
under the supervision of the contractor during the commissioning and
performance test phase
 Production Planning
  By company and contractor
 Company’s production planning for the existing facilities and contractor’s
production plan for the commissioning and operation of the new facilities must
be integrated during the commissioning, start-up and initial operation phase.
 This commences with first requirements for fuel gas, etc. from the existing plant
for boilers start-up and heaters dry-out through initial feedstock transfer and
final product storage, blending and shipping.
 Emergency Response, Security, Safety
 By company and contractor
 Contractor’s emergency response plan for commissioning will require the
support of company and company’s local facilities/services
 The new plant will be integrated with the existing facilities at commissioning
and start-up. Security of the new facilities requires coordination with the
existing.
 Operations safety procedures and permit system for the new facilities must be
coordinated with the existing facilities from initial commissioning and start-up.
 Maintenance Support
 By company
 Company will perform “hands-on” duties and give technical support during
commissioning and start-up for routine maintenance activities and checks. Such
work will be coordinated with company’s maintenance team.
 Vendors
 By contractor
 All commissioning activities by contractor’s vendor specialist will be carried out
under the supervision of contractor’s commissioning team.
 Licensor
 Where necessary, the process licensor may supervise the commissioning of relevant
systems and provide technical assistance.
 Process operating parameters and conditions will be advised by process licensor’s
process engineers.
9. PSSR
 Pre-Start-Up Safety Review
 Usually by systems
 Usually managed by commissioning manager
 Client commissioning team
 Contractor commissioning team
 Licensor
10. RFSU
 Milestone “Ready For Start-Up”
  API Recommended practice 1FSC
 Signifies that system construction, pre-commissioning, and commissioning work are
complete and the required safety verification is ready to commerce start-up.
 Protocol

Part 7: Start-Up
1. What is Start – Up?

 The phase in a project where the entire plant (all systems and sub-systems) are taken into
operation. Process fluids are introduced and process conditions are established with the intent
of making products.

2. RFSU

 Milestone “Ready for start-up”

 Signifies that system construction, pre-commissioning, and commissioning work are complete
and the required safety verification is ready to commence start-up.
 Protocol

3. Shift Works

 Client
 Contactor
 Vendors
 Licensor

4. Shift log book

 Who?
 How?
 What?
 Paper or electronically?
 Client and / or contractor?

5. PSSR

 Pre-Start-Up Safety Review

 Usually by systems
 Usually managed by commissioning manager
 Client commissioning team
 Contractor commissioning team
 Licensor

6. Pre-Start-Up Checks

 What is required to be in place before start-up?

 utilities
 feed
 product storage

7. Start-Up Procedures

 Pipe and equipment purging

 Pipe and equipment evacuation
 Initial introduction of feed and chemicals
 Initial heating or cooling
  To put a catalyst or other media into initial condition
 Valve positions for start-up
 Start-up sequence
 Holding steps
 Detailed procedures how the systems and the whole plant is brought into operation
 “Normal” operation including data
 Shut down
 Emergency shut down

8. Interfaces (“real” example)

 Operations and Maintenance

 By company
 “hands-on” activities
 Product Quality Control
 By company
 product quality control laboratory analysis
 Production Planning
 By company and contractor
 Emergency Response, Security, Safety
 By company and contractor
 Maintenance Support
 By company
 “hands-on” duties and technical support
 Vendors
 By contractor
 Licensor
 Where necessary, the process licensor may supervise the start-up of relevant system
and provide technical assistance.
 Process operating parameters and condition will be advised by process licensor’s
process engineers.

Part 8: Initial Operation

1. What is Initial Operation?

 The entire plant is running in continuous operation, fine-tuned and prepared for the
performance test.
2. Shift Works
 Client
 Contractor
 Vendors
 Licensor
3. Shift Log Book
 Hopefully already set-up during start-up phase
 Who?
 How?
 What?
 Paper or electronically?
  Client and / or contractor?
4. Activities
 Fine tuning of control loops
 Tuning of process
 Testing of operating limits
 Emergency shut down?
 Preparation of performance test
 Data collection
 Equipment data
 Process data
 Performance data
5. Interface (“real” example)
 Operations and Maintenance
 By company
 “hands-on” activities
 Product Quality Control
 By company
 product quality control laboratory analysis
 Production Planning
 By company and contractor
 Emergency Response, Security, Safety
 By company and contractor
 Maintenance Support
 By company
 “hands-on” duties and technical support
 Vendors
 By contractor
 Licensor
 Where necessary, the process licensor may supervise the start-up of relevant system
and provide technical assistance.
 Process operating parameters and condition will be advised by process licensor’s
process engineers.

6. Performance Testing
 Mutual agreement between client, contractor and licensor

Part 9: Performance Testing

1. What is Performance Testing?

 To check if the plant is operating according to the design

 API Recommended Practice 1FSC
 “Performance testing involves operating thee facility and carrying out a series of defined
tasks, demonstrations and tests to measure the new plant and equipment against the
contract, design, and nameplate parameters.”
2. Duration
 Varies from plant to plant and industry to industry
 E.g. simple water treatment plant
 24 – 72 hours
 E.g. sulphuric acid plant 3 x 4,500 tons per day
 4 x 5 consecutive days
 E.g. 800 MW coal fired power station
 Several months
3. Shift Works
 Client
 Contractor
 Vendors
 Licensor
4. Shift Log Book
 Hopefully already set-up during start-up phase
 Who?
 How?
 What?
 Paper or electronically?
 Client and / or contractor?
5. Mutual Agreement
 Company and contractor mutually agree on performance test procedures, tests, sequences,
schedules and other conditions for carrying out the performance testing
6. Interfaces (“real” example)
 Operations and Maintenance
 By company
 “hands-on” activities
 Product Quality Control
 By company
 product quality control laboratory analysis
 Production Planning
 By company and contractor
 Emergency Response, Security, Safety
 By company and contractor
 Maintenance Support
 By company
 “hands-on” duties and technical support
 Vendors
 By contractor
 Licensor
 Where necessary, the process licensor may supervise the start-up of relevant system
and provide technical assistance.
 Process operating parameters and condition will be advised by process licensor’s
process engineers.
7. Don’t forget
 Are you able to take all necessary readings?
 Does everybody involved know where to take the readings?
 Does everybody know what can be touched and what should not be touched during
performance testing?
 Is the laboratory ready?
 Do you have enough sample bottles?
 Does everybody know when and how to take samples?
 Does everybody know where and how to store the samples?
8. FAC
 Final acceptance
 After successful performance test
 Care & custody transferred from contractor to client
 “Handover”

Part 10: Post Commissioning

1. What is Post Commissioning?

 The phase starting after handling over the plant to the client (FAC) – until operations assistance
is not needed anymore and the outstanding punch points are solved.
2. Activities
 Adjustments, modifications and fault correction
 Completion of outstanding punch list items
 The first routine maintenance checks are performed, findings evaluated and reported
 Process equipment and items covered by warranty are observed for possible problems
 Operating data is collected and evaluated to ensure consistent plant operations are maintained
3. Interfaces
 Contractor
 Solving of outstanding punch points
 Usually, at the beginning a few experienced commissioning engineers from the “old”
crew
 Later usually just one
 He or she is the first contact person for thee client in the daily routine
 Usually, just in a day shift
 Company
 Production Planning
 Operations
 Maintenance
 Product Quality Control
  Emergency response, Security, Safety
 Vendors
 By Company
 For repair works
 Licensor
 Where necessary, the process licensor may supervise the operation of relevant systems
and provide technical assistance
4. Duration
 Varies from plant to plant and industry to industry
 From a couple of months till years (yes, really)