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KEIL/SIBA/2015/C-051-REVCPF EPC
Document Number

Document Title
Pre-commissioning Manual

INTRODUCTION

Page

Rev.
Date

OBJECTIVE

4
4

DEFINITIONS

DATA AND INFORMATION

TOOLS AND EQUIPMENT

SAFETY

II

OVER VIEW OF THE PLANT

10

III

SYSTEMS DESCRIPTION

10

A . SYSTEM DEFINITION

10

B . SYSTEM APPROACH

11

C . SYSTEM APPROACH

12

D . PRE-COMMISSIONING SYSTEM LIST

12

IV

PROJECT COMPLETION SYSTEM: WinPCS

14

PRE-COMMISSIONING GUIDELINES

16

VI

PRE-COMMISSIONING PROCEDURES

17

A . GENERAL

17

B . INSPECTION AND TESTING

17

B.1.1 CHECKING AGAINST P&IDs

18

B.1.2 VESSELS AND TANKS

19

B.1.3 ROTATING EQUIPMENT

19

B.1.4 VENDOR PACKAGE ITEMS

21

B.1.5 PROCESS PIPING

21

B.1.6 HYDROTESTING AND CLEANLINESS OF LINES

23

B.1.7 LEAK TESTING & INERTING

26

B.1.8 BUILDINGS

27

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Pre-commissioning Manual

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ELECTRICAL

27

INSTRUMENTATION

36

MISCELLANEOUS MECHANICAL EQUIPMENT

43

PRE-COMMISSIONING FORMS

43

PUNCH LIST CATEGORIZATION TABLE

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I. INTRODUCTION
A. OBJECTIVE
The objective of this "Pre-commissioning Manual" is to provide a detailed, uniform system for
verification, inspection, testing, documentation and preparing for operation of the SIBA GAS
development Project. When the procedures outlined in this manual are completed it marks the
respective item or system is pre-commissioned, and is ready for commissioning.
This manual will be used by the Pre-commissioning Team to verify and document that all equipment
and systems have been checked out and are ready for commissioning.
The pre-commissioning team shall ensure that all procedures described in this manual are followed
and documented with appropriate forms at every stage of pre-commissioning.
The completion activities are separated in two phases, called Pre-commissioning and Commissioning,
this split generally corresponds to static and dynamic testing phases respectively. Commissioning
is considered complete, after completion of Performance Test Run.
PRE-COMMISSIONING
The pre-commissioning phase includes three main types of field activities:
a) Systematic conformity checks, carried out on each item of equipment or component, such as
pressure gauges, level gauges, motors, cables, etc., to verify their visual condition, the quality of
the installation, the compliance with project drawings and specifications, manufacturers
instructions, safety rules, codes, standards and good engineering practice.
Conformity check will be carried on constructed facility against the design and P&ID. These visual
checks will be carried out to find the gaps / deviations in the constructed facility with respect to
the approved drawings issued for construction. The facility will be checked for provision of all the
instruments/equipments, their operability / maintainability issues, correct installation etc. All the
gaps thus found out will be listed on the punch lists.
b) Equipment static/de-energized tests, to ensure critical components quality and condition. This
cold testing covers all discipline activities, e.g., calibration of instruments, machinery
alignments, setting of safety valves, pressure testing of piping (hydro/pneumatic), cable
continuity, etc.
c) Checking installation, cleaning, flushing and drying of the pipe lines and the vessels
shall be carried out as part of pre-commissioning of the facility.

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The completion of Pre-commissioning activities marks the end of the Mechanical Completion. The
Plant status thus reached at the end of Pre-commissioning phase is called Ready For Commissioning
(RFC).
The implementation of each pre-commissioning procedure will be immediately followed by completing
the applicable pre-commissioning check lists / forms for the respective equipment / pipelines. If any
item is not in line with drawings and or specification, it will be noted on the punch list form of the
system / sub-system.
The Punch list items shall be categorized / marked A B and C as defined below

A - Items are those activities that must be completed prior to Mechanical


Completion.

B - Items are those activities that must be completed prior to Hydrocarbon


Introduction.

C - Items are those activities that must be completed prior to issuance of


Performance Acceptance Certificate

When all A punch list items from the Pre-commissioning Punch list are attended and cleared then
the system is considered as Ready for Commissioning (RFC).

COMMISSIONING
The commissioning phase essentially includes the four categories of tasks as follows:
a)

Dynamic verifications of each elementary electrical and instrument function that the plant
equipment is designed to achieve, performs properly. Typical examples of such tests are electrical
motors uncoupled runs, instrument loop tests, electrical breakers operation. The energization of
the electrical distribution network is part of this activity.

b) The mechanical runs, the actual running and on-line tests for a significant period of the plant
utilities, and wherever applicable, of the main process equipment in closed loop
c) A number of activities related to preparation of the plant for feed Hydrocarbon introduction, such
as loading of various chemicals, catalysts, molecular sieves, activated carbon, etc.,
d) Hydrocarbon Introduction and Performance Test.

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Once commissioning activities are complete, the plant reaches the Initial Operation or Reliability
Test Run.

Following summarizes the activities and milestones of the pre-commissioning, commissioning phases.

SUMMARY OF COMPLETION ACTIVITIES


PHASE

ACTIVITIES

MILESTONE

CONFORMITY CHECKS
PRE-COMMISSIONING

STATIC TESTS
FLUSHING & CLEANING

MECHANICAL
COMPLETION
(or Ready for Commissioning RFC)

ENERGIZATION
DYNAMIC TESTS
EQUIPMENT RUNNING-IN
COMMISSIONING
PRE-START UP
ACTIVITIES
HYDROCARBON INTRODUCTION
AND
PERFORMANCE TEST RUN

START OF INITIAL OPERATION


(RELIABILITY RUN)

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B. DEFINITIONS

BASIC FUNCTION: group of items of equipment that performs an elementary function of


the plant / process.
PRE-COMMISSIONING: corresponds to non-operating adjustments and cold checks
performed at the end of the construction phase to verify that the installation conforms to
plan, specifications, drawings, instructions and applicable codes and rules. This phase leads
to ready for commissioning (RFC) stage, also called mechanical completion (MC).
PRECOMMISSIONING CHECK LIST: definition of the scope of work conformity checks to be
performed on elementary items of equipment.
COMMISSIONING: corresponds to dynamic test and pre-start up activities associated with
the operation of items of equipment or facilities for Hydrocarbon Introduction followed by
Performance Test. The utility system is operational during commissioning phase and utility
streams are available at the required specifications [for example, Instrument Air (IA) with
required dew point].
COMPLETION ACTIVITIES: pre-commissioning and commissioning operations
HAND OVER DOSSIER: compilation of the construction, pre-commissioning,
commissioning and performance test support documents of a subsystem / system.
MECHANICAL COMPLETION: status of the plant when all subsystems are made ready for
commissioning.
PRELIMINARY CHECKS: verifications of a subsystem to become ready for commissioning
stage.
PRE-START UP ACTIVITIES: process operations of preparing the system / sub system ready
for oil or gas-in.(Hydrocarbon Introduction to the processing units)
PUNCH LIST: is a detailed list of items requiring completion or correction before the
acceptance of the works at different stages such as mechanical completion or hand over.
READY FOR COMMISSIONING: status of a subsystem when all pre-commissioning operations
on that subsystem are complete.
READY FOR START-UP: status of the plant when all systems of the plant are commissioned
and are ready to receive the Hydrocarbon Introduction for operation start up.
STATUS INDEX: list of equipments subjected to pre-commissioning operations and summary
of the pre-commissioning scope of work.
SYSTEM: major subdivision of an installation, being either process or utility, including the
various equipments required for that system to operate as stand-alone.
Examples:
1. Gas Turbines System
2. Cooling water System
3. Compressed Air System
SUBSYSTEM: subdivision of a system that performs a given operational function. Each
system may be divided if necessary into functional sub-systems corresponding to
independent pre-commissioning and commissioning activities based on its location in the
process or the pre-commissioning and commissioning stages.

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TECHNICAL DATA BASE: list of basic functions constituting a subsystem, i.e. physical
description of that subsystem.
WinPCS: WinPCS is a windows Project Completion, certificate tracking System employed
for this project.

C. DATA AND INFORMATION


The Pre-commissioning Team shall need a complete set of drawings and data listed
below:
1. Design drawings of the complete facilities, stamped "AS BUILD/ISSUED FOR CONSTRUCTION
(IFC)" where applicable.
2. Vendor-supplied equipment design specifications, installation drawings, and operation and
maintenance manuals.

D. TOOLS AND EQUIPMENT


Pre-commissioning work described in the manual will require all necessary tools, test instruments,
water & air supply and electric power shall be available for the Pre-commissioning operations.
Each craftsman such as mechanical technician, instrument technician, or electrician, who is
assisting the Pre-commissioning Team, shall have his normal tool kit available. In addition a list of
equipments / tools required for instrumentation and electrical checkout is given in the respective
Pre-commissioning Procedures.
Temporary electric power supply will be available for pre-commissioning.
All necessary tags, warning tapes, barricade tapes and safety gears supply shall be available at the
site. The following signs in Arabic and English shall be posted at strategic locations before
proceeding with the appropriate Pre-commissioning activities:
Tags:

No smoking
Danger, high voltage
Do not enter beyond this point

E. SAFETY
The following safety gears (PPE) supply shall be available to all personnel involved in the pre
commissioning:
-

Ear Protection
Safety Glasses

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Hard Hats
First Aid Kit
Face Shield
Chemical Gloves
Safety Goggles
Safety Boots
Boiler suits/overalls
Safety belts / harness to work at height
Self Contained Breathing Apparatus-SCBA (if required during Nitrogen
handling)

Permit to Work (PTW) will be controlled by PETROJET till mechanical completion (MC) stage or
energization of substation, whichever is early. Thereafter permit to work (PTW) will be controlled
by Company (KEIL) following their existing system and procedures.

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II. Over View of the Plant:


The Siba field will be developed in two phases Phase 1 and Phase 2.
Phase 1 development will include, but not be limited to, the infield gathering system
consisting of two wellheads, Christmas tree at the wellheads, chemical injection skids in
the individual wellheads, flow lines from the two wells, a gathering hub, a trunk line from
the gathering hub to CPF, the CPF consisting of Train # 1 of the Gas Processing Plant and
all other units, an export system for the products (dry export gas, LPG and condensate)
consisting of export pipelines and custody metering stations, infrastructure and utilities
and all other ancillary units in the facility.
Phase 2 development will include, but not be limited to, installation and tie-in of the
Train # 2 of the Gas Processing Plant and ancillary units.
COMPANY has specified that the whole system from wellhead to export pipeline shall be
capable of a peak production rate of 110 mmscfd (by the completion of Phase 2). The target
availability for the whole system is currently assumed to be 96%.

III. SYSTEM DESCRIPTION


A.

System Definition
System: A system is a major subdivision of an installation or facility, either process or utility,
that performs a major operational function of the plant. The system includes all
components/equipments that allow it to operate. Typical example of a system is:

Compressed Air System

Sub-System: A sub-system is a further division of a system that performs a given operational


function with no or little interference from the other sub-systems. Typical example of a subsystem is :

Instrument Air

At the pre-commissioning stage same system, sub-systems format will be used to check the
completeness of the construction phase (Mechanical Completion).

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WinPCS will be used to collect and store the data from Pre-commissioning and Commissioning
stages of the project.
B.

System Approach
The pre-commissioning activities will be carried out system wise. All the data will be assimilated
system wise and stored in WinPCS. The general approach during pre-commissioning is described
below:

When the system is ready for Pre-commissioning, Company shall be informed in writing, the
intent to start the installation checks / pre-commissioning activities. Company will be
requested to witness the activities.

All the Pre-commissioning documents (viz., Pre-commissioning / installation checklists,


Punch lists etc) shall be maintained for each system. On completion of these documents,
these will be stored system wise / sub-system wise in WinPCS.

Each item on the installation / pre-commissioning check lists shall be completed or


checked, signed and dated by the pre-commissioning representative from PETROJET.

The P&ID (Piping and Instrumentation Diagram) of each system / sub-system shall be colormarked when each item in the list is checked against the Issued for Construction P&ID of
the system / sub-system subjected to punching.

Should an item in the check list is not completed or not meeting the design drawings and
specifications, the Pre-commissioning / Commissioning Coordinator shall compile a punch
list of all such items. The coordinator will categorize the punch list based on the punch list
Categorization Table (Defined in this document). The categorized punch list shall be
transmitted to Company for review and approval.

Pre-commissioning shall be considered as complete only after all systems are checked and
any required follow-up corrective action on punch list items which are to be addressed for
start of commissioning (Category A) are completed. The Company approval shall be
obtained for completion of pre-commissioning.

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C. STAGES OF SYSTEM COMPLETION


Following is the sequence of Pre-Commissioning of each of the system

Mechanical Completion checks

Installation checks per P&ID

Pre-commissioning check lists of all equipments for Mechanical, Electrical and


Instrumentation.

Flushing (or air blowing), cleaning, drying and inerting of the piping and equipment

Leak tests (For lines, vendor packages etc)

Purging for commissioning (If applicable)

D. PRE-COMMISSIONING SYSTEM LIST

SIBA FIELD DEVELOPMENT PROJECT


System and Sub-System Lists
System

Area
code

Subarea
code

Subsystem

System
Number

System Defination

Process
020

000X

XX

01

SYS-020-01

DIESEL STORAGE AND SUPPLY SYSTEM

020

000X

XX

02

SYS-020-02

AIR COMPRESSOR AND DRYER; AIR AND


NITROGEN

020

000X

XX

03

SYS-020-03

RAW WATER SYSTEM

020

000X

XX

04

SYS-020-04

POTABLE WATER SYSTEM

020
020
020
020
020
020
020
020
020
020

000X
000X
000X
000X
000X
000X
000X
000X
000X
000X

XX
XX
XX
XX
XX
XX
XX
XX
XX
XX

05
06
07
08
09
10
11
12
13
14

SYS-020-05
SYS-020-06
SYS-020-07
SYS-020-08
SYS-020-09
SYS-020-10
SYS-020-11
SYS-020-12
SYS-020-13
SYS-020-14

FIRE WATER SYSTEM


GAS TURBINES
DEMIN WATER SYSTEM
OILY WATER SYSTEM
COOLING WATER SYSTEM
CLOSED DRAIN SYSTEM
HP/LP FLARE SYSTEM
AMINE STORAGE
FUEL GAS SYSTEM
GAS INTAKE SYSTEM

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Document Number

020
020
020

000X
000X
000X

XX
XX
XX

020

000X

070

Rev.
Date

SYS-020-15
SYS-020-16
SYS-020-17

GAS TREATMENT PLANT

XX
18
ELECTRICAL

SYS-020-18

DRY GAS EXPORT

000X

XX

01

SYS-070-01

11KV GENERATORS

070

000X

XX

02

SYS-070-02

070
070
070
070
070
070
070
070
070
070
070
070

000X
000X
000X
000X
000X
000X
000X
000X
000X
000X
000X
000X

XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX

03
04
05
06
07
08
09
10
11
12
13
14

SYS-070-03
SYS-070-04
SYS-070-05
SYS-070-06
SYS-070-07
SYS-070-08
SYS-070-09
SYS-070-10
SYS-070-11
SYS-070-12
SYS-070-13
SYS-070-14

070
070

000X
000X

071
071
072

15
16
17

Page

XX
15
SYS-070-15
XX
16
SYS-070-16
CATHODIC PROTECTION
000X
XX
01
SYS-071-01
000X
XX
02
SYS-071-02
ELECTRICAL HEAT TRACING SYSTEM
000X
XX
01
SYS-072-01
INSTRUMENTS

080

000X

XX

01

SYS-080-01

080

000X

XX

02

SYS-080-02

080
080
080
080
080

000X
000X
000X
000X
000X

XX
XX
XX
XX
XX

081
081

000X
000X

043

000X

000
000

000X
000X

03
04
05
06
07
TELECOM
XX
01
XX
02
HVAC
XX
LIFE SAFETY
XX
01
XX
02

SYS-080-03
SYS-080-04
SYS-080-05
SYS-080-06
SYS-080-07

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LPG STORAGE AND EXPORT


CONDENSATE STORAGE AND EXPORT

11 KV SWITCHGEAR / OUTDOOR
ISOLATORS
TRANSFORMERS
3.3 KV SWITCHGEAR
400V SWITCHBOARD
DC UPS
POWER MANAGEMENT SYSTEM (PMS)
EMERGENCY DG SET
AC UPS
CONTINUOUS RATED DG SET
SOLAR POWER SYSTEM
EXTERNAL CABLE (11KV)
400V DISTRIBUTION BOARDS
POWER AND CONTROL CABLES
EARTHING AND LIGHTNING
PROTECTION
LIGHTING AND SMALL POWER
CATHODIC PROTECTION - DRAIN LINES
CATHODIC PROTECTION - MOUNDED
BULLET
EHT system
INTEGRATED CONTROL AND SAFETY
SYSTEM (ICSS)
ICSS AT METERING STATIONS - SAFETY
MANAGE (SM)
HIGH INTEGRITY PRESSURE
PROTECTION SYSTEM (HIPPS)
WELL HEAD CONTROL SYSTEM (WHCS)
HUB CONTROL SYSTEM (HCS)
MULTI-PHASE FLOW METER (MPFM)
FLOW METERING SYSTEMS

SYS-081-01
SYS-081-02

TELECOM SYSTEM

SYS-043-1

HVAC system

SYS-000-01
SYS-000-02

DELUGE SPRAY SYSTEM


DELUGE FOAM SYSTEM

FIBER OPTIC CABLING SYSTEM

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Document Number

000
000
000

000X
000X
000X

XX
XX
XX

03
04
05

SYS-000-03
SYS-000-04
SYS-000-05

000

000X

XX

06

SYS-000-06

000
000

000X
000X

XX
XX

07
08

SYS-000-07
SYS-000-08

000

000X

XX

09

SYS-000-09

IV.

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SPRINKLER SYSTEM
FIRE HYDRANT / MONITOR SYSTEM
FIRE PUMP HOUSE
NOVEC GAS BASED CLEAN AGENT
SYSTEM
CF3I GAS BASED RIM SEAL FIRE
PROTECTION SYSTEM
WATER FOAM TENDER VEHICLE
FIRE FIGHTING AND SAFETY
EQUIPMENTS

PROJECT COMPLETION SYSTEM WinPCS

The project will employ the WinPCS database. This enables the project to greatly control and simplify
the collection of data and includes scanning software that can sign off, organize and store all
procedures and documents produced by WinPCS when completed in the field by various discipline
authorities.
WinPCS is a powerful tool for data collection helping the project to organize their engineering, and
test & inspection data. WinPCS allows all documentations related to equipments and systems to be
stored in WinPCS and thereby makes information easily retrievable and valuable to the operation of
the project.
This will help and simplify the handling and status review of all documents. At the same time the
project will achieve a full set of records related to installation, calibration, functional tests and
certificates, in the form of electronic copy.

WinPCS administrator / Turnover Coordinator ensures the integrity of the system, sub-system
limitation, the engineering data, project document data and vendor data; provides the inputs
for the development of the reports, monitor the inputs and create the daily and weekly status
reports, as required.

System and Sub-system boundaries shall be prepared utilizing design data in the form
of marked-up:
P & IDs
Electrical Single Line Diagrams (SLD)
Fire & Gas Drawings
Telecom Drawings
Instrument Block Diagram
HVAC Flow Diagrams
Plot Plans (for Civil)

WinPCS administrator will maintain pre-commissioning completion status including other


supporting information such as punch list etc.

Generate the necessary forms and records for recording completion activities and acceptance
and verification.

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Report completion status throughout all project completion stages.

Provide overall completion status of all facilities, systems, sub-systems and other plant areas.

Provide standardized documentation and indices for all certification completion aspects of the
project.

WinPCS Administrator / Turnover Coordinator will ensure that Quality control Records(QCRs),
System Acceptance forms, Mechanical Completion (MC) Certificate, Ready For Start up (RFSU)
Certificate, Plant Performance Test Records, Initial Acceptance (IA) Certificate, Final Handover
Certificates and other documentation for specific systems, buildings and areas are prepared
and collated for Turnover to Company in accordance with project requirements.

Prepare the WinPCS standard reports and other agreed status reports on daily basis and forward
to construction and pre-commissioning authorities for their feedback during the Progress
Review Meeting.

The check sheets those will be used during Pre-commissioning and Commissioning for gathering
the data of the checks of these stages will be shared separately. These check sheets will be stored
in the WinPCS and used during the Pre-commissioning and Commissioning activities.

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PRE-COMMISSIONING GUIDELINES

The following guidelines summarize all activities required to be completed during the precommissioning phase of the project. Detailed procedures for these activities are provided in the next
section of the manual.
The pre-commissioning check of each piece of equipment is to be as complete and comprehensive as
possible to ensure that the equipment is installed as specified and will operate as designed. Proper
pre-commissioning will ensure that the facilities can be made operable with the least number of
problems.
a)
b)
c)
d)

The Pre-commissioning Team shall become familiar with all data and information.
The Pre-commissioning Team shall start the pre-commissioning checks as early as possible.
Witness or conduct and record all ground/earthing tests for all wiring.
Witness or calibrate and test all instruments in accordance with the Pre-commissioning
Procedures, and record all the calibration & test data on the checklists provided for each
instrument and instrument loop.
e) Verify that all materials used for the construction of the facilities are new and damage-free.
f) Verify that lubricants, oils, coolants, etc., required for all equipments are available on the job
site and in good condition (i.e. not contaminated).
g) Check the following safety systems:
1.
2.
3.
4.
5.
6.
7.

Ensure that portable fire extinguishers are in place.


Check all electrical closures.
Ensure that all escape routes are clear of obstacles.
Ensure that all PSV outlet block valves are locked open (LO).
Wear appropriate personal protective equipments (PPEs)
Clear the movement of unauthorized personnel in the work area.
Ensure wind socks are mounted in designated locations to create awareness of wind
direction
8. Be aware of designated emergency assembly location (Safe Assembly Point or Muster
Point).
j) Ensure that the following safety equipments are available in the field at designated places,

First aid kit


Self Contained Breathing Apparatus (SCBA)
LEL meter / Oxygen meter
Spark Arrestors for vehicles
Oxygen measuring kit

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VI. PRE-COMMISSIONING PROCEDURES


A. GENERAL
The Pre-commissioning of the facility will be carried out system wise. All Pre-commissioning
documents (Viz. Pre-commissioning / installation check lists, punch lists, mechanical completion
certificate) shall be maintained system wise in WinPCS.
For each system, a set of installation / Pre-commissioning check list banks shall be compiled
covering all the items in the system. When a system is ready for Pre-commissioning, Company shall
be informed in writing of the intent to carry out Pre-commissioning activities.
Specific pre-commissioning procedures and instructions for inspections, tests, and/or calibration
of each item and system are provided in Section B through E. These procedures and instructions
shall be followed throughout pre-commissioning activities and completing the checklists.
Ensure that the debris is removed and the work place is clean. While the pre-commissioning checks
and tests are being performed, all discrepancies, damaged or missing equipment and/or parts
there of, malfunctions, missing documents, discrepancies arising out of safe operating,
maintenance and accessibility of equipment/machinery pipe fittings (valves etc.) and
instrumentation (viz. pressure transmitter, control valves etc.) shall be identified and recorded in
the pre-commissioning punch lists. These punch list items should be attended to and rectified.
B. INSPECTION AND TESTING
Pre-commissioning shall be conducted as follows:
1. The pre-commissioning of the facility shall be carried out system wise. All pre-commissioning
documents (viz. Pre-commissioning / installation check lists, punch lists, etc) shall be
maintained for each system separately.
2. For each system, a set of installation/pre-commissioning check list blanks shall be compiled
covering all the items in the system. When a system is ready for pre-commissioning, Company
shall be informed in writing of the intent to start the installation/pre-commissioning activity /
checks.
3. Each item on the installation/pre-commissioning checklists shall be checked for construction,
installation completion and related approval.
4. Each item on the installation/pre-commissioning checklists shall be completed or checked,
signed and dated by the Pre-commissioning Representative from PETROJET

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a. Separate field work punch lists shall be used by the field staff conducting the precommissioning work and the information shall be transcribed on to a master set for signatures
and date. These will be stored in WinPCS.
b. The master set of punch lists shall remain intact as a back up.
c. As each punch list is compiled in the master set, it is suggested to highlight the item(s) be
by color in the master set of Process and Instrument Diagrams (P&IDs).
5. Should an item is incomplete or not meeting the design drawings and specifications, the Precommissioning Representative shall compile a punch list of all such items. This punch list (after
categorization) and pre-commissioning checklists shall be transmitted to Company for review
and approval.
6. Pre-commissioning shall be considered complete only after all equipments and systems are
checked, and any required follow-up corrective action on the categorized punch-list is
completed. The approval of Company shall be obtained for the clearance of all punch list items.
B.1.1 CHECKING AGAINST P&IDs
The pre-commissioning team shall divide the plant area into systems and subsystems and shall
check the system/subsystem against the relevant P&IDs approved for construction.
The important checks are listed as follows:
FIELD CHECKS:

Check that control valves, flow orifices and check valves are installed in the
right
direction. Ensure that proper isolation valves (gate, globe, ball, plug or butterfly valves)
are installed in right direction as per P&IDs.
Check the correct relief valves are installed in equipment/piping as per the P&IDs
(check tag plate details).
Check that the locking arrangement for locked open and locked closed valves are
installed on specific valves. The spectacle blinds are inserted in open or closed
positions as shown in P&IDs.
Check that all drains from the equipments / vessels etc. are connected to the closed /
open drain header.
Check that all vents from the equipments / vessels etc. are connected to flare system
or routed to safe location as per P&ID.
Check all piping/fittings meet the specification as per P&ID.
Check that correct type of insulation (hot/cold/personnel protection) and tracing are
installed on hot systems or cold systems as per P&ID.
Check that adequate tie-out valves as per P&ID are installed in proper locations of the
system.
Check all piping specification breaks are as shown in P&ID.
Ensure that proper slope is provided as shown in P&ID in flare, drain and gravity flow
liquid lines / headers.

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Check specific distance / clearance is provided as mentioned in P&ID for pipeline and
instruments.
Check the compliance for the notes given in the P&IDs.

VESSELS AND TANKS


Review all vessels and tanks for compliance with specifications as follows:
1. Verify that nameplate data is in accordance with specifications, drawings and vendor
data.
2. Verify that mist extractors, weirs, baffles, sand jets, anodes, ladders, float guides,
floats, Vortex breakers and all internals have been installed as per approved drawings
for construction.
3. Verify that all nozzles are connected to appropriate piping, instruments or anodes, or
are blinded in accordance with the IFC drawings.
4. If applicable, verify that tank gauging equipment is properly installed and operates
freely.
5. Check for any external damage to the vessel, or tank shell, heads nozzles and supports.
6. Verify that all spectacle blinds are installed in the proper position in accordance with
the issued P&IDs for construction (IFC).
7. Verify that the vessel or tank has been successfully hydro tested.
8. Verify that the external paint and coatings are in accordance with the specifications as
to surface preparation, application, type, color, and thickness, and that any damaged
coating has been repaired.
9. Verify that vessels, tanks or drums are grounded to the ground loop.
10. Verify that all safety relief valves and pressure / vacuum relief valves, flame arrestors,
emergency hatches are installed as per issued P&ID for construction (IFC).
11. Check that the right types of internals for the equipments (e.g. demisters, inlet devices,
filter element, bed support, etc.) are correctly installed and verify for any damage to
internals.

B.1.3

ROTATING EQUIPMENT
The Pre-commissioning Team shall use the specific vendor data books as reference for each
piece of rotating equipment when conducting pre-commissioning work. Vendor procedures
shall take precedence if different from the procedure listed below.
1.

All rotating equipments


a) Verify that the name plate data is in accordance with specifications, drawings and
vendor data.
b) Verify that equipment is firmly anchored and dowels are in place.

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c) Verify that driver, coupling and driven equipment is properly aligned. Alignment shall
be checked in cold and hot condition, in accordance with procedures in the vendor
manual. It is recommended to use the Rota-align (Laser Alignment Device) for the
alignment of all critical rotating equipment.
d) Check that all guards are firmly secured to protect personnel from rotating shafts,
couplings, and belts. Check that proper clearances are maintained between rotating
parts and guards.
e) Verify that the external paint and coatings are in accordance with the specifications as
to application, type, color, and thickness, and that any damaged coating has been
repaired.
f) Verify that recommended quantities of spare parts, materials and lubricants are on
hand. Refer to vendor data books.
2.

Electrical motor drivers


In addition to the procedure in this manual, specific electrical procedures shall be used
as detailed in the specific vendor data books.

3. Pumps

Verify that temporary suction strainers are installed on all pumps.


Verify that discharge check valves are installed in the proper flow direction on all
pumps.
Verify that vent and drain valves are installed on all pumps and they are free to
operate. Verify that specified instrumentation is installed, checked and calibrated
in accordance with description given below in this manual.
Centrifugal or rotary gear pump shaft seals shall be checked with the following
procedures:

Stuffing Boxes
(1) Verify that the stuffing box packing is of the correct type and material for the pump
shaft and the process fluid. Check that the stuffing box gland is tightened evenly
so as to prevent excessive leakage but not so tight as to overheat the packing
during initial startup.
(2)

If the stuffing box is equipped with external lubrication, verify that the lubricator
or oiler is filled with the proper lubricant.

Mechanical Seals
(1) Verify that seal flush lines and strainers are clean and will allow free flow
of process fluid.

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2) Check seal oil reservoirs, gauge glasses, tubing connections, and level
switch installation, etc. to verify that the system is undamaged and that
reservoir is filled to the correct operating level with proper oil as specified
in the vendor data book.
B.1.4 VENDOR PACKAGE ITEMS
The vendor package items which essentially fall under the category of package should be precommissioned as per the procedure given in the respective vendor manuals. Vendor
representatives shall be involved in the pre-commissioning of the package. Record all the data
as per the procedure and store it in WinPCS.
B.1.5 PROCESS PIPING
1. Process piping
After construction is completed, the piping and pipelines must be cleaned of all
construction debris, hydrostatically pressure tested, dried and inerted, if required.
Vessels and tanks are to be cleaned internally before man ways are closed and bolted. The
process lines to and from the vessels, however, must be cleaned by water flushing or air
blowing. The hydrostatic test water can be used to flush the lines connected to vessel
bottom.
Note: The flushing and blowing of process lines can be done before or after hydrostatic testing. It is
suggested that it be done before hydro testing. Then all flanges broken to clean the lines will have
new gaskets and will be included in the test. All orifice plates can then be installed and joints tested.

Experience has shown that the time and effort put into flushing and blowing systems and
pipelines prior to start up results in less trouble encountered during and immediately following
start up. Special attention shall be given to the lines upstream of control valves and upstream
of pumps.
Before draining water from vessels, make sure that a high point vent on the vessel is opened to
prevent pulling vacuum on the vessel.
The Pre-commissioning Team shall use the specifications, plans and detailed drawings for
reference in checking all piping systems to determine that they have been properly fabricated,
installed and tested.
a. Verify that all piping tie-in points match with the drawings.
b. Verify that all temporary blinds have been removed and that all spectacle blinds are in the
correct position for operation, as shown in the P&IDs.
c. Verify that the material and ANSI pressure rating of all piping, flanges, valves, and equipment
are in accordance with the drawings by checking the records.

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d. Verify that welding procedures and weld examinations are in accordance with the
specifications, by checking construction records.
e. Verify that hydro testing (or pneumatic testing) has been successfully completed at the
required pressure, either by witnessing the work or checking construction records. Also
check the following:

Verify that the correct Testing Medium has been used for hydro testing e.g. hydro test
water for stainless steel pipes shall not contain chlorides above 100 ppm or it should be
inhibited water. Potable water is the recommended for hydrotesting purpose.
Verify that hydro test fluids were drained from all systems after the completion of tests,
and disposed of away from the site as directed. Open hydrotest vents to ensure complete
draining.
Verify that process and utility systems have been flushed properly by water. Pre-identified
line will be chemically cleaned, viz. the inlet lines of the compressors.
Verify that all blinds, temporary spools, valves and fittings used for hydro testing have
been removed.
Verify that all process piping systems are essentially free of water after testing, if required
air drying can be done.
Make up required water level in the Utility Water System as soon as it is pre-commissioned.

f. Check that all piping has no arc burns, and has not been damaged during shipment and
construction.
g. Verify that insulation and heat tracing is installed in accordance with the specifications,
plans, and drawings.
h. Verify that all flange gaskets are installed and that bolts after fixing, shall protrude equal
lengths either side of the flanged joint.
i. Verify that insulating flange kits are installed as shown on the drawings.
j. Verify that valves are installed in right position properly as per P&ID:
1) Nameplate data, including valve type, pressure/temperature rating, and materials are
as specified and shown on the drawings.
2) Check valves, globe valves, and choke valves are installed in the correct flow direction.
3) Block valves, where applicable, are installed in the correct flow direction.
4) Valve handles are properly located for clearance and ease of operation.
5) All valves operate freely and all valve stems should be greased.

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B.1.6 HYDRO TESTING & CLEANLINESS OF LINES


1.

Hydrostatic Testing

This test is carried out by filling water in the pipe to be tested and increasing the pressure
to the specified pressure. Normally, a portable positive displacement pump will be used
to raise the pressure. This test should not be confused with other less severe tests generally
carried out before a start-up to check tightness of connections.

The hydrostatic testing is done by construction personnel. Pipe work to be tested is


generally divided into groups (hydrotest packs) of similar test pressures and isolated from
other sections by installing suitable blinds or disconnection.
A low pressure air test can be performed on the sections of the unit prior to a hydrostatic
test so that any open lines or flanges may be discovered and taken care of before water is
admitted. However, a hydrostatic test is necessary for final testing. A low pressure air test
may be used in place of hydrostatic test for low design pressure, flare lines.
It should be remembered that in pressure testing of vessels and towers that the test gauge
should be placed at the bottom of the vessel so that the liquid head will be taken into
account. Site hydrotest is not required for shop fabricated vessels.
Before introducing water into a tower or vessel, vents should be opened. Same vents should
also be opened before draining the test water.
After the test, reduce the pressure developed during the hydrostatic test very slowly and
gradually.
All water testing and cleaning (hydrotesting and other) shall be done with water that has
low chloride content (preferably potable water).
Since it will not be practical to pressure test all equipment in the plant simultaneously, the
plant should be divided into sections (namely Test packs) as governed by the test pressure
for each section. Blinds must be made and installed in the system to isolate sections. Blind
all safety valves and disconnect all instruments.
Some further suggestions which should be followed prior to and during the hydrostatic test
period are as follows:

1. Relief valves must be removed or blinded.


2. All items under test must be liquid filled and all air vented.
3. Internals such as level ball floats, which are not designed for the test pressure, must
be removed before the testing.
4. All the instruments and control valves must be isolated and removed.
5. Orifice plates shall not be installed.
6. Items, such as connecting piping to a vessel under test, which are capable of
withstanding the test pressure, may be subjected to the test.
7. Items, such as vessels connected to piping under test, which are not capable of
withstanding the test pressure, must be isolated by blinding.
8. A water filled system must be vented while draining to avoid collapsing of the
equipment, which is not designed for vacuum.
9. All relief valves (PSVs) must be bench tested and set before final installation.

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Prior to filling and pressurizing, it shall be ensured that:

Hydrotest clearance certificate is endorsed by the QA/QC section.


Warning signs are displayed to restrict the entry of unauthorized personnel into the testing
area.
All pressure gauges have valid calibration and calibration status for each gauge is available
on it.
The filling hose from the pressure generator is connected to the lower most drain point of
the system to be tested.
The pressure generator and the high and low sections of the pipe loop to be tested are
provided with separate pressure gauges.
The hydrostatic test pressure shall not be less than 1.5 times the design pressure or as per
contractual requirement.
The test gauge used for hydrotesting shall be calibrated prior to hydrotest and gauge
identification shall be indicated on the pressure test report.
The piping subjected to hydrotest shall be brought up to the pressure and shall be held
under pressure for a period of approximately 1 hour for above ground (AG) pipes and 24
hours for underground (UG) pipes before a detailed inspection is started.
Leaks and defects, if any, shall be rectified after the pressure is brought down and media
is drained. The system / line shall be pressurized to the test pressure and maintained for
sufficient time duration to enable Company inspection, if required. On completion of
holding time, the line shall be de-pressurized using the high level vent points.
The contractor shall prepare a hydrotest report with supporting documentation.

2. Flushing

Flushing shall be carried out prior to pressure testing (Leak test / Tightness Test) of the line.
Flushing of the system shall not include pumps.
The flow through the screen shall preferably be horizontal. Precautions shall be taken to place
screens in a location where the dirt particles will not drop into an inaccessible place in the line
during flushing. If this happens, it would not be possible to remove the dirt after removal of
the screen.
Flushing shall be carried out by introducing a calculated quantity of water through the system
at a sufficient velocity. Flushing shall be continued for a minimum time till flushing media
becomes clear at the exit point.
All temporary strainers shall be periodically checked during flushing and if contaminated with
sediment, shall be cleaned.
On completion of flushing, any blinds installed for the purpose of flushing shall be removed
unless otherwise required. Dismantled joints shall be provided with new gaskets.
Remove the instruments which are susceptible for damage, like flow meter, during flushing.

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3. Draining
a. The hold up duration between filling and commencing draining of a system under test shall be
no longer than 24 hours.
b. Upon completion of draining, the system shall be dried and it will be ensured that no residual
water pockets remains.
c. Open high level vents to ensure complete draining of the pipelines/systems.
4. Air Blowing / drying
The pipe lines are dried by air blowing. This operation helps to clean the pipe lines of
dirt, debris, scales etc. and guarantees the cleanliness of lines for smooth start-up.

The cleanliness of the lines must be witnessed by all the concerned parties and relevant quality
documents will be maintained.
A dedicated mobile compressor may be used for this air blowing / drying operation.
As a standard practice for air blowing, care must be taken, not to blow into a vessel or
equipment.

The preparation for air blowing shall include following:

Preparation of detailed procedure outlining the proposed methods and loop covered, supported
by marked up P&IDs. This will generally be a combination of hydrotest packs, as far as possible.
Temporary blow spools will be fabricated and installed taking into account the line pressure
and air velocities. These spools will have identification marks.
The inline instruments, susceptible to damage by air blowing, shall be removed or isolated
from the air blowing operation.

5. Piping Hand Cleaning


Hand cleaning may be required in situations where air blowing is not practical or is time
consuming. The items / areas or parts of equipment that may require hand cleaning are as
follows:
a. Control Valves /PSV cleaning prior to reinstatement: The control valves /PSVs will be
brushed out with soft brush and then air blown with hand held air hose or blower.
b. Equipment Nozzles: The equipment nozzles will be cleaned by brushing. Special care
must be taken in case of rotating equipment so that dirt does not enter the machine.

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c. Small Spools: usually pump suction/discharge spools are removed for flushing, some
drain lines and sample connections on vessels are not flushed. These require blowing
out using a hand held air hose/blower.
d. Large Spools: These are usually long lengths of line which do not require cleaning or
lines which are inspected and certified as clean prior to erection. These can be cleaned
by sending a man down the line with a brush to sweep the sand / debris out.
(Note: In this case utmost care should be taken and this activity should be reviewed
with site HSE personnel to decide whether this is a confined space entry)
6. Chemical Cleaning:
The inlet process pipe lines associated with compressor package will be subjected to chemical
cleaning. The detailed cleaning procedure will be worked out with the specialist contractor
who will carry out this operation.
7. Reinstatement of the System
The system shall be reinstated, as per construction drawings, after the testing. Blanks and spool
pieces provided for test purposes shall be removed and permanent service gaskets shall be
provided where test gaskets were used during the test.
Thorough inspection of the incoming lines of the rotating equipment will be carried out before
reinstatement of these lines. The intention is to ensure that the pipeline are clean up to the
equipment throat. Special care must be taken in case of rotating equipment inlet lines, for the
portion after the temporary strainers till the throat of the equipment.

B.1.7 Leak Test and Inerting


Leak tests are carried out on all systems after flushing and cleaning operations to
prove the integrity of the following

Gaskets and other flange joints


Miscellaneous connections like vents, drains, safety valves and instruments.

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After leak test, inerting of the system will be carried out. All the pipelines which will handle
hydrocarbons will be inerted with nitrogen and a positive pressure will be maintained in the
lines.

B.1.8 BUILDINGS
1.

Verify that all buildings have been constructed in accordance with the applicable drawings,
specifications, and standards

C.

ELECTRICAL

1.

General
PETROJET shall inspect and test each item on the pre-commissioning check list in accordance
with the procedures outlined in the following sections.
Each item of equipment shall be inspected upon arrival at site. Should any piece of equipment
show signs of damage, the carrier shall be notified immediately.
Testing of each item listed in the enclosed Electrical Equipment Schedule shall be performed
as much as practicable after installation.

2.

Test Equipment
a) The following is a list of recommended test equipments as a minimum, required to perform
the pre-commissioning test on the electrical equipment as per the Equipment Schedule.

(1) Multimeter (2) Clamp on Ammeter (3) Ductor tester (4) 500 - 5000 V megger
(5) Phase rotation indicator (6) Primary injection test set
(7) Secondary injection test set (8) Grounding resistance test set
(9) Any special test device required to perform any recommended test by the
equipment vendor.
b) All test instrument sets shall be calibrated prior to use for testing. If any instrument is subjected
to physical or electrical damage, that instrument must be calibrated before it goes to
subsequent usage for testing.
3.

Pre-commissioning Procedure
All electrical equipments shall be inspected for physical damage before

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installation.
A pre-commissioning representative shall inspect the inside and outside of the equipment
enclosures. Internally the equipment shall be inspected for missing, loose and out of place
components.
3.1

Insulation Testing
Insulation tests shall be carried out at the pre-commissioning stage and prior to energizing the
equipment and cables. The following two methods shall be used:
a) Insulation Resistance (IR) testing for motors, transformers, LV switchgear and all equipment
other than those items susceptible to damage by over voltage (example electronic
components).
b)

High voltage AC or DC testing for HV switchgear and HV cables.

3.1.1 Insulation Resistance (IR) Test


IR testing shall be carried out using a DC voltage megger.
3.1.2 High voltage test

Before executing high voltage test, insulation resistance test shall be done.
High voltage testing shall be done either by applying AC (power frequency) or DC voltage
at a level above the normal operating voltage.
DC high voltage test equipment shall be used for HV cables.
AC high voltage test equipment shall be used for HV switchgear and generators.
Current Leakage versus time shall be recorded during HV testing of cables.

3.1.3 Polarization Index (PI)


PI is the ratio between the insulation resistance measured after 1 minute and after 10 minutes
of continuous testing at the appropriate voltage (PI = R 10 min / R1 min).

3.1.4 Interpretation of Results

Should the reading obtained for IR or PI fall below the recommended minimum values as
per IEC, then the equipment shall not be energized or subjected to high voltage testing.
Appropriate action shall be taken e.g. drying to normalize the figures.

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Should flash over occur during high voltage testing then the test shall be deemed to have
failed. Appropriate method / measures shall be taken (e.g. cleaning, drying, repair) to
eliminate the cause.
After elimination of the cause retesting shall be performed.

3.2 Conductivity and Earth Resistance Tests


3.2.1 Conductivity Test

Conductivity tests shall be done on switchgear bus bar connections and switchgear earth
system joints to establish their tightness and condition.
Conductivity testing shall be done using a low resistance test set ductor test with a 10 A
(DC) output.
For identical connections the measured value shall not differ by more than 20%.

3.2.2 Earth Resistance Test


3.2.2.1 Earth Electrodes

All earth electrodes shall be tested by the measurement of electrode resistance against the
mass of earth using an earth resistance megger. For resistance values for respective systems
refer Electrical Design Basis and approved Earthing Calculations.

3.3 Wiring and Terminal Checks

3.4

Electrical wiring shall be checked against the schematic diagram.


The tightness of all terminals shall be verified.
Functional Test
Functional testing shall be done to prove the correct operation of the complete
system.

4.0

Testing and Pre-commissioning Procedures

4.1

Hazardous Area Equipment

4.1.1

Installation

All items of electrical equipment including bulk ordered material installed in a hazardous
area shall be inspected strictly in accordance with Area Classification requirements.

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Special care shall be taken to ensure that cable glanding has been carried out correctly.
Certificates shall be examined to ensure that the installation is in compliance with the
certification requirements.

4.2 HV Switchgear Testing


4.2.1 The type, model and rating of the switchgear shall be identified.
4.2.2 The equipment shall be inspected to ensure that it is free from mechanical damage.
4.2.3

Initial Checks

4.2.3.1 Initial checks on the installed switchgear shall be done as per the HV switchgear installation
check sheet and the vendor manuals.
4.2.3.2 The alignment of the circuit breaker truck in the panel for free movement, and engagement
of mating contacts shall be checked for all panels. In case of any discrepancy, these shall be
rectified.
4.2.4

Ductor Test
This test shall be carried out to ascertain the contact resistance of the circuit breaker and
bus bar joints.

4.2.5

Circuit Breaker Test

4.2.5.1

Individual CBs, shall be checked / tested as detailed in the form for HV Circuit Breaker
and Cubicle Test Sheet and the results recorded.

4.2.5.2 Breakers shall be tested MANUALLY and ELECTRICALLY, both in TEST and SERVICE
positions.
4.2.5.3 Trips for the breakers shall be simulated from the protective relays and process
interlocks. Caution shall be exercised that no power is fed to the end equipment while
performing the tests.
4.2.6

Earthing

Earth continuity bar in the switchgear shall be tested for continuity and contact resistance.
Earth bar connection to the earth grid shall be tested for tightness and continuity.

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Testing of Protection Relays

4.2.7.1 Testing General

Relays shall be tested and commissioned in accordance with the manufacturers


instructions. Use shall be made of the standard test forms.

C.T. ratio shall be verified by primary current injection. Caution shall be exercised that
while energizing the primary of the C.T., secondary of the C.T is not accidentally opened.

All protection relays shall be first tested at the normal setting (wherever possible) to verify
their operating parameters by primary injection.

Wherever it is not possible to use a primary injection test set because of extreme current
requirements, the relays shall be tested by secondary injections.

Relay testing shall include verification of operation of the switching devices tripping
mechanism, all alarms and inter trip and lockouts.

4.2.7.2 Testing of IDMT O/C Relay


The following parameters of the adopted setting of the relay shall be checked and recorded.

Current sensitivity.
Curve
Timer multiplier data
Instantaneous element
The above parameters shall be recorded for all the 3 phases viz R, Y, B & earth fault.
After recording the above adopted settings, secondary injection tests shall be done.
Test shall start with verification C.T shorting switches by withdrawing the relay
elements.
D.C. supply voltage shall then be checked and a trip test shall be carried out.
After carrying out the above test The current level to trip I inst the current level not
to trip I inst. and current sensitivity for all the three phases & earth fault shall be done
at the adopted setting.
After the above test & setting, current injection 2 times the set current and then
current injection 5 times the set current shall be done.
All test data of the above shall be recorded in the format for inverse time over current
relay test sheet.

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4.2.7.3 Testing of Under Voltage Relays

The relays shall be tested for PICK UP & DROP OFF voltage levels for various relay
settings by adopting different percentages of set voltages.
All the test values and other relay data shall be recorded in the format for / under voltage
relay test sheet.

4.2.7.4 Testing of Differential Relay


o
o

o
o

o
o
o

Interposing C.T. ratio and connections shall be first verified before commencing the test
on the relay.
PICK UP test shall be carried out by keeping the pick up current tap setting at various set
points and injection of current shall be done on all three phases and pick up values shall
be recorded.
The operating time of the relay shall be tested by setting taps at various values. Current
shall be injected on all the three phases and the operating time shall be recorded.
Percentage bias current test shall be carried out. The relay shall be set at various bias taps
and current injected through the bias and operating coil of the relay. The through current
and the operating current shall be recorded and the percentage bias arrived at shall be
calculated (according to the manufacturers manual) and the data recorded. The bias test
shall be conducted on all the three phases.
The test data and the other relay shall be recorded in the format for Differential Relay
Test Sheet.
The recorded data shall be verified against the manufacturers data / specifications.
The final setting of the relay shall be checked and the data shall be recorded.

4.2.7.5 Testing of Motor Protection Relay


o

As per the recommended procedure of the relay manufacturer, this relay shall first be
tested for the current settings. The pick up values for negative phase sequence unit, O/C
unit and instantaneous O/C unit and earth fault unit shall be measured and recorded for
all the three phases.
After completing the above tests, the relay shall be tested to check the accuracy of the
timer settings. The current shall be injected at different phases and the pick up current
and the pick up time: at 150 % of the set current shall be measured and recorded.
The above data shall be recorded in the format for Motor Protection Relay Test Sheet.

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4.3 Power Management System Panel Testing


4.3.1 Visual inspection to ensure that all components/equipments are intact & free from
damage.
4.3.2 Isolation Test
Ensure all main switches, circuit breakers, PLC power supplies, Interface cards, cables from
direct connected devices are disconnected
Check impedance between all power distribution circuits and ensure it approaches infinity
4.3.3 Check the continuity of all the earthing systems.
4.3.4 Power up the PMS panel by switching on first the UPS supply & then the non-ups
supply and check the distribution of supply.
4.3.5 Control logics Hardware check.
Before engaging the interface card, ensure that the power supply is turned off.
Ensure all jumpers, interface card switches, adaptors are set correctly.
4.3.6 System I/O interface test.
All the field inputs & outputs including both serial & hardwired cables shall be hooked up
to the system.
Check the functioning of input/output signals from serial link with DCS,ESD,MV/LV Switch
gears, Vests Controller, GTG control panel, AC/DC UPS system etc.
Check the functioning of input/output signals from hardwired link with Thyristor control
panel, HVAC panel, EDG control panel, Battery room exhaust fan etc.
4.3.7 Software test.
The programming display will be checked to verify the functionality of all controls,
inputs/outputs, status, alarm, measurement, etc.
Check the printout of the software output data.
4.4

Testing of Power Transformers

Initial tests as per the Transformer Installation Check Sheet shall be done and recorded.
Ratio test shall be done by applying low voltage on high tension side and measuring on low
tension side of the transformer.
Vector group test, shall be done to verify the vector group for the transformer.
DGPT2 relay shall be tested for proper functioning of the alarm & trip contacts.
Oil temperature indicators shall be calibrated with a standard thermometer.
Neutral CTs mounted in the transformer shall be tested.
Earth resistance of body to earth and neutral to earth shall be measured and recorded.
The Stability Test for the differential protection of the transformer shall be done.

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LV Switchgear Testing

4.5.1

Initial Checks

The checks shall be carried out and recorded as per the L.V. Switchgear Installation
Check Sheet
Ductor Test shall be carried out on all bus bar joints, circuit breaker bus bar plug in
contact and isolator contacts.

4.5.2 Test for Circuit Breaker & Starter / Switch Fuse Units

4.6
4.6.1

Test on circuit breakers shall be carried out as detailed in LV Circuit Breaker Test
Sheet.
Starters & switch fuse units shall be checked & tested as per the LV Starter / Switch
Fuse Unit Test Sheet and the results shall be recorded.
Male / female contacts mating for both power & control circuitry shall be checked for
proper operation.
The protection relays, CTs & PTs shall be tested as described under the LV Switchgear
Testing.
Remote Switching & Tripping of the starters shall be checked.

Testing for Lighting & Other Distribution Boards & Sockets etc.
Initial Check

Check for proper wiring and termination of the circuits and earthing.
Check for proper installation of the boards as per vendor recommendations.
4.6.2 Pre-commissioning Tests
4.6.2.1 Tests for Lighting DBs and small power

After checking and ensuring that all wiring is correct and of good IR value, the fittings shall
be energized and functioning of the fitting and the on-off operation of all switches shall be
tested. During this test, the isolator shall be in manual position.
Photo electric cells shall be tested and the functioning of the fittings shall be tested with
the selector switch in auto position.
Welding sockets shall be energized and phasing, earthing and output voltage shall be
checked.
The check sheet for Lighting and Small Power Fittings shall be completed.

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Testing of Motors

4.7.1 Initial Check


The details of the motor shall be recorded in the check sheet for Electrical Motor

4.7.2

Pre-commissioning Test

4.8

Polarization Index (PI) for stator windings shall be measured.


If required the motor stator windings shall be warmed up, to improve the polarization
index.
Insulation resistance of the motor space heaters, if provided, shall be measured.
The winding temperature detector shall be checked for compliance to the
specification. The insulation resistance of the temperature detector to earth shall be
measured.
The motor shall be uncoupled from the driven equipment and the shaft shall be observed
for free rotation.
The starter shall now be closed and the motor bumped to check the direction of rotation.

Emergency DG Set

4.9

Name of the manufacturer.


Type.
Rating.
Serial number.
Tag number.
Rated voltage, current and frequency.
Rated speed and winding type.
Hazardous Area Classification.
Class of insulation.
Bearing details at DE & NDE.
Space heater rating, voltage and resistance.

Testing and Pre-commissioning activities shall be carried out as per vendors


recommendation and under their supervision.

Uninterrupted Power Supply System (UPS)

Testing and Pre-commissioning activities shall be carried out as per vendors


recommendation and under their supervision.

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Electrical Heat Tracing

Testing and Pre-commissioning activities shall be carried out as per vendors


recommendation and under their supervision.

D. INSTRUMENTATION
1. General
These instrumentation procedures are intended to provide a comprehensive and coordinated means
to ensure that all instrumentation items have been installed and calibrated according to the
specifications & drawings and to serve as a procedure for pre-commissioning the systems.
a. The calibration and checkout procedure necessary to complete the form shall be in accordance with
this specification.
This checkout generally consists of an installation check and measurement of output, with input
provided via test equipment, to ensure that the instrumentation is performing correctly in
accordance with the specifications and that no damage was caused during installation.
The technician shall also complete the equipment documentation section of the form (i.e.,
manufacturer, model, serial number, etc.), if not previously included.
The wiring shall be checked point to point for continuity, ground faults, and termination
correctness.
Tubing shall be checked point to point for leaks and termination correctness.
Should a problem exist, it shall be noted on the checklist. Specify the exact problem and corrective
action taken, if any, to correct it.
b. Instruments shall meet the manufacturer's specifications. Instruments which do not satisfy the
manufacturer's specification shall be repaired or a replacement is sought.

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c. The manufacturer's recommended calibration procedure shall be used for all instrument
calibrations. The following sections are, in some cases, additional requirements for specified
instruments.
d. All instruments shall comply with the specification sheet for:

Instrument Tag Number


Model Number
Size and Connection
Material of Construction
Instrument Range of Calibration
Valve Action
Control Modes on Controller/DCS
Thermowell Length
Ball, Globe and any other type valve where specified

e. Instrument Commissioning which consist of,

Functional Testing and operation of control loops


Process Control System
Shutdown System
Fire and Gas (F&G) detection system

is part of the commissioning activities of the plant, which are likely to be taken up parallel with
pre-commissioning activities.
2. Test Equipment
The minimum test equipment, with accuracies shown, shall as a minimum consist of:
Accuracy
Instrumentation

Inclined water manometer


Pneumatic calibrator
Dead weight tester
Precision pressure gauge
Digital voltmeter
Current and/or voltage generator
Precision potentiometer

(% Full Scale)
0.1
0.15
0.1
0.25
0.1
0.25
0.1

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Precision temperature potentiometer


Precision wire wound resistor
decade box

+1 deg. C
0.25

Milli-Ammeter
Temperature bath with precision
thermometer

0.1
0.25

Stop watch
Misc. Manufacturer's signal

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Generators required for testing

3.

Test Air compressor

General instrument checkout

All instruments and accessories shall be visually inspected for damage after installation. If
damage is observed, corrective action shall be initiated. A checklist shall be completed for
each instrument that was inspected.
All instruments shall be left free of shipping restraints and stops. Glass shall be left
clean. Temporary protective devices shall be removed prior to placing instruments in service.
Verify that all instruments and tubing are correctly tagged, labeled, and installed at the correct
location.
All primary elements shall be checked for proper installation with respect to direction of flow,
elevation, orientation, insertion depth, and any other applicable considerations.
Verify instrument piping and / or tubing shown on the P&IDs and the Instrumentation Schematic
Drawings for fitting type, materials, connection sizes, and rating. Verify that adequate
brackets and supports have been used to maintain a continuity of rigid construction.
On installations which involve instrument seal pots or reference legs, the system shall be filled
with the recommended fluid.
Verify that the air supply for each instrument is correctly provided.
Do not install primary elements until the process line has been flushed clean. All transmitters
shall be disconnected from the process lines and vented to atmosphere for overpressure
protection during hydrotesting.

Prior to beginning the instrument operational check and calibration, the following leak tests shall be
performed:

Pressurize the instrument air headers with clean filtered instrument air, and spray all screwed and
flanged connections with a soapy solution (leak-test). Repair all leaks. Each header branch,
lateral, and instrument air take-off shall be blown through to remove all foreign material. Open
valves or remove flange or pipe caps at each header extremity to obtain maximum air velocity in
the piping.
Process tubing that has not received a hydrostatic test shall be pressurized to the maximum
working pressure of the connected instrument with water or, in exceptional cases, nitrogen gas. If

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nitrogen is used, spray all fittings with a soapy solution. If liquid is used, hold test for five (5)
minutes without loss of pressure.
Pneumatic transmission lines are to be disconnected from all receiving instruments (I/Ps, switches
etc.) and blown through to remove deposits. The lines are then to be reconnected to all of the
receiving instruments and tested for leaks.
Pneumatic output control lines are to be disconnected and blown through to remove deposits. All
solenoid valves should be bypassed during this cleaning blow down. The lines are then to be
reconnected to the device and leak tested.
All Pneumatic Control tubing is to be leak tested with a bubbler apparatus. Allowable tolerance
is four or less bubbles per minutes. All connections used for the leak testing are soap leak tested
after the bubble test. The same is true for fittings disconnected for calibration and action of
instrument.

4.

Process Transmitters (Electronic) calibration-General

Disconnect field wiring from transmitter and connect a receiver test instrument which will
provide the required power to the transmitter. Accurately read the transmitter output as
specified on the instrument checklist.
Vary the process input signal to the transmitter, as required by the checklist, and check output
for proper zero and span. Transmitters are to be rechecked at 0%, 25%, 50%, 75% and 100% of
span.
If zero and span are not correct, adjust until instrument meets specifications and repeat the
above step until correct.
Remove test connections, and reconnect field wiring and process inputs.
Ensure that all covers and protective devices are replaced and secure.
Transmitters with indicators shall have the indicators calibrated with the transmitters
For displacer level transmitters use water as the process fluid and ensure that associated vessel
block valves are closed during the test.

5. Pressure / Temperature Indicator (Direct reading)


a)
b)
c)
d)
e)
6.

Verify that the installation is in accordance with the installation drawings.


Check the tag number and range.
Check for visible damage.
Ensure that the face is clean and facing in a direction easily visible to the operator.
Check for liquid in gauge (for liquid filled gauge) and that the gauge is zeroed properly.
Flow Element (Orifice)

a) Check the meter run with the mechanical flow diagram to ensure proper installation in relation
to the direction of flow.

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b) Check the upstream and downstream pipe lengths to verify that they are according to
specifications.
c) Check the pressure taps to ensure that the high and low pressure sides of the orifice are
connected to the corresponding sides of the field instrument.
d) Remove orifice plate carrier, wherever installed, out of the assembly as per manufacturers
recommended practice.
e) Check the orifice size against the Instrument Specification Sheet and verify that the orifice
plate is installed with the square edge upstream.
f) Replace orifice plate as per manufacturers recommended practice.
7.

Level Transmitters (displacer type)


a) Check for the Transmitter and accessories free of damage.
b) Check for correct Tagging and the label is visible.
c) Check and ensure the level transmitter is installed at correct elevation and the instrument
connections are properly bolted.
d) Check for free access for operation and maintenance.
e) Check the isolation and vent / drain provision matches to the AFC drawing.
f) Disconnect field wiring from transmitter and connect a receiver test instrument and check for
zero error & span and get it corrected.
g) Remove test connections, and reconnect field wiring and process inputs.
h) Ensure that all covers and protective devices are replaced and secure.
i) Where possible all float or displacer elements shall be checked for pin hole leaks i.e. immerse
element in bath of clear hot water and inspect for Air Bubble Streams.
j) For displacer type level transmitters use water as the process fluid and ensure that associated
vessel block valves are closed during the test.

8.

Control valve calibration (General)

(a)

Control Valves shall be inspected rigidly and ascertained to conform to both the specification
sheet and the valve nameplate. The following points shall be verified:

(b)

(1)

Valve connection size and type.

(2)

Valve Action.

(3)

Travel direction indicator installation.

(4)

Any special features.

(5)

Actuator type, size and bench set.

The valve shall be stroked the entire length and the actuator spring compression shall be
adjusted if necessary. The valve shall be checked to ensure that it seats properly when the
appropriate signal (bench set) is applied to the actuator.

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9.

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Verify that the valve position matches for "fail open" or "fail close" operation.
Control Valve (With Positioner)
a) Turn on the air supply to the positioner, and set the regulator at the proper air pressure.
b) Slowly increase the input using the test device while observing the positioner output pressure
and valve position.
c) Note the positioner output pressure and the input whenever the valve begins to move.
d) Stroke the valve for 0%, 25%, 50% and 100% open and close and check the hysterisis.
e) Note the positioner output pressure and the input.
f) If the input operating range of the control valve is not the same as that shown on the checkout
form, recalibrate the valve positioner assembly as per the manufacturer's recommendations.
g) Vary the input signal as required by the checklist and note the required data.
h) Disconnect the test equipment.

10.

Shutdown valve
a) Verify that the valve, actuator and control box are in accordance with the specifications and
are installed in accordance with the drawings.
b) Connect 24 V DC supply to solenoid valve and keep it energized.
c) Connect a 5.5 bar(g) air supply to the shutdown valve actuator supply. Use the permanent air
supply, if operational; otherwise, connect a temporary supply to the branch from the air supply
header. (Note : Check minimum air pressure available is 4.5 barg)
d) Check the operation of the limit switches for open / close position and adjust as necessary.
e) Check the open / closing time of the valve as per specification. Stroke the valve for
repeatability and check the satisfactory operation of the limit switches.
f) Reduce the air supply pressure to a minimum specified and re-check satisfactory operation of
the valve.
g) Check the Fail-Safe operation against specification.
h) Check the partial stroke test as per the manufacturers instruction and specification.
i) Where air reservoir or other peripheral device is concerned, check the piping in accordance
with the appropriate pneumatic hook up.
j) After the shutdown valve test is complete, disconnect temporary air supply, test equipment,
and reconnect the valve to the field connections.

11.

Wiring checks
Wiring/Loop and Continuity Checks:
A point to point wiring and loop check shall be performed to verify correct connection of all
wiring and response of instruments interconnection schedule loop schematics and wiring

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diagrams shall be utilized by the technician as required to ensure a complete and correct
functioning of system.

12.

Any discrepancy observed shall be brought to the attention of the Pre-commissioning


Representative before wiring hookup changes are made.
The wiring check shall be made utilizing a Volt/ohm meter with the resistance scale set at 10
ohms.
Loop schematics shall be used to carry out the checking.
Loop Test Procedures

a) Visually inspect all items of the loop and set air/electrical supplies where appropriate. In
particular check the air supply pressures for control valves and in accordance with their
specification.
b) For electric loops, check all signal polarities and adjust any loop impedances if applicable.
c) Manually, or with applied input signal, transmitter output signals of 0%, 50% and 100% shall be
generated to check the response of all other instruments and control valves in the loop.
d) Instrument zero settings and calibration adjustments shall be made as necessary, unless the
instrument is of the SMART type. In the case of SMART based instruments the instrument
settings should be checked using a hand held communicator of the correct type against
manufacturers data and instrument data check sheet.
e) Switch controller to Manual operation and check the valve stroke correctly. Valve positioner
gauges should also be checked during this stage.
f) With set-point, measured variable and control output all at 50% check for bumpless
auto/manual change over where applicable and adjust if necessary according to
manufacturers instructions.
g) Check all associated alarm or trip functions by varying the transmitter signal and adjust switch
level accordingly.
h) Trips and alarms not covered by the above tests i.e. direct process operated switches such as
float switches, etc should be separately tested for correct operation.
i) All systems shall be checked for correct fail-safe operation including burn-out features of
thermocouple systems.
j) Thermocouples and resistance bulbs shall be removed from their wells and inspected for
damage. Resistance bulb resistances shall be measured and recorded together with the
ambient temperature.
k) After the above check, all elements will be replaced in their protective wells ensuring that the
element length matches the associated well length.
l) On re-connection a detailed inspection should be made of all connections to ensure TC
polarities and 3-wire resistance bulb connections are correct.
m) Analyzers and other special systems should be fully checked and calibrated to manufacturers
instructions with consent of the Supervising Engineer. It shall be agreed where suppliers
engineers are required to give assistance and when necessary the contractor shall give the
supervising engineer adequate notice so that arrangements may be made.

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13. DCS / ESD System


a)
b)
c)
d)
e)
f)
14.

Wiring Checks
UPS power up and commissioning.
Power on new DCS & new shutdown system and allow warm up time.
Loop check by simulation of signals from marshalling cabinets all DCS I/Os.
Loop check from field instruments and other instrument loops.
Loop check from the field the fire detection and protection system.
Serial Interface

a) Check the physical connection of serial link cable at the DCS and at the non DCS end.
b) Set the communication parameters (Baud rate, parity, address etc.) at DCS.
c) Simulate and check that the communication and individual I/O mapping is satisfactory.

15.

Fire & Gas detection system


a) Carry out wiring checks
b) Simulate from field and check for the alarm / shutdown function as per C & E matrix.
c) Check the alarm on the DCS over serial link.

E.

MISCELLANEOUS MECHANICAL EQUIPMENT


Verify that all Miscellaneous Mechanical Equipments have been installed according to specification
and applicable drawings.

F.

PRE-COMMISSIONING FORMS

Attached

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G . PUNCH LIST CATEGORIZATION TABLE


A punch item

B punch item

(From)

(Fit & Function)

C Punch item (Not


Required for Safe
Operation)

Piping

Static equipment
Reactors
Rotating Equipment

Piping,Fitting&Supports Valves,Gaskets,Bolting

Paint & Non essential

Erected according to

Final,Reinstatement,QA/QC

Insulation

Design

Documentation.

Setting,Supports

Internals,Gaskets.Bolting

Paint & Non essential

Final Closure.

Insulation

Internals,Catalyst,Gaskets,

Paint & Non essential

Bolting Final Closure.

Insulation

Machine&piping

There shoud no C

Aligment,Trip,

items allowed for

Control,Lube System

Rotating Equipment

Setting,Supports
Setting,Supports

Motor Control

Installation and

Control and Logic Fully

There shoud no C

centers

resistance testing

Functional

items allowed for


switch,Gear and
Transformers

Electrical Equiment

Setting,Supports

(motors)

Machine&piping Aligment,

There shoud no C

Control,Trip, Fully

items allowed for

Functional

Electric motors

Electrical Equiment

Installation and

Control and Logic Fully

There shoud no C

(Transformers/light

resistance testing

Functional

items allowed for

ing)

switch,Gear and
Transformers

DCS Including

Installation and

Control and Logic Fully

There shoud no C

Remote I/O

Continuity Checks

Functional

items allowed for


control systems

Instrument Sensing

Installation and

&Control Loops

Continuity Checks

Control and Logic


Fully Functional

There shoud no C
items allowed for
control systems

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Installation and

Control and Logic Fully

There shoud no C

Continuity Checks

Functional

items allowed for


control systems

Solenoids and Trip

Installation and

Circuits

Continuity Checks

Fully Functional

There shoud no C
items allowed for
control systems

Buildings

Structural Components

Building Utilities including


Fire and Gas

Minor Repairs and paint