Methodology of

Testing & Commissioning

By: T&C Team

 What is commissioning .!?
Commissioning is running and testing of the system,
but it is not only that, but also monitoring the
production process, pushing through and to make sure
each and every systems are completed on time safely
as per the schedule.
 Commissioning Process

Installation
Verification

Pre-Functional

Operational
performance
testing

Functional

Functional
performance
testing
 Installation Verification
What need to be inspected .?
What is specified actually provided.
Installation meets class/owner standards.
Actual design meets design intend.
Installation operates per design intend.
 Installation Verification
Machinery:
Inspect equipment for shipping/installation
damage.
Supplied equipment matches approved submittal
- Equipment size,HP,voltage & accessories.
Equipment installed per manufacturer
recommendation.
Equipment is properly hooked up with connected
services(piping , electrical).
Verify equipment access & serviceability.
 Installation Verification
Piping:
Verify piping is installed per certified
doctation(piping material, pressure
rating,welding,size,insulation,supports etc.)
Verify all valves, devices & instrumentation
are provided & properly installed.
Verify piping leak/pressure test, flushing done.
The routing of the piping is under allowable
limit for specified operation/yard standard.
 Installation Verification
Electrical:
Visual inspection for complete & correct
installation.
Verification of cable & accessories types.
Installation & continuity testing of cables.
Megger/Insulation testing of equipment's.
Earthing checks.
 Operational Performance
Instruction from Original Equipment
Manufacturer(OEM) will be referred under
individual discipline.
Pre-checks to be conducted per specifications.
The system will be checked for safety function
operation .
Results tabulated & compare with set standard
values.
If outcome within specification range, system will
be integrated & performed for its function.
 Functional Performance
All the mechanical & electrical devices to be
operated together to achieve intended output
from the system.
The out put from the system tabulated &
compared with standard operation datas.
If required the tuning/modification has to be
performed under allowable limit to get actual
figures.
Tools
Tools
 Safety - Lockout/Tag out:
Electrical:

Piping:
 BALLAST & PRELOAD SYSTEM

BALLAST & PRELOAD SYSTEM FUNCTION :

The purpose of Ballast & preload system is
achieving/ maintaining proper trim and
stability of the vessel and preload the vessel to
simulate the maximum leg load before jacking
up.
 BALLAST & PRELOAD SYSTEM
P&ID:
 BALLAST & PRELOAD SYSTEM
Installation Verification & Operational function:
Mech. Completion Report:
Ballast & G.S. pump
Submersible pumps
Piping Completion Report:
Ballast & preload piping
Accessories
Pressure test & flushing.
 BALLAST & PRELOAD SYSTEM

Electrical Completion Report:

440V/220V Transformers
Main Switchboards
Control Panel & Starters
Motors
Tank Completion Report:
Level Sensors
Tank final cleaning & man hole cover closing.
 BALLAST & PRELOAD SYSTEM

Line Tracing:
Check pipe system to ensure compliance with
approved piping P&ID drawing.
Verify the valves dimension and flow direction
is correct.
Confirm overboard discharge valves are
tested with Class certificate.
Check the fittings, strainers, accessoriesfor
proper installation and ensure space for
maintenance/operation.
 BALLAST & PRELOAD SYSTEM

Confirm correct marking/name plate of valves

and ensure valve operation. Put lock out/Tag
out where necessary.
 BALLAST & PRELOAD SYSTEM

Check name plate data of pump (Ballast, GS

and Submersible Pump) for specification.
Check bolt foundation, free rotation and
alignment of pumps before starting
 BALLAST & PRELOAD SYSTEM

Ensure that the cables are connected or

termination to starter, motor, pressure switch
and control panel are correct & tighten.
Perform Megger test on motors and starters.
 BALLAST & PRELOAD SYSTEM
Ballast & GS pump operation:
Close discharge valve, open sea chest valve to check suction
line .
Release air inside suction pipe by strainer air vent at Suction
strainer (ensure element filter available). And release air
inside pump housing by pressure gauge connection.
Open up discharge valve & line up system to Over board valve
( in this line all valve must be opened)
Free Turning shaft of Pump by hand and make sure pump
condition in normal working condition.
Check cable connection from starter panel to motor with good
condition & tightened properly.
check insulation of motor.
 BALLAST & PRELOAD SYSTEM

Ballast & GS pump operation:

Power up the starter panel, check Voltage/Ampere of input
supply.
Close CB to supply power to motor.
Press start/stop button to run/stop motor (running time 1-2 s)
and check pump rotation direction (ensure rotation of pump
is correct per pump specification).
Press start button to run pump about 5-10 minute to check
and record Suction/discharge pressure, starting/running
current, temperature of Pump/Motor. Check piping leakage
and function.
 BALLAST & PRELOAD SYSTEM

Ballast pump and General Service Pump will be taken suction

from Sea chest (or any preload tank had filled) and discharge
to other preload tanks (as test protocol). Record all pumps
suction and discharge pressure.
No From To Pump Results
1 Sea chest Ballast/ Buffer 1S Ballast Pump
2 Ballast/ Buffer 1S Ballast 1P Ballast Pump
3 Ballast 1P Ballast 2S Ballast Pump
4 Ballast 2S Preload TK 2P Ballast Pump
5 Preload TK 2P Preload TK 3S Ballast Pump
6 Preload TK 3S Preload TK 3P Ballast Pump
7 Preload TK 3P Preload TK 4S Ballast Pump
8 Preload TK 4S Preload TK 4P Ballast Pump
9 Preload TK 4P Preload TK 5S Ballast Pump
10 Preload TK 5S Preload TK 5P Ballast Pump
11 Preload TK 5P Preload TK 6S General Service Pump
12 Preload TK 6S Preload TK 6P General Service Pump
13 Preload TK 6P Preload TK 7S General Service Pump
14 Preload TK 7S Preload TK 7P General Service Pump
15 Preload TK 7P Preload TK 8S General Service Pump
16 Preload TK 8S Preload TK 8P General Service Pump
17 Preload TK 8P Preload TK 9C General Service Pump
18 Preload TK 9C Preload TK 10C General Service Pump
19 Preload TK 10C Overboard General Service Pump
 Troubleshooting Commissioning

Trouble shooting is a form of problem solving,

often applied to repair/modify failed device,
equipment or operation.
No power to motor :
Check power connection, fuse & circuit
breaker.
Loose/faulty capacitor.
Check motor winding & measure resistance.
Apply power, check voltage at motor terminal
should be in range of 10% of normal voltage.
 Troubleshooting Commissioning

Few general trouble shooting method as below,

Pump cannot take suction:
Check suction pipe to find any blanking (suction pressure
deep vacuum -0.5~ -07 bar)
Check any leakage on the suction line (suction pressure 0 ~ -
0.1 bar).
Check any foreign object in side impeller& pump housing
Air remain inside pump housing/ suction line.
 Troubleshooting Commissioning

Valve not open/close properly:

Damaged Spindle or valve seat.
Stopper pin not removed/lost.
Check for limit switch function.
 Troubleshooting Commissioning

High pressure on system:

Blanking/choke on the discharge line
Valve/pipe accessories not functioning or wrong direction.
Air vent pipe of tank have not remove blank after test.
 Troubleshooting Commissioning

Pump working with low capacity:

Foreign object in side impeller or pump housing.
Size of Suction/discharge pipe is not comply with pump
capacity.
 Troubleshooting Commissioning

Pump high vibration:

Pump foundation too weak
Bolt of foundation have not tighten properly.
Pump Misalignment
Pipe routing to much short bench

WP_20130825_016.mp4
 Deserved Improvement!!!

Climbing on equipment to carryout job

resulting damage in machinery parts
 Deserved Improvement!!!

Need standard way of hose & cable

arrangements during working onboard.
 Deserved Improvement!!!

Clogged filter & fuel oil pump Insufficient

flushing
 Deserved Improvement!!!

Improper method of filling oil & coolant-

overflow
 Deserved Improvement!!!

Water inside crank case due to ingress of

cleaning water.
 Deserved Improvement!!!

Welding slag inside turbocharger.

Lack of support on exhaust line resulting stress
on bellow.
 Deserved Improvement!!!

Unremoved protection end caps

 Deserved Improvement!!!

Damaged equipment parts after installation

due to improper material handling.
Thank You