Commissioning & Start-up Directory
Commissioning& Start-up DirectoryINTEGRATED SERVICE SOLUTIONS
Index1CHAPTER2CHAPTERINTRODUCTION4COMMISSIONING & START UP SERVICE52.12.22.32.43CHAPTERCommissioning Standard Implementation PathThe Home Office Phase2.2.1 (Pre-) Commissioning Engineering2.2.2 (Pre-) Commissioning and Start-up Manuals67811The Site Phase142.3.2 Pre-Commissioning Period152.3.1 Mechanical Completition Check & Interim Handover2.3.3 Commissioning & Start-Up PeriodSystem Turnover ManagementDEDICATED TOOL14161718
1CHAPTERIntroductionISS International is well experienced in Pre-Commissioning and Commissioning activities and can providethe in-deph experience, guidance and qualified personnel necessary to deliver a unit Safely prepared andready to achieve a successful Start-up.2CHAPTERThe senior technicians and the engineers who make upour staff have been all chosen on the basis of the professionalism, versatility and ability to adapt themselvesto the different environment and industrial culture of ourcustomers covering both “Home-Office” and “Site”phases providing specific services as well as the implementation of fully integrated projects even on a“Turn-Key” approach.The standard definitions used are as follows:Pre-CommissioningPre-Commissioning activities start when the plant, or system, achieves Mechanical Completion. Frequently however, Pre-Commissioning activities overlap Mechanical Completion activities and for thisreason the plant should be separated into easily manageable system package, each system package will be Pre-Commissioned as a whole and isolations at the boundaries of the system packagewill be maintained until the completion of Pre-Commissioning activities.Pre-Commissioning activities include: checking for design conformity, checking the status of electrical, mechanical and instrument installations, running-in of equipment, flushing and cleaning activities, drying, etc.CommissioningCommissioning is the phase in a project when design process fluids are introduced to the process.Note that for hydrocarbon systems the commissioning activities commence with inerting operations.Commissioning activities normally consist of activities associated with running or operating the plantand include operating adjustments necessary for satisfactory operation of the plant or part thereof.Also included are “Functional checks” which are methods used to prove that an item of mechanicalequipment or control system functions correctly.Start-upStart-up is the point in a project where process fluids and conditions are established with the intentof making products.SystemA section of the plant or facility that can be Pre-Commissioned and commissioned independently,but in parallel, with other sections of the plant or facility under construction.Unit Ready forCommissioningThis is the point in a project where all utilities are commissioned and operational and theunit is ready to accept the introduction of hydrocarbons.Unit Ready forStart-upThis is the point in a project where the unit is ready to establish process conditions withthe intent of making product.Manage your business even before “you turn the key”4Commissioning & Start-up DirectoryCommissioning& Start-up ServiceCommissioning & Start-up Directory5
2.1 COMMISSIONING STANDARD IMPLEMENTATION PATH2.2 THE HOME OFFICE PHASEISS International Standard Pre-Commissioning,Commissioning and Start-up Methodology is organizedconsidering the entire project frame and having in mindthe following objective: TO CONDUCT THE PLANT INOPERATION.During this phase the preparation of Tool for measurement and reporting of Pre-Commissioning & Commissioning activities Progress, project detailed plan,project detailed and operative deployment plan, preparation of detailed “procedures”, etc. take place.During this phase the following activities will be carriedout, but not limited to:The entire Commissioning Service process is developed according to the following phases:Home Office PhasePreparatory Works(Home office Activities).Site PhaseMechanical Completion Check(according to API 700 Sec. 3 & 4)Pre-CommissioningCommissioning & Start-UpPerformance Tests.The ISS International Standard implementation pathis shown in the following figure:Preparatoryworks(Home tsTool for Measurement and reporting ofPre-Comm & Comm. ActivitiesProgress, preparation of details (planning, etc.)Turnover management system(CWPMS) operating manual& Procedures check and/or preparationAPI 700 sec. 3&4Filed inspections, documentation inspection(outstanding Item verification)Interim Handover Certificateverification (P/L oustanding)Inspections, Punch-list issuing, utilities comm, cleaning,flushing blowing, chemical cleaning, non operating adjustment,motor run-in, catalyst, internal inspection, .Ready for commissioningCertificateCooling water start-up, spring hangers check,operating adjustment, purging, pressure test, .Ready for Start-upCertificateOil-InReady for performance testConduct performance testsProvisional Acceptance Certificate(Pre-)Commissioning Engineeringa. System/Subsystem definitionMarked-up P&ID by Systemb. Detailed Pre-Commissioning / Commissioning Execution PlanOrganization ChartDeployment plan per activityc. Generic Method Statementd. Commissioning Plan and Critical Path NetworkActivities to be performed by Systeme. Organisation Roles And Responsibilitiesf. Punch-listing method Statementg. Commissioning input to the Design ProcessP&ID ReviewHazOp Reviewsh. Commissioning Spare Parts & Consumablesi. Sample and Testing Schedulej. Equipment Data Logging(Pre-)Commissioning & Start-Up Manuala. Development of (Pre-)Commissioning and StartUp Manualsb. Quality ManualQuality Control PlanQuality Control FormsSystem Turnovera. Handover: The Turnover Management System forCommissioning (TMSCOM ). Tool implementationand configuration.END6Commissioning & Start-up DirectoryCommissioning & Start-up Directory7
2.2.1 (Pre-)Commissioning EngineeringISS International commissioning and technical personnel will produce a number of deliverables. The documents will entirely fulfil the contractual requirements forthe pre-commissioning, commissioning, start-up andinitial operation of the complex as per customer documents.Main activities of these phase can be summarized asfollows:System/Subsystem DefinitionTo enable a smooth transition from construction to commissioning it is required to complete construction workin small packages (known as systems). This enablesPre-Commissioning work to progress from an earlierpoint in the schedule, thus reducing the final pre-commissioning peak workload substantially. However, systemised turnover is more complex to co-ordinate andmanage due to the:increase in boundaries between the constructionand commissioning groups.increase in parallel activities during the final stagesof construction.The size and content of a system changes for eachproject, however it is essential to take the followingpoints into consideration when defining system sizeand content.Units separated into a large number of systemshave high manpower expenditure for the pre-commissioning phase.Units separated into a low number of systems havean uneven workload pattern throughout the precommissioning phase.8Commissioning & Start-up DirectoryHydro-test boundaries should coincide with systemboundaries, where possible.Systems should be defined by colour coding a set of A3P&IDs. System boundaries should be “flagged” in REDand system numbers should be clearly marked at regular intervals on the respective line-work and equipment.System summary sheets should be prepared which listthe system content by line and equipment numbers.Detailed Pre-Commissioning / Commissioning Execution PlanA plan is developed that identifies all of the major precommissioning activities by system. ed for testing. Post-hydro punchlists would be prepared and followed through on to ensure that the systems were fully completed and readyfor pre-commissioning.Electrical Installation - Each electrical circuit and motorinstallation and their electrical polarity check and insulation resistance measurement would be demonstratedby electrical subcontractor to the Commissioning Subcontractor Team.Instrument Installation - Review of instrument installation of correctness according to the instrument drawings and specification. The CommissioningSubcontractor Team would witness and/or approve allinstrument calibration and check out procedures orwork performed by instrument subcontractor.System Pressure Testing - Although the constructioncontractor is responsible for the actual pressure testingof each system prior to mechanical completion, theCommissioning Subcontractor Team would review thetest program and the methods used to ensure satisfactory tightnes.2.3.2 Pre-Commissioning PeriodThe site phase of the project will commence at approximately 60% construction completion and activities willbe mainly centred on:Progression of all of the procedures developed during the Home office phase of the projectCo-ordinating system turnover and completionMonitoring and reporting progressCo-ordinating resources, including sub-contractand vendor supportLiaising with licensors.Main activities developed during Pre-Commissioningphase are:Punch-ListingPunch-Listing will be undertaken on a systems basis. Anintegrated team will be formed to participate in PunchListing. An initial Punch-List will be undertaken immediately prior to system handover for Pre-Commissioningpurpose. This will probably occur at around the hydrotesttime. Punch-List items generated at this stage will be incorporated into the Project master Punch-List system.A final Punch-List will be undertaken by system immediately prior to the commencement of commissioningactivities. This will be a less stringent Punch-List andaimed at checking the system over before introducinghydrocarbons. Utilisation of the Pre-Commissioningcheck sheets will assist in completing a full range of required checks. Punch-Listing progress will be recordedon an A3 set of P&IDs.Commissioning & Start-up Directory15
System CleaningThis would include directing the cleaning of systems either by flushing, blowing or chemical cleaning by issuing directives for the necessary temporary connections,utilities and proper line up of the system to be cleaned.When the services of a chemical cleaning subcontractor are required, the Commissioning Team will monitorhis performance to ensure a satisfactory cleaning job.Before each system is closed for operating, the linesand equipment would be inspected for cleanliness.Cleaning progress will be recorded on an A3 set ofP&IDs.Equipment Run-InThis would include planning and co-ordinating Vendorrepresentatives for the running in of the equipment andobtaining the necessary utilities to accomplish the runin for equipment such as blowers, pumps, compressor,motors, turbines, and other machinery or mechanicalequipment without process fluids before start-up.Vessel LoadingThis phase would ensure that all catalysts, packing,resins and desiccant loading is performed in a propermanner and accurate records and samples of eachmaterial loaded are retained.When all the activities foreseen in the Pre-Commissioning phase (the Process Units will be ready to receive hydrocarbons, most of the utility systems will belive to the respective units and all of the hydrocarbonlines will be positively isolated at the unit battery limits)have been performed successfully a Ready for Commissioning Certificate will be issued and so Commissioning activities can start.16Commissioning & Start-up Directory2.3.3 Commissioning & Start-Up PeriodOnce the unit is precommissioned, the CommissioningTeam will conduct the following main activities:PurgingLeak Test / Tightness TestSpring Hanger Check to start with initial Start-up operations assuring thatevery activity is accomplished smoothly and safely.The Commissioning Subcontractor Team would takecare in troubleshooting any operating or process problems, should they arise, and would investigate any operating deviations as they occur. Team will:a. Develop and Review Specific Operating InstructionThe procedures and practices outlined in each unit’s operating manual will be followed. As these manuals cannot cover every conceivable operating situation, it will benecessary to develop specific operating instructions tocover critical areas of operating as they arise. Any additional operating procedures and practices will be giveneither in writing, if time permits, or verbally, if immediateaction is required, to operating supervisors. An operating logbook will be kept in order to record the instructions and relevant changes in the operating conditions.b. Conduct and supervise all activities during theIntroduction of Feedstock to the UnitsLicensor’s process and operation specialists will bepresent for providing advice during the critical first startup from a technical point of view and will help troubleshoot any problems that arise or investigate anydeviations that occur. The Commissioning team willmonitor the plant operations and make any operatingchanges for stable, efficient operation.c. Stabilize the UnitThe Commissioning Team will provide to work withprocess licensors (if required) on how to bring the unitson stream and up to design rate. Control variables andflow rates will be specified to stabilize the unit at designrate in preparation for the acceptance test and duringthe performance test.d. Conduct Performance Test RunThe Commissioning Team will pompon the proceduresguarantee and documentation and witnesses the instrument calibration. During the execution of Performance Test the Initial Operation Team will conduct theplant according to the procedure already agreed between the ISS International and the Client.2.4 SYSTEM TURNOVER MANAGEMENTSystem HandlingConstruction will progress from a “bulk-area” completion basis to a “system” basis approximately 60%through the erection programme. It will be essential tocontrol and co-ordinate the temporary and permanenttransfer of systems from one group to another toprogress construction completion, Pre-Commissioningand commissioning work. A Systems Co-ordinator willprovide the necessary link between construction andcommissioning. The co-ordinator will be responsible fordeveloping system completion strategies on a dailybasis to ensure a smooth handover process.Each system will have a turnover package of commissioning dossier associated with it. A co-ordination procedure will be utilised for the “offering” or “receiving” ofsystems. At the schedule date for system turnover, theconstruction group will compile diagrams, equipmentlist, instrument lists, exception lists, inspection reportsand other QA/QC documentation for that system.The routing of each system will be from the constructiongroup to the commissioning group. The commissioning group will have an internal handover mechanism torecognise the importance of introducing hydrocarbonsto a process unit for the first time.Pre-Commissioning CompleteWhen the Pre-Commissioning work on each utility system is complete it can then be commissioned providing it is safe to do so. For non-utility systems the pointat which the process Unit is considered to be “ready forStart-up” is when all non-hydrocarbon systems havebeen pre-commissioned. At this stage the Unit is presented as “Ready for Commissioning” This triggersseveral safety activities as follows:A final Punch-List to determine if the unit is ready toaccept hydrocarbonsA pre-start up safety reviewThe introduction of a full permit to work and safetysystem.Commissioning CompleteWhen all commissioning for a process unit is completed the unit is declared “Ready to Start-up”. At thispoint normal conditions are established to produce thedesigned products.Commissioning & Start-up Directory17
3CHAPTERDedicated ToolIn order to control the commissioning activities thatshould be integrated with the construction activities,ISS International has been developed an In-Housesoftware: TMSCOM (Turnover Management Systemfor Commissioning).The purpose of the Plant turnover Management Systemis to provide the appropriate tool to follow the ISS International policies, procedures and quality (QA/QC)checks, in order to administrate all the documentationand to control the Turnover of the facilities from ISS International to its Client / the Owner.ISS International has developed the above mentioned tool that allows the turnover engineer to follow18Commissioning & Start-up Directoryconstruction, Pre-Commissioning and commissioningactivities from the plant’s area definition up to the finalhand-over of the plant reducing time and costs relatedto this kind of activities given a time by time progress.The TMSCOM is a modular and tailored tool thatallow more then 10 users to access together into thesystem for on-line up-date and view using a normalTCP/IP network.It shall be the direct link between Construction andCommissioning activities.In details, the TMSCOM allows to:Manage QA/QC certificatesManage Construction piping activitiesManage Construction electrical activitiesManage Construction instrument activitiesManage Construction machinery activitiesManage Construction punch listsHave Construction progress per areaHave Construction overview progressHave day by day reportsManage the transaction between construction andcommissioning activitiesManage pre-commissioning activities based on construction progressManage punch list outstanding itemsManage pre-commissioning and commissioningpunch listManage Turnover progress and certificatesManage mechanical completion progress, certificates and activit
Commissioning Commissioning is the phase in a project when design process fluids are introduced to the process. Note that for hydrocarbon systems the commissioning activities commence with inerting operations. Commissioning activities normally consist of activities associ
Defining Commissioning for GSA Buildings Commissioning ensures the delivery of efficient, durable, and comfortable facilities. ASHRAE Guideline 0‐2019 The Commissioning Process defines commissioning as follows: “Commissioning Process (Cx): a quality‐focused process for enhancing the delivery of a project. The
Commissioning Your Way To High Performance Buildings THE COMMISSIONING PROCESS Core Phases Of The Commissioning Process PRE-DESIGN STAGE The owner selects the design team, which includes the commissioning authority (CxA). Commissioning authority consists of the initial Cx team and team leader, and they are involved from project initiation
How to manage risks associated with commissioning Process Plant Start-upand Commissioning Telephone : 982188553230 Fax : 982188552734 e-mail: training@matgroup.org www.matgroup.org WHO SHOULD ATTEND? TRAINING METHODOLOGY: Process Plant Start-up and Commissioning is a hands-on, stimulating learning experience.
Commissioning the Building Building Commissioning Building commissioning: Is a systematic and designed process coordi nated by a commissioning authority or team. Includes documentation, verification pro cedures, functional performance tests, valida tion, and training. Is performed specifically to ensure building
“Commissioning” (Cx) Process Applied to New Buildings “Re-Commissioning” (RCx) Process Repeated for Buildings That Have Been Commissioned “Existing Building Commissioning” (EBCx) Process Applied to Existing Buildings Not Previously Commissioned (replaces the older term “Retro-commissioning”). 5
This guideline describes the total building commissioning process and the responsibilities of the Commissioning Authority and the Owner. Selecting and developing a Commissioning Plan following this guideline assures Caltech of whole-building commissioning meeting the OPR, and a sustaina
b. A Certified Building Commissioning Professional, certified by the Association of Energy Engineers (AEE); c. An Existing Building Commissioning Professional (CBCP) as certified by the AEE; or d. A Commissioning Process Management Professional (CPMP) certified by ASHRAE The retro-commissioning
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