Mechanical Commissioning 2

PIPING PRE-COMMISSIONING PROCEDURES
Joint Integrity Procedure
Joint Data:
Flange Data
Flange Type, Size and Class and Material
Joint and Gasket Type
Bolt and Nut size, material and grade
Bolt Data
Bolt Diameter;
Number of Bolts;
Thread Type, Imperial or Metric;
Bolt Material;
Lubricant
Joint Data - Continued:

Tightening Data
Torqueing:
Residual Bolt Stress,
Torque Value Required
Pump Pressure for specified tool.
Tensioning:
Residual Bolt Stress,
Tensioner 1st pass,
Tensioner Subsequent passes for specified tool
Thread Type
Tagging:
Flange Alignment:
If the bolts can be passed through the bolt holes of both flanges
without force, then this misalignment is acceptable.
Horizontal/vertical offset
Flange rotation
Flange Alignment:
Face separation
Flange Alignment:
Tools
Flange Face Defect

Flanged Joint Bolt Tightening
Hydraulic Torque Tightening

Hydraulic Torque Tightening
Criss-Cross Tightening Sequence Examples::

4 Bolt Flange 1-3-2-4
8 Bolt Flange 1-5-3-7-2-6-4-8
12 Bolt Flange 1-7-4-10-2-8-5-11-3-9-6-12
16 Bolt Flange 1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
20 Bolt Flange 1-11-6-16-3-13-8-18-5-15-10-20-2-12-7-17-4-
14-9-19
Manual Torque Tightening

Manual Torque Tightening
Criss-Cross Tightening Sequence Examples::

4 Bolt Flange 1-3-2-4
8 Bolt Flange 1-5-3-7-2-6-4-8
12 Bolt Flange 1-7-4-10-2-8-5-11-3-9-6-12
16 Bolt Flange 1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
20 Bolt Flange 1-11-6-16-3-13-8-18-5-15-10-20-2-12-7-17-4-
14-9-19
Bolt Tensioning
100% procedure 50% procedure 50% procedure

Cleaning and Flushing
Cleaning of lines after assembly and erection. After the completion

of erection, scale, dirt, welding electrodes, slag, and other foreign
material should be removed from the lines.
Flushing Media:
Flushing should be carried out using clean fresh water, potable
water, treated sea water, air or steam as appropriate.
For systems containing austenitic stainless steel piping and
fittings the chloride ion content of the water shall be less than
30ppm.
Carbon steel Pipe work flushed with sea water should be dried
immediately after flushing to prevent corrosion.
Cleaning and Flushing Certificate

Pressure Test
Each piping system shall be tested to ensure tightness prior to

initial operation and after completion of the applicable
examinations applies to quality control functions.
Testing must be carried out in accordance with the requirements

specified on the isometric drawing and piping line specification or
otherwise must take into account the duty of the system, namely
the process fluid and the operating pressures and temperatures.
Pressure test can be done with a several methods:

Hydrostatic test
Pneumatic test
Hydrostatic / pneumatic test
Hydrostatic Test
Test Media:
The fluid shall be water unless there is the possibility of damage
due to freezing or to adverse effects of water on the piping or
the process. In that case another suitable nontoxic liquid may
be used and you have to a make sure the test media will not
contaminate the final product.
For austenitic stainless steel piping the chloride ion content of
the water shall not be more than 30 ppm
Test Pressure:
The hydrostatic test pressure at any point in a piping system
shall be defined by the design documents and not less than 1.5
times the design pressure.
Hydrostatic Test
Test Records:
Records shall be made of each piping system during the testing,
including
Date of test
Identification of piping system tested
Test fluid
Test pressure
Certification of results by examiner
Pressure and temperature charts.
Hydrostatic Test
Pressure and temperature charts.

Hydrostatic Test Certificate

Steam Blowing For Piping Networks Procedure

Reference to “Steam Blowing For Piping Networks Procedure”

“000470_DV_EX.DPM.0354.000_00”.
The purpose of blowing or cleaning the steam lines prior to

starting up a new unit is to remove any foreign matter remaining
in the equipment (i.e. superheater) and steam piping after
installation is completed.
The operational test package covers the pipework cleanness by

steam blowing method (Medium & Low Pressure Steam Headers
and sub-headers network).
listed below are the systems and the loop numbers for the
following Systems:
Sub-System Description
525-BW01-01 Boiler Feed Water Generation package
525--BB01-01 Boiler Feed Water Distribution
525RG01-01 Boiler Blow Down
525-MS01-01 Medium Pressure Steam Generation
525-MS01-02 Medium Pressure Steam Distribution
525-LS01-01 Low Pressure Steam Generation
525-LS01-02 Low Pressure Steam Distribution

TYPES OF STEAM BLOW METHODS:

Shock blow:
With shock blow, the pressure inside the steam generator is
raised to a certain maximum and reaching the required
pressure, a temporary sacrificial valve is opened quickly.
Continuous steam blow:

With continuous blow there is no pressure build up, but after
calculations, the K-factor is reached continuously. During the
continuous steam blow the target plates are checked on impacts
of particles.
TARGET PLATE:
The results of steam blowing shall be checked by means of
target plate to consist of holding fixture to witch a mirror-
finished impingement plate of carbon steel with a brinell
hardness.
The possible locations of target plate are:

Installation of target plate in the inlet section of temporary
pipe network.
Installation of target plate in the outlet section of the steam
line.
Steam Blowing Results, Control, Evaluation and Records
TARGET PLATE:
PIPING AND STATIC EQUIPMENT COMMISSIONING
Leak Testing
Reference to “Leak Test & N2 Purging Procedure for Systems

Commissioning” “000470_DV_EX.DPM.0361.000_00”.
Leak tests shall be carried out on entire systems, after flushing

and cleaning operations, and completion of the installation, to
prove the integrity of the following:
Gaskets and flanged joints in general;
Valve packing;
Miscellaneous connections such as vents, drains, safety
valves, instruments;
Connections between the system being tested and inter-
related systems.
Leak Test Procedure
Systems test limits

Pressurization / De-Pressurizing Points.
Flange Taping in case complemented by HLD (Helium Leak
Detection) or Soap Testing.
Pressure recording
Relief systems
Issue a Witnessed Joint Register waiting Services Test
Leak Test Report

Witnessed Joint
Inert Purging Of Process Piping General Conditions
It is the removal of oxygen from all pipework and vessels to

provide safe hydrocarbons introduction.
This operation is required only if the process system is filled with

air after leak testing (depending on leak testing methodology
adopted) which shall be decided by the Commissioning Team.
There are several gases which are considered as "inert" but for all
practical purposes only nitrogen is to be used.
Purging Methods
Continuous flow or "sweeping“:

This method will generally be used for small, low-volume
systems such as piping systems up to 4" line diameter.
Continuous flow / sweeping of large diameter piping is
unsuitable due to the very high flow required to produce the
ideal velocity (3 m/s) to displace air.
Pressurization / depressurization:
This is the preferred method of inert gas or nitrogen purging
for reasons of economy and safety and is used for both vessels
and associated piping
Inerting and Drying out Certificate

ROTATING EQUIPMENTS INSTALLATION
Storage and Preservation
Protecting project machinery from deterioration in the field.

Upon arrival of the machinery The following checks should tack
place:
Visually inspect components for physical damage or
contamination by opening packages and crates.
Ensure the equipment is received after the completion of all FAT
punch lists.
Verify that loose components and separate packages match the
packing lists.
Verify that special handling instructions are provided and carried
out etc.
Storage and Preservation Certification

Mechanical Installation Procedure
The following points are to be checked on all Machinery

equipment, static Equipment and Skid mounted unit:
Confirm that Storage and Preservation Protection Procedure was
applied
All installation activities will be according to vendor's manual.
Confirm proper foundation, levelling and position in accordance
with the mechanical drawings and vendor manual.
All drains and vents - including bedplate drains are fitted and
clear.
All mechanical seals are clean and completed
All pipe work is complete and correctly aligned, e.g. seal and
lube oil systems are flushed correctly (pickled where necessary)
and filled with the correct oil.
Pump Installation Procedure
Confirm that Jobsite Receiving and Protection Procedure was

applied.
Confirm that Generic Mechanical Installation procedure was
applied.
Mounting pads shall be provided for the pump and all drive train
components.
When the vendor mounts the components, a set of stainless
steel shims at least 3 mm (0.12 in.) thick shall be furnished.
When the vendor does not mount the components, the pads
shall not be drilled, and shims shall not be provided.
Level and properly grout the base-plate.
Remove jackscrews removed and tighten foundation bolts.
Flush and re-lubricate bearing housing.
Surface to Be Rough Chipped

and Clean. The overhang of the base pad
allows levelling of the pads
Level baseplate using Jack without removal of the pump.
screws and levelling pads.
Pump Feet with Dial Indicator:

The dial is attached with the button
on the top of the foot.
The hold down bolt is then
loosened.
Align driver to pump:

This alignment is to ensure that
coupling alignment can be made
prior to grouting of the base.
Grout Baseplate Install Main Piping

Check for Pipe Strain

Final Alignment
Thermal Offset Map as

Supplied by OEM
Pump Installation Certificate

ROTATING EQUIPMENTS PRE-COMMISSIONING
Methods of Machinery Alignment
Reverse Alignment.
Face and Rim Alignment.
Optical Alignment .
Machinery Alignment Procedure
The following Procedures are to be performed in conjunction with

the Machinery Alignment Certificate Form.
All machinery will have the alignment checked by one of the
following methods described below. Tolerances are to be within
the manufacturer's standard requirements.
Enter the type of Alignment Procedure to be used i.e.
Reverse/Optical/Face & Rim.
Enter the target alignment that is to be achieved in the required
Alignment section.
Reverse Alignment
Reverse alignment is the measurement of the axis, or centerline

of one shaft to the relative position of an opposing shaft
centerline.
This measurement can be projected the full length of both
shafts for proper positioning if you need to allow for thermal
movement.
The measurement also shows the position of the shaft
centerlines at the coupling flex planes, for the purpose of
selecting an allowable tolerance.
The centerline measurements are taken in both horizontal and
vertical planes.
Reverse Alignment Advantages
Very accurate especially for small diameter flanges

Not affected by axial float.
Can be used with a flexible coupling in place.
You have to rotate both shafts.
Reverse Alignment
REVERSE INDICATOR
dF
DRIVER
dM
Inboard Outboard
Reverse Alignment
HOW TO FIND THE SAG ?
BRACKET
STRAIGHT PIPE
STAND V BLOCK STAND V BLOCK

Reverse Alignment
CHECK BASE FRAME & SOFT FOOT
Reverse Alignment
CHECK RUN OUT BOTH OF COUPLINGS
DRIVER
Magnetic Dial
Rim and Face Alignment
WHY USE THIS METHOD ?

Use this method if one of the shafts cannot be rotated.
An excellent method for large shaft diameters (8 inches or
200mm or greater) or if the diameters are equal to, or greater
than the span from the bracket location to the face and rim
location where the readings are to be taken.
Not too good a method if there is axial float from sleeve or
journal bearings.
dP
D dA DRIVER
L1
L2
Before Alignment Confirm????

A straight shaft that has been dynamically balanced.
Good wear rings with the proper clearance.
The correct impeller to volute, or back plate clearance.
The elimination of "soft foot".
Eliminate all pipe strain.
Good bearings installed on a shaft with the proper finish and
tolerances.
A good mechanical seal set at the proper face load. The closer
the seal is to the pump bearings the better off you are going to
be.
Machinery Alignment Certificate

ROTATING EQUIPMENTS COMMISSIONING
Operational Test
This operational test consists of bringing the system equipment
into operation under conditions as close as possible to normal
operating conditions for a significant period of time.
Once the Operational Tests are complete, the system is “Ready

for Start-Up” or can be put under normal operation.
“Operational Test Certificate” will be issued to Company for

approval and for commencement of the associated start-up
activities as require.
OTP Pumps Run-in Procedure
Preliminary Check:
Visual Inspection; Oil quality analysis;

Cleanliness; Coupling of driver and driven unit;
Removal of preservation; Filling of consumables;
Freedom of rotation; Filters and oil cartridge inspection;
Final alignment checks; Connection of temporary facilities;
Lubrication; Running and verification of all
Lube, seal and hydraulic oil filling auxiliaries
OTP Execution:
Once the system is ready for its first start-up with the equipment
mechanically prepared and the system lined-up, it will be started
for two hours following a detailed step by step procedure as
recommended by the manufacturer (or under supervision by
Vendor’s representative).
The second phase of the operational test is essentially devised for
planning and resources purposes.
Actual dynamic verifications that all the sequences and interlocks
of the main equipment, its auxiliaries and of the whole
system/sub-system perform properly.
Actual verifications that the main equipment is mechanically
sound, by taking all the required reading during several hours
after stabilization.
OTP Execution:
Once the system is ready for its first start-up with the equipment
mechanically prepared and the system lined-up, it will be started
for two hours following a detailed step by step procedure as
recommended by the manufacturer (or under supervision by
Vendor’s representative).
The second phase of the operational test is essentially devised for

planning and resources purposes.
Actual dynamic verifications that all the sequences and interlocks

of the main equipment, its auxiliaries and of the whole
system/sub-system (or other system, if they are interlocked),
perform properly:
Start/stop normal sequences; Remote/local modes;

Hot/cold start; Duty/stand-by modes;
Emergency shutdown; Auxiliaries changeover;
Pneumatic/ Electric starts; Synchronisation.
Automatic/manual modes;
Actual verifications that the main equipment is mechanically

sound, by taking all the required reading during several hours
after stabilization for:
Noise levels; Fuel and oil leaks;

Equipment, bearing, gearbox Piping vibrations;
vibrations; Strainers and filters differential
Lube oil/coolant flows, temperatures, pressures;
pressures Oil consumption;
Seals integrity; Signs of mechanical wear.
Actual verification of the equipment performance:
By taking process or electrical readings during several hours

after stabilisation, at various loads;
By plotting the actual performance against theoretical

characteristics supplied by the manufacturer / vendor.
Actual dynamic verifications as practicable that the key process

and equipment alarms and trips function properly:
ESD/Manual push-buttons; High/low flows;

F&G detection; High/low temperatures;
High/low pressures; Over speeds
OTP Fan, Blower & Coolers Run-in Procedure
Run-in activities:
Review manufacturer operating Rotate group by hand, verifying that it

instructions. turns freely;
Check that installation is correct and Check that electric power is available
complete; from switchgear to starter of electric
Verify that equipment and driver are motor drivers;
correctly aligned; Close air inlet damper (if applicable)
Check belt tension of driven pulleys (if and start the blower(s);
applicable); Increase slowly air flow (as applicable);
Verify that bearings are properly Check for abnormal vibrations. Correct
lubricated and cooled (if applicable); as necessary;
Check control and monitory Measure bearing temperature and
instruments and safety devices vibrations;

Mechanical Commissioning 2

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Mechanical Commissioning 2

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PIPING PRE-COMMISSIONING PROCEDURES

Joint Integrity Procedure

Joint Integrity Procedure

Joint Data - Continued:

Joint Integrity Procedure

Joint Integrity Procedure

Joint Integrity Procedure

Joint Integrity Procedure

Joint Integrity Procedure

Flange Face Defect

Flanged Joint Bolt Tightening

Hydraulic Torque Tightening

Flanged Joint Bolt Tightening

Hydraulic Torque Tightening

Criss-Cross Tightening Sequence Examples::

Flanged Joint Bolt Tightening

Manual Torque Tightening

Flanged Joint Bolt Tightening

Manual Torque Tightening

Criss-Cross Tightening Sequence Examples::

Flanged Joint Bolt Tightening

100% procedure 50% procedure 50% procedure

Cleaning and Flushing

Cleaning of lines after assembly and erection. After the completion

Cleaning and Flushing Certificate

Each piping system shall be tested to ensure tightness prior to

Testing must be carried out in accordance with the requirements

Pressure test can be done with a several methods:

Pressure and temperature charts.

Hydrostatic Test Certificate

Steam Blowing For Piping Networks Procedure

Steam Blowing For Piping Networks Procedure

Reference to “Steam Blowing For Piping Networks Procedure”

The purpose of blowing or cleaning the steam lines prior to

The operational test package covers the pipework cleanness by

Steam Blowing For Piping Networks Procedure

525-BW01-01 Boiler Feed Water Generation package

525--BB01-01 Boiler Feed Water Distribution

525RG01-01 Boiler Blow Down

525-MS01-01 Medium Pressure Steam Generation

525-MS01-02 Medium Pressure Steam Distribution

525-LS01-01 Low Pressure Steam Generation

525-LS01-02 Low Pressure Steam Distribution

Steam Blowing For Piping Networks Procedure

TYPES OF STEAM BLOW METHODS:

Continuous steam blow:

Steam Blowing For Piping Networks Procedure

 The possible locations of target plate are:

Steam Blowing For Piping Networks Procedure

Reference to “Leak Test & N2 Purging Procedure for Systems

Leak tests shall be carried out on entire systems, after flushing

Leak Test Procedure

 Systems test limits

Leak Test Report

Inert Purging Of Process Piping General Conditions

It is the removal of oxygen from all pipework and vessels to

This operation is required only if the process system is filled with

Continuous flow or "sweeping“:

Inerting and Drying out Certificate

Storage and Preservation

Protecting project machinery from deterioration in the field.

Storage and Preservation Certification

Mechanical Installation Procedure

The following points are to be checked on all Machinery

The possible locations of target plate are:

Systems test limits

Confirm that Jobsite Receiving and Protection Procedure was

Reverse alignment is the measurement of the axis, or centerline

Very accurate especially for small diameter flanges

Once the Operational Tests are complete, the system is “Ready

“Operational Test Certificate” will be issued to Company for

By taking process or electrical readings during several hours

By plotting the actual performance against theoretical