Commissioning Procedure Prepared by: HAH

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Date: Sept 2019
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SOP-OPS-001
COMMISSIONING PROCEDURE

Action Name Designation Date & Sign

Prepared By Hussain Ahmad
Review By
Approval
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CONTENTS

1. Introduction

2. Scope

3. Commissioning Procedures

Checklist:

1.0 Introduction
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This procedure is prepared for SRS Middle east FZC. It incorporates the relevant
procedures and guidelines from API 700 (Checklist for Plant Completion), Owners Manuals,
Regulations and industry best practices pertaining to commissioning of Petroleum storage
Terminals.

2.0 Scope
The purpose of this manual is to document procedures necessary for the safe
commissioning of SRS terminal & associated facilities at Port of Hamriyah.

3.0 Commissioning procedure

This section lists down the procedures to be followed equipment wise in order to make the
facility ready for commissioning. The facility will be considered ready for commissioning when
the facility or any part thereof has been erected in accordance with Drawings, specifications,
instructions and applicable codes and regulations to the extent necessary to permit
commissioning.

3.1 General

3.1.1 Manufacturer or Vendor Service Assistance

 Obtain the assistance of the manufacturer or vendor when necessary to make

satisfactory installation of the equipment’s.
 Obtain the assistance of the manufacturer or vendor as required for technical
assistance during run in by the owners operating and maintenance personnel, for
training or for informational and operating purposes.
 Furnish names and telephone numbers including emergency contacts of manufactures
and vendors technical service representatives.

3.1.2 Statutory Clearances

 Procure all necessary permits and certifications required to start up the facility. Ensure
that application for all necessary permits required for plant use , occupancy and
operation have been made to relevant authorities.

3.1.3 Instructions

 Maintain an adequate vendor instruction file so that information may be readily

received.
 Prepare, review and approve necessary manuals for operations of the facility and
emergency instructions.
 Obtain special instructions if any for operation of specific equipment’s from
manufacturers.
3.1.4 Removal of Rust Preventives
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 Ensure that all rust preventives and oils used to protect the equipment during
construction period are removed before pre-commissioning.

3.1.5 Lubricants

 Provide a list of manufacturers recommended lubricants for use in the plant.

 Ensure lubricants are available in sufficient quantity.
 Ensure that all lubricating systems have been flushed and initial charge of lubricant
installed.
 Ensure that the flushed lubricant is disposed as per manufacturer’s instructions.
 Maintain Lubrication after initial charge.

3.1.6 Packing and Seals

 Ensure that all mechanical seals, packings and their accessories as per manufacturer’s
instructions have been provided and properly installed.

3.1.7 Removal of Temporary Bracing

 Ensure that all temporary supports, bracing or other foreign objects that were installed
during shipping, storage or erection are removed and damages caused if any are
repaired.

3.1.8 Rotation and Alignment

 Check rotating machinery for correct direction of rotation and freedom of moving parts
before connecting the driver.
 Ensure alignment is done as per manufacturers tolerance.
 If required ensure presence of factory representative during installation of equipment.

3.1.9 Leak and Pressure Tests

 Obtain the schedule of field leak tests or field pressure test on critical equipment’s and
pipelines.
 Ensure that all tests are conducted as per applicable codes, specifications and
regulations.
 Witness test and/or verify records.
 Ensure all test media is disposed as per regulation.
 Conduct all operational tightness tests.

3.1.10 Inspection
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 Inspect the plant to verify that erected facilities confirm to flow diagrams, construction
drawings, vendor prints and specifications.
 Verify that specified materials have been installed in the plant and document
verification.
 Note any exception on a separate work order list (punch list).
 Provide for special inspections such as those required by insurance or governmental
agencies.

3.1.11 Pressure / Vacuum safety release devices

 Obtain list of proper pressure settings.

 Ensure that all devices are installed after testing adjusting and tagging.
 Verify test reports.

3.1.12 Flushing and Chemical/Mechanical cleaning

 Ensure media used for flushing and/or cleaning is disposed off as per regulations.
 Ensure that the systems taken over are free of trash and construction debris.

3.1.13 Temporary Screens, Strainers and blinds

 Ensure all temporary strainers are installed and locations marked physically as well as
on drawings.
 Remove strainers when system is adequately cleaned and replace/remove with original
ones.
 Provide/install and remove all blinds required for flushing or isolation .

3.1.14 Purging/Inerting

 Ensure all purging and Inerting connections are installed.

 Conduct necessary purge/Inerting operations as required.

3.1.15 Housekeeping

 Ensure proper housekeeping of facility, equipment during hand over.

 Remove all trash, scaffolding, scrap etc from facility after completion of construction
and prior to hand over.

3.1.16 Maintenance, Spare Parts and Special Tools.

 After pre-commissioning is complete protect equipment from normal weather

conditions corrosion or damage.
 Provide adequate maintenance for equipment including the cleaning of strainers and
repair of steam traps.
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 Obtain spare part list as recommended by manufacturer and procure necessary spare
parts.

3.1.17 Environmental Surveys

 Ensure environmental surveys are carried out and keep copy of reports. For eg. Noise
surveys for individual equipment.

3.2 Specific Procedures

3.2.1 Pumps Compressors and Drivers

 Ensure Baseplates and soleplates are level and grout all bearing surfaces.
 Excess piping stresses imposed on pumps drivers and compressors should be
alleviated.
 Chemically clean lube oil/ seal oil system as specified.
 Charge the lube oil, seal oil, oil cooling system flushing oil and circulate for cleaning
purposes.
 Charge the lube oil, seal oil, and oil cooling systems with the operating oils
recommended by the manufacturer.
 Operate the equipment and make vibration, trip, governor and safety devices checks
and any operating tests and adjustments as required.
 Obtain assistance of a service engineer for technical advice during installation prestart
up if desired/required.

3.2.2 Piping System

 Obtain the test schedule for piping system.

 Hydrostatically or pneumatically test all piping as required by codes, specifications.
 Witness field pressure tests when notified.
 Flush and drain system and install orifice plates. Orifice plates shall not be installed
before hydrostatic testing.
 Drain system, remove blinds and perform tightness tests as required.
 Check pipe hangers, supports, guides, expansion joints and other pipe specialties for
the removal of all shipping and erection stops and for the correctness of cold settings
for the design service.
 Check pipe hangers, supports, guides and pipe specialties for hot settings and make
minor adjustments if required.
 Ensure permanent filter elements as required are installed.
 Verify that the specified valve packing has been provided in the valves installed.
 Retorque all hot and cold service bolting during commissioning and start up.

3.2.3 Electrical Power and Lighting System

 Obtain the test schedules.

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 Witness tests when notified.

 Insulation tests should be carried out on all wiring except lighting wiring using megohm
meter.
 Insulation tests, phase to phase and phase to ground for motors and transformers
should be done with megohm meter.
 Make grounding system tests to determine the continuity of connections and the value
of resistance to ground.
 Breakdown tests on oil samples from oil insulated transformer larger than 100kV
should be carried out.
 Ensure electrical system is charged with oil or any other media as required.
 Perform trials and adjustments on all switchgear, motor control equipment and
generators.
 Test and set switchgear and circuit breaker relays for proper coordination.
 If required ensure local inspectors’ approval is obtained.
 Check phase sequence, polarity and motor rotation.
 Check installation of emergency power and lighting systems, including light intensity.
 Check suitability of fittings as per area classification requirements.

3.2.4 Instrument Systems

 Conduct any non-operating checks to ensure instrument operability, that is, remove all
shipping stops, check pointer travels and verify instrument capability to measure,
operate and stroke in the right direction.
 Ensure all equipment is bench/field calibrated using standard test equipment.
 Ensure all transmission and control tubing by blowing with cooled and filtered clean air
before connecting to instrument components.
 Check all air supply headers for tightness.
 Leak test pneumatic control circuits.
 Check piping from instruments to process piping for tightness.
 Check all electrical signals and alarm wiring for continuity, correct source of power and
polarity.
 Ensure sealing fluids as required are installed
 Fully pressurize and energize the transmitting and control signal system(s) by opening
process connections at primary sensors and final regulators and by making control
mode settings for automatic operation of equipment as the process unit is charged and
brought to stream.

3.2.5 Waste Disposal

 Inspect facilities for completeness and correctness of installation and make any
non-operating checks to ensure their conformance to specifications.

3.2.6 Buildings and Accessories

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 Check installation of buildings and accessories including all heating, ventilating and
air- conditioning equipment to ensure their completeness and conformance to
specification.
 As required obtain certification that all plumbing, electrical, fire protection and
special materials handling installations comply with local government regulations.
 Obtain certificate of occupancy and use if required.

3.3 ISPS Code Compliance

 Check for compliance of the access control systems.

 Check for physical compliance like completed fencing, gates , lighting, etc.
 Check CCTV coverage and display monitors.

Check List for Pipelines

no Item To be Checked Status Remarks
1 Pipe loop to be checked identified and
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marked on drawing.
2 Pipe resting properly on supports.
3 Pipe clamps, hangers, supports provided as
per drawing.
4 High points have vent and low points have
drain.
5 All vent and drain valves provided with blind
flange.
6 All flanges properly bolted with specified
gaskets.
7 Flange to flange alignment checked.
8 Blinds and spacers inserted as per drawing.
9 Anchors (where applicable) properly
installed.
10 All end flanges in leak proof area.
11 Specified slope provided.
12 Max and Min design limits for Flow, temp,
pressure etc tabulated.
13 Hydrotest reports submitted and verified.
14 Pipe cleaning reports submitted and verified.
15 Material datasheets submitted and verified.
16 All QA/AC documents submitted and verified.
17 Pipe painted as per specification. Check
reports and random DFT.
18 Colour as specified.
19 Proper labelling of pipe and valves done in
specified locations
20 Valve checklist for valves on the pipeline
filled.
23 All as built drawings and documentation
received.

Remarks/ Observations:
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Check List Filled by:

Signature :

Date :
Check List For PUMPS

Pump number:
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Type: Centrifugal / Screw / Other (________________)

Location:

S No Item To be Checked Category Status Remarks

1 Any physical damages General
observed
2 Foundation bolts ok General
3 All drain points closed / Mechanical
blinded
4 All flanges secured & line Mechanical
pressure tested
5 Bearing Oil Level Ok Mechanical
6 Both pressure gauge in Mechanical
suction connected / Instrument
7 Discharge Pressure Gauge Mechanical
connected / Instrument
8 PSV discharge to suction Mechanical
connected
9 Thermal Relief for Suction Mechanical
installed
10 Thermal Relief for discharge Mechanical
installed
11 Seal pot oil level Ok Mechanical Oil Grade, Minimum & Max
Level, Min & Max Temp to
be specified
12 Pump Alignment done Mechanical Alignment reading to be
attached.
13 Vent point for Suction & Mechanical
Discharge installed
14 Coupling properly fixed Mechanical Type of coupling to be
specified
15 Coupling guard installed Mechanical
16 No Load Test done. Any Electrical / Vibration / Bearing
observations during No Mechanical Temperature/ Starting &
Load test Running current records to
be attached
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17 All Cables properly Electrical

terminated with correct
sized glands
18 All extra openings in the JB Electrical
& Starter panel in field &
panel plugged
19 All glands covered with Electrical
gland caps or heat shrinking
sleeves
20 Earthing / Grounding for Electrical
Pump, Motor & Frame
done
21 All relays & other protective Electrical Checklist / Documents to be
equipment in panel & attached
motor of correct rating and
calibrated / checked /
tested before installation
22 Testing for motor winding Electrical Checklist / Documents to be
done attached
23 Motor rotating freely by Electrical /
hand Mechanical
24 Pump rotating freely Mechanical
25 Flow Switch Installation Instrument
done
26 Control Room Interface for Instrument
Starting /Stopping the
pump tested
27 Cable trench covered back Civil
28 Ex-Proof Certificate for Electrical Copy to be attached.
Motor Available
29 Space Heater in Motor
Switched ON
30 Manual for Pump & Motor Mech / One Set of Pump & Motor
Available Electrical manual to be attached
31 Equipment Data Sheet Mech /
prepared Electrical
32 Painting of Pipeline, valves Mech
& fittings complete
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33 Load test parameters Electrical / Record Sheet to be attached

recorded Mechanical
34 All foundations bolts Mechanical
checked after load test and
observations recorded

Remarks/ Observations:

Check List Filled by:

Signature :

Date :
Checklist for Pump station
Sno Item To be Checked Status Remarks
1 Safe access provided into the pump station and
located as per drawing
2 Area properly graded and finished.
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3 Area clean and free of debris/construction

material.
4 Pipelines have proper cross overs.
5 Leak proof areas in place as per specifications.
6 Leak proof area slope correct.
7 OWS pits free of debris and provided with proper
cover as specified.
8 Safety Handrails properly installed
9 All cables routed properly on cable trays.
10 All Junction boxes properly sealed and closed.
11 All electrical fixtures as per the specified IP and EX
rating.
12 Glands on cable terminations properly installed.
13 Earth pits installed as per specification. Check and
record earth resistance.
14 All drains clean and properly sloped.
15 Lighting inside the berth area
16 Tower monitors
17 Fire Extinguishers
18 Safety Shower
19 Utility points / couplers
Remarks/ Observations:

Check List Filled by:

Signature :

Date :
Checklist for Tank Pit area
Sno Item To be Checked Status Remarks
1 Safe access provided in to the tankpit and located
as per drawing
2 Area properly graded and finished.
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3 Area clean and free of debris/construction

material.
4 Fire walls have proper cross overs.
5 Pipelines have proper cross overs.
6 Leak proof areas in place as per specifications.
7 Leak proof area slope correct.
8 OWS pits free of debris and provided with proper
cover as specified.
9 Fire seals provided and filled with fresh water.
10 Pipe provided through dyke wall with a valve for
storm water draining.
11 Pipe sleeves in Dyke wall properly sealed.
12 All cables routed properly on cable trays.
13 All Junction boxes properly sealed and closed.
14 All electrical fixtures as per the specified IP and EX
rating.
15 Glands on cable terminations properly installed.
16 Earth pits installed as per specification. Check and
record earth resistance.
17 All drains clean and properly sloped.

Remarks/ Observations

Check List Filled by :

Signature :

Date :
Checklist for Fixed Roof Tanks

Tank No: Capacity:

S No. Items to be Checked Status Remarks

1 All valves & other nozzles are in leak proof area
2 All pipes have proper & safe supports.
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3 All flange connections are properly bolted and bonding

wire provided.
4 Check slope of leak proof area provided towards drain
sump.
5 Condition of concrete of leak proof area, is it properly
finished or not.
6 Finishing of curbing of wall of leak proof area is proper.
7 Check proper bitumen packing between annular plate
and bottom.
8 Slope of bitumen apron should be away from annular
plate.
9 Is there proper & safe access to all valves and MOVs?
10 Are all valves freely operational?
11 Valves checked as per valve checklist. (Attach Valve
checklist)
12 Earthing connection between tank & earth grid is
proper, check & record the value.
13 Check earthing connections are properly installed &
secured.
14 Sealant between annular plate and bitumen apron is
proper & continuous.
15 Visually check bottom plate leak detection pipe end. Is
open or not?
16 Tank settlement benchmarks to be identified.
17 Proper & safe access to tank staircase is given.
18 Visual check of tank periphery & annular plate.
19 Manhole blind flange holding arrangement / assembly
is provided or not.
20 Internal cleaning & general appearance of the tank.
21 Internal paint condition and random DFT.
22 All external spare nozzles properly blinded and gasket
provided.
23 Bottom sump is clean & free of all Debris.
24 Check clearance between pipe end and bottom sump
for Low suction & water draw off.
25 Tank internal piping is complete in all respects, resting
on its supports etc.
26 All tank internal flanges properly tightened & gaskets
present.
27 Datum plate is properly fixed & secured.
28 Distance of nozzle from inside tank with respect to
bottom plate.
29 Inlet duct is properly welded / supported to bottom
plate.
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30 Distance of low suction nozzle from bottom flange to

tank bottom.
31 Visual check of tank bottom slope towards centre
sump.
32 Overall status & appearance of the roof is ok.
33 All roof manholes are closed and properly secured.
34 All manual gauge openings are properly closed/blinded
& secured with gasket.
35 Dip hatch opening provided with compatible rubber
seal.

36 Check reference height of tank & record it.

37 Primary wind girder and Tank top Periphery is clean &
free from any object.
38 Sufficient lighting is provided at dip hatch.
39 All wind girders should be free of debris.
40 Foam pourers angled towards shell.
41 Foam pourers property installed.
42 Respirator or venturi is clear and properly fitted, pores
are clear also.
43 All sprinklers installed on the cooling ring.
44 All fire lines are red, & foam lines are yellow in color.
45 Staircase of tank is properly secured.
46 Proper lighting is provided on staircase at every landing
with toe guard given.
47 Confirm that all electrical fittings are intrinsically safe
cables properly glanded.
48 Tank name plate properly affixed with correct name.
49 Tank valves properly tagged & visible.
50 Valve operating platform is safe and easy access for
valve operation.
51 Sufficient lighting at valve operating area.
52 In case tank is internally coated get list of products
compatible with the paint system used.
53 PVRV installed- record settings
54 Emergency relief valve installed- record settings

Documents required for tank:

1. Calibration table received in both hard & soft copy. Hard copy stamped by relevant
third Parties/authorities.
2. Manuals of all tank fixtures are provided such as, Pivot master. Tank body valves,
Level Gauges, QA/QC documents.
3. PFDs, P&IDs, GADs, detailed drawings of each tank. Tank settlement details.
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4. All Hydrostatic test details.

Remarks/ Observations

Check List Filled by :

Signature :

Date :
Checklist for Internal Floating Roof Tanks

Tank No: Capacity:

S No. Items to be Checked Status Remarks

1 All valves & other nozzles are in leak proof area
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2 All pipes have proper & safe supports.

3 All flange connections are properly bolted, and bonding
wire provided.
4 Check slope of leak proof area provided towards drain
sump.
5 Condition of concrete of leak proof area, is it properly
finished or not.
6 Finishing of curbing of wall of leak proof area is proper.
7 Check for adequate water level in fire seal.
8 Check proper bitumen packing between annular plate and
bottom.
9 Slope of bitumen apron should be away from annular
plate.
10 Is there proper & safe access to all valves and MOVs?
11 Are all valves freely operational?
12 Valves checked as per valve checklist. (Attach Valve
checklist)
13 Earthing connection between tank & earth grid is proper,
check & record the value.
14 Check earthing connections are properly installed &
secured.
15 Sealant between annular plate and bitumen apron is
proper & continuous.
16 Visually check bottom plate leak detection pipe end. Is
open or not?
17 Tank settlement benchmarks to be identified.
18 Proper & safe access to tank staircase is given.
19 Check roof drain sump for any debris.
20 Elbow provided to the sump of roof drain or not?
21 Roof drain valve is securely fixed to piping, nuts & gasket
fastened.
22 Roof drain valve should be open & sealed.
23 Visual check of tank periphery & annular plate.
24 Manhole blind flange holding arrangement / assembly is
provided or not.
25 Internal cleaning & general appearance of the tank.
26 Internal paint condition and random DFT.
27 All external spare nozzles properly blinded and gasket
provided.
28 Bottom sump is clean & free of all Debris.
29 Check clearance between pipe end and bottom sump for
Low suction & water draw off.
30 Tank internal piping is complete in all respects, resting on
its supports etc.
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31 All tank internal flanges properly tightened & gaskets

present.
32 Roof drain Pivot master is free to move or obstructed by
something or tightened with ropes.
33 All bleeder vent legs inserted and bleeder vent open.
34 Emergency roof drains; water seal is full of clean fresh
water
35 Datum plate is properly fixed & secured.
36 Still well/guide pole is properly connected to bottom
plate.
37 Primary seal is touching & pressed with tank shall at all
places.
38 Rim vent opening is free of debris & not clogged.
39 Length of roof legs to be measured, maintenance and
operation as well.
40 Distance of nozzle from inside tank with respect to bottom
plate.
41 Inlet duct is properly welded / supported to bottom plate.
42 Distance of low suction nozzle from bottom flange to tank
bottom.
43 Visual check of tank bottom slope towards centre sump.
44 Roof Manhole fixed ladder is properly installed or not?
45 Roof centre sump is clear, check valve installed & freely
rotating and not stuck.
46 Centre sump painting & cleaning is done.
47 Overall status & appearance of the roof is ok.
48 Pontoons to be checked randomly for any debris or
foreign objects.
49 Foam dam should be clean & clear.
50 Weather shield is properly installed or not.
51 Bonding plates between secondary seal & tank shell is
proper or not.
52 Rim vent PV valves properly installed. Mesh free of debris.
53 Rubber sleeve / vapor locks on roof legs provided.
54 Spilt pins are provide on all roof leg locks.
55 Roof drain sumps are clean & clear.
56 Emergency drain properly covered with mesh.
57 Bleeder vents installed, legs installed & visibly open with
pin attached & secured.
58 Bleeder vent top plate is reinforced with thick flange from
bottom or not.
59 Bleeder vent plates/discs are provided with brass cladding
or ring/plating.
60 Still well/guide pole provided with brass rollers from
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either side.
61 Guide pole brass rollers are free and rotating.
62 Guide pole opening is sealed by brass plate or not.
63 Exposed area between guide pole and brass plate is sealed
with compatible material or not.
64 All roof manholes are closed and properly secured.
65 All manual gauge openings are properly closed/blinded &
secured with gasket.
66 Dip hatch opening provided with compatible rubber seal.

67 Check reference height of tank & record it.

68 Primary wind girder and Tank top Periphery is clean & free
from any object.
69 Sufficient lighting is provided at dip hatch.
70 All wind girders should be free of debris.
71 Foam pourers angled towards shell.
72 Foam pourers property installed.
73 Bend barriers provided or not.
74 Respirator or venturi is clear and properly fitted, pores are
clear also.
75 All sprinklers installed on the cooling ring.
76 All fire lines are red, & foam lines are yellow in color.
77 Stair case of tank is properly secured.
78 Proper lighting is provided on star case at every landing
with toe guard given.
79 Confirm that all electrical fittings are intrinsically safe
cables property glanded.
80 Tank name plate properly affixed with correct name.
81 Tank valves properly tagged & visible.
83 Valve operating platform is safe and easy access for valve
operation.
84 Sufficient lighting at valve operating area.
85 PV valves are installed on the Dome roof (record settings)
86 ERV is installed (record settings).
87 Safe access is provided to the foam pourers for maint.

Documents required for tank:

1. Calibration table received in both hard & soft copy. Hard copy stamped by relevant
third Parties/authorities.
2. Manuals of all tank fixtures are provided such as, Pivot master. Tank body valves,
Level Gauges, QA/QC documents.
3. PFDs, P&IDs, GADs, detailed drawings of each tank. Tank settlement details.
4. All Hydrostatic test details.
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Remarks/ Observations

Check List Filled by :

Signature :

Date :