Professional Documents
Culture Documents
GES C.60
INDEX
1.1 Introduction 3
1.2 Other NOC Specifications 3
2.0 DEFINITIONS 3
2.1 Technical 3
2.2 Contractual 4
3.0 GENERAL 4
4.1 Introduction 7
4.2 Plant Systems and Sub-Systems 7
4.3 Punch Lists 7
4.4 Pre-Commissioning and Commissioning 7
4.5 Start-Up 8
5.1 General 9
5.2 Check Lists 9
GENERAL ENGINEERING SPECIFICATION GES C.60
PLANT PRE-COMMISSIONING, COMMISSIONING Page 3 of 14
AND START-UP GUIDELINES Rev 0 1999
1.0 SCOPE OF SPECIFICATION
1.1 Introduction
1.1.1 This specification covers the minimum requirements for the completion of plant and mechanical equipment
pre-commissioning, commissioning and start-up activities for refineries, onshore oil and gas installations
and processing facilities.
Commissioning of electrical equipment is covered by GES C.56. Commissioning of instrument and control
systems is covered by GES C.54.
1.1.2 In this specification, it is assumed that the plant is mechanically complete, prior to the beginning of the pre-
commissioning, commissioning and start-up activities. The definition of `mechanical completion' is given
below.
1.1.3 The Vendor/Contractor shall produce pre-commissioning, commissioning and start-up procedures that will
cover items in their supply. These shall be used in conjunction with this specification, and be integrated
into the overall pre-commissioning, commissioning and start-up procedures for the entire plant.
2.0 DEFINITIONS
2.1 Technical
Plant system or sub-system: A discrete utility, maintenance or process system, that forms part of the
overall plant, e.g. instrument air system, cooling water system, fuel gas system.
Mechanical Completion: The construction stage at which all items of equipment have been installed,
equipment skids aligned and grouted, interconnecting process and utility piping flushed and hydrotested,
valves, instrumentation and interconnecting wiring have been fitted.
Pre-commissioning: Begins after mechanical completion and means all cold/static checking, verification,
testing, adjustment, calibration work on plant systems and sub systems, to ensure that all function in
accordance with their intended service, including the flushing and filling of oil systems.
Commissioning: The dynamic testing and adjustment of a plant system or sub-system, by the introduction
of utility and process fluids, to ensure that the system functions in accordance with its intended purpose.
Start-up: The introduction of oil, gas or feedstock to the plant, and the operation together of the plant
systems and sub-systems, leading to the manufacture of the plant product.
Operational Test: On-line test of a sub-system in conditions as close as possible to normal operation.
GENERAL ENGINEERING SPECIFICATION GES C.60
PLANT PRE-COMMISSIONING, COMMISSIONING Page 4 of 14
AND START-UP GUIDELINES Rev 0 1999
Site Performance Tests: Those tests made by the Owner with assistance from the Vendor/Contractor,
during start-up, which confirm that the plant is operating at its design condition.
Handover: The passing of responsibility for the plant from the Vendor/Contractor to the Owner, after
demonstration of satisfactory start-up and operation.
2.2 Contractual
Owner
The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.
Vendor
Contractor
Sub-Contractor
A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.
Inspection Authority
The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.
Inspector
A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.
3.0 GENERAL
The Vendor/Contractor shall comply with this specification and the following API Code:-
The codes and standards applicable to individual equipment and plant items are specified in the respective
specifications.
3.2.1 The Vendor/Contractor shall produce an overall set of pre-commissioning, commissioning and start-up
procedures covering the entire plant. This manual, for individual equipment items, shall be compiled into
the overall set of procedures for the entire plant.
GENERAL ENGINEERING SPECIFICATION GES C.60
PLANT PRE-COMMISSIONING, COMMISSIONING Page 5 of 14
AND START-UP GUIDELINES Rev 0 1999
3.2.2 The Vendor/Contractor shall pre-commission, commission and start-up the plant, following the procedures
approved in the manual.
b) to provide all commissioning tools, spares, lubricants, chemicals, temporary utilities and facilities;
c) to obtain technical assistance from the equipment Sub-Vendor's engineers, during commissioning;
f) to notify the Owner, two days in advance, of site tests to be made during pre-commissioning and
commissioning;
h) to provide continuous clean-up of the construction area, remove excess materials, temporary
facilities, scaffolding and rubbish;
i) to verify to the Owner that all pre-commissioning activities have been completed, prior to the
commencement of the commissioning phase;
j) to verify to the Owner that all commissioning activities have been completed, prior to start-up of
the plant;
k) to assist the Owner in site performance tests of specified equipment prior to handover.
The Vendor/Contractor shall submit the following documentation for review by the Owner.
3.3.1 A detailed list of Plant systems and sub-systems included in the pre-commissioning, commissioning and
start-up programme, four weeks prior to the start of pre-commissioning.
3.3.2 A pre-commissioning, commissioning and start-up plan four weeks prior to pre-commissioning, containing:
- a detailed schedule, in network form, and arranged by plant system, for carrying out the pre-
commissioning, commissioning and start-up activities;
- an organisation chart showing the Main Vendor/Contractor's personnel, who will be responsible
for pre-commissioning and commissioning;
- a list of spare parts required for pre-commissioning and commissioning;
- a list of temporary utilities and facilities required during pre-commissioning and commissioning;
- a list of lubricants and consumables required for commissioning;
- a list of Sub-Vendor's representatives who will be available on site to support commissioning.
3.3.3 A Pre-Commissioning, Commissioning and Start-Up Manual as Section 3.2.1, four weeks prior to the start
of pre-commissioning, containing:
- a set of approved for construction drawings and survey data, to be used during pre-commissioning
and commissioning;
- a marked up set of plant P&IDs and utility P&IDs showing various plant systems;
- a pre-commissioning and commissioning plan, arranged by plant systems, and detailing all of the
GENERAL ENGINEERING SPECIFICATION GES C.60
PLANT PRE-COMMISSIONING, COMMISSIONING Page 6 of 14
AND START-UP GUIDELINES Rev 0 1999
activities and procedures to be used during pre-commissioning, commissioning and start-up;
- a list of all equipment, machinery and packages, arranged by plant systems which are subject to
pre-commissioning and commissioning tasks. The list shall indicate the tasks, checks and tests to
be made, and shall be a summary of the pre-commissioning and commissioning scope of work, the
list shall be a working document that monitors the progress of the work;
- operational test procedures;
- design data and process flow diagrams;
- process description;
- pre-commissioning procedures;
- commissioning procedures;
- equipment Vendor/Contractor's procedures;
- start-up procedures;
- functional/performance test procedures;
- proforma of check lists;
- proforma of inspection logs;
- proforma of test logs;
- proforma of the weekly report sheet;
- proforma of non-conformance certificate;
- proforma of release certificate.
3.3.4 A pre-commissioning and commissioning data dossier arranged by plant systems prior to start-up of the
plant, containing:
All documentation pertaining to the Commissioning operation shall be compiled in a specific Handover
Dossier, arranged by sub-systems which will contain all information required to demonstrate a subsystem
has reached the 'Ready For Handover' status. Its content shall include but shall not be limited to:
- Handover Certificate;
- Commissioning Acceptance Certificate;
- Punch List;
- Operational Test Procedures and Test Results;
- Functional Test sheets;
- Completed Commissioning Check Lists;
- Mechanical Reports;
- Leak Test and Inerting Reports;
- As-Built Drawings;
- List of Modifications.
The Handover Dossier shall be produced and presented to the Owner when the commissioning team are
confident the plant is "Ready For Handover", all the start-up activities have been completed and the plant
operates trouble free for a defined period of time.
GENERAL ENGINEERING SPECIFICATION GES C.60
PLANT PRE-COMMISSIONING, COMMISSIONING Page 7 of 14
AND START-UP GUIDELINES Rev 0 1999
4.1 Introduction
4.1.1 The essential steps to achieve plant completion are to define, prepare and carry out all pre-commissioning
commissioning and start-up activities by plant systems and sub-systems.
The partition of a plant into systems and subsystems shall be a key preparation activity, see Section 3.3.1.
The subsystems shall be defined so as to be as independent as possible, not too small, but of manageable
size, and exactly adapted to the start-up sequence.
During pre-commissioning checks and tests, all discrepancies, damaged or missing equipment,
malfunctions, missing documents, etc., shall be recorded in the subsystem punch lists. These lists shall be
updated during the pre-commissioning operations, to indicate the precise status of each subsystem at the
Ready for Commissioning stage.
In general the pre-commissioning and commissioning scope of work shall include but not be limited to:
4.4.2 The pre-commissioning and commissioning scope of work may be divided into four separate activities:
a) Preliminary Checks
The Preliminary Checks shall be the cross verification by the Commissioning Team that a Plant
system is ready for pre-commissioning. They shall take place when a system reaches the
mechanical completion status, and consist of;
The Preliminary Checks shall be carried out by each discipline and formalised by a specific report.
b) Functional Tests
These shall be live tests performed on each piece of equipment. For instrument and electrical
items refer to GES C.54, C.55 and C.56 for precise requirements.
The functional tests shall be carried out in accordance with technical specifications, the results
being recorded on Functional Test Sheets.
c) Operational Tests
The operational tests shall consist of bringing the system into operation under conditions as close
as possible to normal, in order to live test the automated devices, controls, normal start up and
shutdown sequences and monitor pressures, temperatures, vibration, and fluid tightness.
GENERAL ENGINEERING SPECIFICATION GES C.60
PLANT PRE-COMMISSIONING, COMMISSIONING Page 8 of 14
AND START-UP GUIDELINES Rev 0 1999
Typical subsystems subject to an operational test shall be, fire water system, air compressors,
power generation equipment, export pumps in recycle mode, process compressors in recycle (with
air or nitrogen).
Every operational test shall be conducted in accordance with a test procedure which has been
approved by the Owner.
d) Pre-Start-Up Activities
These shall be the specific activities required to prepare for the introduction of oil, gas or
feedstock.
4.4.3 Field equipment and packages shall be equally subject to commissioning operations, irrespective of the
amount of testing that may have taken place at the place of manufacture.
4.5 Start-Up
Since the start-up of utilities is considered a commissioning operation, the real start-up phase begins with
the introduction of the feedstock into the plant.
5.1 General
5.1.1 This check list includes, but is not a complete list of all pre-commissioning, commissioning and start-up
activities, arranged by major types of equipment. The Vendor/Contractor shall submit a detailed list
specific to each individual item of plant.
5.1.2 The following lists the general activities applied to all equipment that shall be carried out during pre-
commissioning:
a) remove rust inhibitor, oil, grease, etc. used to preserve equipment during construction and fill with
the specified lubricants;
c) clear the operating area free of debris, tools and extraneous materials. Accessways shall be open
for emergency operation;
d) Set or check pipe anchors, guides, spring hangers and supports after X
hydrotest. Provide cold and hot setting data.
e) Remove as necessary and transport all safety valves to and from test X
facilities.
f) Test, set, and tag all safety valves, then carry out safety valves final X
installation.
a) Set and align fan and driver if applicable. Set V belts and check they X
are antistatic if in hazardous area. Check fan blades pitch. Check fan
ring clearances. Check for any damage.
e) Start-up fans and check airflow, noise, vibrations, motor loading, and X X
proper operation of autovariable fans.
5.2.3 Pumps
a) Functionally check all subsystems such as lube oil and seal piping X
hookup.
c) Carry out uncoupled run of motors and check bearing temperatures and X
vibration.
e) Check discharge dampers are correctly charged with nitrogen (if fitted X
- reciprocating pumps).
m) Run pump on process fluid and repeat pump checks above plus X
performance check where possible.
c) Fill and carry out flushing of lube and seal oil system until test screens X
and filters are clean; drain and refill with new oil as required to correct
level. Check auxiliary/standby pump.
f) Operationally check all subsystems such as lube and seal oil systems, X
fuel system, start air system, surge control system, etc as applicable.
a) Flush clean, check cleanliness of oil filters and fill lube oil system. X
f) Drain lube oil system then refill with new oil, if required. X
k2 X X
Conduct performance test.
a) Check that fans and motors rotate manually and run freely. X
d) Check that linkage and blades of dampers operate correctly and freely. X
h) Prepare furnace and fuel systems for dry-out operation. Ensure tubes X
are vented adequately.
k) After dry-out, clean stack and duct, open manholes and other openings X
for inspection. Check operation of dampers. Close stack and duct after
inspection.
d) Properly close up all vessel internal manways and openings after final X
inspection and after loading of chemicals, catalysts, etc. is completed,
as applicable.
5.2.9 Tankage
d) Close manways. X
d) Carry out checks and tests on fire and gas detection systems. X
S:\NOC9077\ADMIN\SPECIFICATIONS\C-SERIES\C-60\GESC60RF