Alpha International Consultancy &

Training LLC
Operations & Safety

Gas Processing
Course

Part
Prepared by
Process Plant Commissioning and
Hamdy Ahmed Abd ElStartup
Rahim

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Introduction

The commissioning phase follows the construction phase and

results in an operational plant, i.e. all components and equipment
that make up the plant are tested and verified to be in accordance
with their design intent, operating and maintenance procedures are
available and in place and the operation staff able to operate a fully
operational facility.
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Approach to Commissioning
The Commissioning Phase can be split into 5 distinct activities that are
usually performed in chronological order

Factory Acceptance Testing FAT

Mechanical Completion (Post-installation Testing)

Pre-Commissioning

Commissioning

Start-Up
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Factory Acceptance Testing (FAT)

The intention of Factory Acceptance Testing is to maximize

Mechanical Completion, Pre-Commissioning, Commissioning and
Performance testing activities of Vendor Packaged equipment,
offsite prior to release and shipment to site.

This includes running the package around a significant portion of

the operating envelope using simulated media, temporary supplies
and maximum control simulation where necessary in order to
confirm that the package will function correctly and meet design and
field conditions.

Vendor packages will undergo acceptance testing at the

manufacturer's premises. These tests will be attended by members
of the Project and Operations teams, in accordance with a FAT
Program.

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Factory Acceptance Testing (FAT)

FAT should be witnessed and accepted by the discipline

commissioning engineers, package engineers and/or third party
inspection services at the manufacturers site.

Copies of the completed Factory Acceptance Test (FAT) procedures

and associated acceptance certification should be made available to
the Commissioning Manager complete with all deviation requests,
release notes and outstanding punchlist items.
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Factory Acceptance Testing (FAT)

Manufacturers drawings, O&M Manuals and certification books, etc,

should be issued in a timely manner to support site installation,
commissioning and handover to operations.

The vendor should provide SAT procedures that will be

implemented on site and verify that the equipment/software has
been assembled/loaded and tested to the requirements of the
supply contract.

The SAT procedure will be accepted by the respective

commissioning engineers prior to commencing pre-commissioning
activities on site.

Hamdy Ahmed

Process plant Commissioning and

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ALPHA

The objectives of the FAT

Test the equipment to a required specification or standard, as

agreed between project and vendor

Ensure operability and maintainability of the equipment

Gather information and familiarity for use in preparation of

commissioning and operating procedures.

A key output from the FAT will be the preparation of a draft

Commissioning procedure, including the provision of appropriate
vendor data in a format usable by Project documentation systems.

Development of the Operations team in the operation and

maintenance of each equipment package

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Commissioning Phase
Size of the Task

The plant equipment will be divided into manageable "chunks" to

allow a structured completion of the Construction and
Commissioning phases, it is called systems/subsystem

System limits will be established with the systems / sub-systems

being uniquely identifiable via the Work Breakdown Structure sheet.

e.g. The Air compressor will be handed over as a complete system

(No. 70A) but will comprise several sub-systems (No. 70A-1, 70A-2,
70A-3, 70A-4, 70A-5 and 70a-6) which will facilitate the structured
completion of Construction and Commissioning activities.

Hamdy Ahmed

Process plant Commissioning and

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ALPHA

Size of the Task

Each system will be clearly defined and marked up on the relevant

Drawings.

Each System was divided into disciplines indicating the

specialization (Civil works, Piping, Static Equipment, Electrical,
Instrumentation, Rotating Machinery, Safety).

Each system shall be checked by disciplines and tested as per the

relevant commissioning procedure described hereinafter by
contractor and commissioning integrated team.

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Work Breakdown Structure WBS

Definition

The Work Breakdown Structure is a Construction / Commissioning

control tool the purpose of which is to provide a structured system
of codes for the sub-division of the works cope. This coding
system will facilitate the planning, execution, reporting, certification
and handover of the plant by providing a common means of
identification of components and equipment.
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Work Breakdown Structure WBS

Objectives

It is the objective of the WBS system to permit planning and

reporting

of

all

aspects

of

the

Project

Construction

Commissioning execution on the basis of summarizing the status

of any part of the work scope.

It is important that this control tool enables the majority of work to

be completed efficiently while allowing for the timely completion of
systems / sub-systems in the sequence required by the
commissioning program.
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Process plant Commissioning and

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Work Breakdown Structure WBS

Objectives

The objectives of the WBS for construction are to enable planning

and scheduling of the construction works on a mass-fill basis in an
efficient manner.

The objectives of the WBS for Function Testing is to facilitate

planning and scheduling of the change over from construction by
area priority to drive subsystem completion by discipline in
preparation for commissioning.

The objectives of the WBS for Commissioning are to ensure

completion of function testing in a sequence to facilitate the
planning

of

commissioning,

completed systems.

certification

and

handover

of

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ALPHA

Process plant Commissioning and

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Work Breakdown Structure WBS

Development of the WBS

It is also important that the WBSis defined in a manner to suit the

requirements of all parties involved in the project. In this respect
the system limits shall be developed by the Commissioning
Manager and agreed with the Construction Manager and
Completions Engineer prior to implementation. The development
and implementation of the WBS will allow the smooth transition
between

Construction,

Commissioning

and

Handover

to

operations.
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Process plant Commissioning and

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ALPHA

Classic Commissioning Team

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ALPHA

DEFINITIONS
Means the assigned person(s) to Coordinate the pre
commissioning and cooperate to the commissioning
Commissioning Manager
activities
With all involved parties until "Ready for
Commissioning"
Site Manager

Integrated Team

Is the main contractor Site Construction Manager

responsible for construction
A team formed from Owner company representatives and
main contractor for checking and testing the Plant
systems.
Commissioning Integrated Team ( CIT )

Part of the System indicating the specialization ( Civil

Discipline
works, Piping, Static Equipment, Electrical,
Instrumentation, Rotating Machinery, Safety).
Means any person representing the firm who have
Supplier Representative supplied packages and/or main items and/or minor items,
which are part of the plant.

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Mechanical
Completion

Construction
Completion

Process plant Commissioning and

Startup

ALPHA

The Plant is Mechanically Completed when all the installation

works and the relevant pre-commissioning have been carried
out. Minor items possibly not completed, but not affecting the
running of the Plant shall be listed in the Punch List that shall
not hinder the certificate of the mechanical completion and
carrying out of the commissioning and further activities.
Transit phase when Integrated Teams check the completeness of
Construction works and notify that the Discipline (X) is "Ready
for Pre-commissioning activities.

Pre-commissioning

Pre-commissioning activities are the non operating adjustments

and cold alignment checks.an activities shall be managed by
Commissioning Integrated Team ( CIT).

Punch List

Means a list of deficiencies identified during final inspection

and check-out prepared by Main contractor and/or the integrated
team comprising items which must be finalized by the
contractor
prior to issue of the mechanical completion certificate or, in

particular cases, prior to issue of the final certificates.

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Ready For Commissioning

The plant, or part thereof, is Ready for

Commissioning, when the plant or any part thereof
has been erected in accordance with drawing,
specifications, instruction and applicable codes and
regulations and when the pre-commissioning
activities detailed completed and duly certified by
the integrated team.

System

Means a part of the plant designated from the

applicable P&ID diagrams for separately
performing pre-commissioning.
Each System was divided into disciplines
indicating the specialization (Civil works, Piping,
Static Equipment, Electrical, Instrumentation,
Rotating Machinery, Safety).

Site Quality Assurance

Coordinator

Contractor QC representative on-site and

responsible for ensuring that all and inspection
were correctly carried out and punch listed during
the pre-commissioning phase.

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Documents

Discipline Ready for Pre-commissioning Notice. (DRPN)

Discipline Mechanical Completion Notice.

System Mechanical Completion Notice.

Mechanical Completion Certificate.

Punch list items.

Discipline Ready for Commissioning Notice (DRCN)

Inspection and Test Report. (ITR)

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Mechanical Completion.
Mechanical Completion means the System or Sub-System is:
1- Physically Complete ( Conformity Check)

Constructed, Installed and connected as per design.

Everything is checked, in working order.

lubricants are added to machinery.

equipment is aligned.

operability checks have been performed.

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Mechanical Completion.
2- Tight
There is no loss of pressure or leakage from equipment, piping, joints,
etc
3- Functional
can operate as intended.
4- Tested
Equipment has been successfully inspected, tested and certified as
required.

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Mechanical Completion.
5- Safe
The facilities are inherently safe and all systems for the protection of
personnel, environment and property are installed, operational and
documented
6- Clean
The facilities have been flushed, are clean, dry and have the
necessary temporary equipment installed ready for Commissioning.
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Mechanical Completion.
Inspection and testing activities performed to achieve Mechanical
Completion by System or -Sub-System are:

Carried out on a single discipline basis.

Require no systems to be energized

Include specific tests by discipline.

Carried out using 'SAFE' Fluids where necessary

All tests are documented on type A ITR's and the status of

completion recorded within and monitored by the Completions &
Certification Management System (CCMS).

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Mechanical Completion Items.

1- Electrical

Verification of manufacturer's equipment and certification details

against

design specifications including Hazardous Area and IP ratings

Completeness of Installation against the approved design

Insulation Resistance testing Point to point testing

Protection Relay Tests and lighting system

Continuity testing and attenuation measurement

Earth Loop Impedance tests

Earth Bar resistance checks

Over potential (Hi Pot) testing

Verification of Heat Tracing Installations

Communications equipment testing

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Mechanical Completion Items.

1- Electrical

Example of Earth Loop tests

1Check and inspect the earth system connections.
Check for continuity of the main earth system loop and continuity
2
of the taps of equipment.
3Check earthing resistance.
4Check of earthing connection to equipment rightness.
5

Check of adequate mechanical protection of earth wire (if

required).

6Continuity test for earthing mesh branches.

Earth grid and ground loop wire sizes (electric and instrument
7
grounding system).

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Mechanical Completion Items.

2- Instrumentation / Control / Fire & Gas / ESD

Verification of manufacturer's equipment and certification details

against design specifications including Hazardous Area and lP
ratings

Completeness of installation against the approved design

Calibration of instrument devices and equipment

Attenuation, continuity testing of fibre-optic cables

Calibration and cycling of Control Valves

Relief Valve testing

Pressure testing of impulse pipe and tubing

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Mechanical Completion Items.

2- Instrumentation / Control / Fire & Gas / ESD

Example
1Instrument tagging.
2Model number and instrument classification.
3Size and connections.
4Material of construction.
5Instrument range and calibration.
6Valve action and air/electrical failure positions

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Mechanical Completion Items.

3- HVAC

Verification of manufacturer's equipment and certification details

against design specifications including Hazardous Area and IP
ratings

Completeness of installation against the approved design

Alignment of motor and fan drives

Mechanical operation of linkages and damper blades

Confirmation of correct airflow direction in pre-heaters

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Mechanical Completion Items.

4- Mechanical

Verification of manufacturer's equipment and ancillaries against

design specifications

Completeness of installation against the approved design

Bore scope inspections

Rotational checks

Equipment alignment checks

Firefighting equipment inspection

Lifting equipment checks

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Mechanical Completion Items.

5- Piping

Completeness of installation against the approved design

Non-destructive examination

Flange and nozzle alignment checks

Bolt tensioning

System flushing

Hydro-testing

Re-instatement

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Mechanical Completion Items.

5- Piping

Coating systems checks and pipe marking

Pipe support checks

3D laser survey results available for items requiring Dimensional

Control

Chemical cleaning

Pickling

Vacuum/air drying

Installation of temporary strainers

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Mechanical Completion Items.

5- Piping

Example 1 Vessel
1Conformity with project documentation.
2Pressure, temperature, rating.
3Nozzles, sizes and orientation.
4Internals: types, dimensions, metallurgy and installation.
5Instrument nozzles and types.
6Ladders, platforms, walkways: Location, size and accessibility.
7Nameplate information/data.
8Grounding connections.
9Vents, drains, relief valves provided as specified.
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Mechanical Completion Items.

5- Piping

Example 2 Pipe
1

Conformity with P and I flow diagrams.

Size.

Pipe: flanges, gaskets, fittings, valves in conformity with specified

piping classes

High point vents and low point drains.

Pipe supports and spring hangers.

Flange bolting tightness: nuts, gaskets and bolts are properly installed.

Orifice plates in correct location and direction.

Spacers and spectacles are properly installed at the open or blind
position

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Mechanical Completion Items.

6- Structural

Completeness of installation against the approved design

Non-destructive examination

Coating systems checks

Pipe support checks

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Flushing or blowing the plant

Small pieces of mill scale, weld rod stabs, weld spatter, insulation,
paper, wood and other debris are sometimes unavoidably left in
piping and equipment on completion of construction.

A systematic program for flushing with water or blowing with air will
eliminate most of the debris that might obstruct control valves and
orifice plates restriction orifices or damage machinery.

The flushing and cleaning entails whatever work is necessary to

obtain a clean unit ready for process operation. Part of this work
can be accomplished after hydraulic test execution and before final
reinstatement of the piping.

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Recommendations

Only fresh water and compressed air should be used.

Dirties and debris should be flushed from the unit and not into it.

Water is supplied with temporary flexible hoses. Prior to flushing,

make a manual cleaning to minimize obstruction.

The P&I Diagrams are used to prepare the flushing sequence and
to follow the progress of flushing. Finally, manual fine cleaning may
be necessary.

The fire water circuit should be washed.

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Recommendations

All control valves should be removed and flushed from both

directions using the bypass and in-line valves, if possible.
Otherwise, open and clean all control valves after flushing are
completed, where will be difficult to remove them.

Instruments must be disconnected or isolated. Restriction orifice

and rotameter must be taken away, if have been installed.

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Recommendations

Circulated flushing of the piping system within the plant may be

carried out, where it is possible. If water circulated flushing, using
process pumps, is applied for system cleaning, special care for
over load trip must be taken '90due to higher density than design
condition. Provisional strainers are installed and periodically
cleaned. Spraying nozzles must be installed after relevant lines
have been flushed to avoid clogging. If necessary, take out the
flapper of check valves (previous check of the availability of spare
gaskets).
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Recommendations

Vessels with de-misters or any other internals must be flushed

from the bottom taking into consideration the water level. It's better
to install de-misters and packing after flushing / air blowing.

Internal man-ways have to be installed after flushing/air blowing of

columns with trays.

Lines connected to vessels without internals can be flushed into

the vessel itself. After the flushing, the vessel must also be
cleaned.

Check that stroke movement; of any valve that was cut in during
the flushing, are free and complete.

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Recommendations

All blinds inserted into lines or equipment must be recorded, and

drawn out after flushing. The water should be drained from every
low point.

Use compressed air for piping blow down after flushing.

Special attention must be paid to certain piping systems such as

lubricating oil and mechanical seal circulation systems where small
orifices and openings are present. It may be necessary to
dismantle the piping to clean it mechanically or by pickling. Once
these systems are clean, they must be kept clean to prevent
repetition of the cleaning operations. These specialized systems
are the Supplier responsibility and normally are cleaned prior to
shipment. If further cleaning has to be done, it shall be conducted
by Supplier representative instructions and responsibility.

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Recommendations

For temporary flushing, use compressed non- asbestos gaskets.

Insert proper gasket only for the final re-assembling of the unit.

Final reinstatement of piping after flushing/blowing/cleaning

activities shall be supervised by Commissioning Integrated Team
(CIT) engineers to report the conformity with the design.

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Pre-commissioning.
Pre-Commissioning means the System or Sub-System is:
1- Physically Complete
The System/Sub-System has been constructed, installed and tested
under power in accordance with the design documents, Vendor
documents and other applicable documents as required.

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Pre-commissioning.
2- Tight
There is no loss of pressure or leakage from equipment, piping, joints,
etc.. during running
3- Functional
Can operate and running as intended.
4- Tested
Equipment has been successfully energized and tested.
.

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Pre-commissioning.
5- Safe
The facilities are inherently safe and all systems for the protection of
personnel, environment and property are installed, operational and
documented
6- Complete
Everything is tested, in working order, lubricants are added to
machinery, equipment is aligned, operability checks have been
performed and the equipment is ready for Commissioning.

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Pre-commissioning.
Inspection and testing activities performed to achieve System/Sub
System Acceptance are:

Carried out on a single discipline basis.

Requires energized checks on systems

Include tests by specific discipline.

All tests are documented on type "B" ITR's and the status of
completion recorded within and monitored by the Completions &
Certification Management System (CCMS).

Pre-Commissioning consists of powered up (energized) checks

and proves the correct operation of the equipment under
simulation prior to the introduction of utility media or non
hydrocarbon process fluids.

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Pre-commissioning Items.
1- Electrical

Energize Electrical systems

Switchgear & MCC checks and Function Checks

Alarm, Trip, ESD and Control Settings Pressure and Power

frequency testing Voltage, polarity and phase rotation checks

Uncoupled / no load motor runs and performance tests

Breaker operation

Motor runs

Load Testing and lighting system test.

Run tests and energized rotation tests of electrically driven motors

Auto / Manual operation

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Pre-commissioning Items.
1- Electrical

Example of Switchgear & MCC checks .

1Complete component and interconnection and cable terminations inspection according to

manufacturer's final approved drawings.
2Inspection, testing and functional check shall be according to supplier instruction.
3Make all necessary adjustment to switch gear
4

and motor control center equipment.

Test and calibration of all switch gear relays (using primary and Secondary injection as applicable),
metering, lights, indicators, space heater, and check proper coordination and setting.

5Check the phase sequence and polarity of all equipment

6Functional check of all motor starters, circuit breakers' incomers, outgoing Feeders and bus ties.
Perform operational tests on all motor control circuits, interlock system, indicating lights, meters
7and all other devices.
Check circuit breakers, motor starters, relays and other equipment for loose connections (both
8mechanical and electrical). Verify that contacts and working parts are correctly aligned and free
from dust and foreign matter.
Inspect circuit breakers with adjustable trips, checking both thermal (if any) and magnetic settings
for proper protection. Also check thermal overload relay settings according to vendor documents.
10Check and sequence test for alarms, interlocks, auto-transfer, ... etc.
9

11Functional checking of switchgear and MCC from remote locations such as Control Room.
12Energizing the substation for readiness of plant commissioning and start-up.

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Pre-commissioning Items.
2- Instrumentation / Control / Fire & Gas / ESD

Energize Control systems

Loop testing Analogue input / output tests

Digital input / output tests

Frequency tests

Auto / Manual switching

Control System configuration

System integrity testing (i.e. Communications between Control

Systems)

Control panel functional testing

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Pre-commissioning Items.
2- Instrumentation / Control / Fire & Gas / ESD
Example
1Level DP transmitters.
2Pressure transmitters.
3Temperature transmitters.
4Transducers.
5Petitioners.
After completion of this work QA/QC stickers should
7be fixed on the instruments, then, the check form
shall be signed by all concerned parties.

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Pre-commissioning Items.
3- HVAC

Damper and actuator Operation

Temperature device operation

Ductwork Leak Tests

Air Conditioning equipment operation

Operation of Fans and Air Handling Units

Airflow and balance testing

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Pre-commissioning Items.
4- Mechanical/Piping
Installation of temporary strainers
Load testing of Lifting equipment
Pre-Commissioning of Lubrication, Cooling, Fuel, Seal Gas and
Hydraulic systems, including flushing, circulation, draining and refilling as required by the specification
Coupling of rotating equipment
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Pre-commissioning Items.
4- Mechanical/Piping
Vibration and Noise testing
Mechanical seal integrity checks
Final inspection of vessels
Critical Valve Testing
Relief Valve re-setting

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Pre-commissioning Items.
6- Common

Package equipment function and energized tests Removal of

internal preservation

Removal of temporary bracing

Activation of all piping spring hangers

Testing of Lifting Equipment for 3rd party inspection Charging of

systems

Loading of Selected Chemicals

Discharge / retention testing

Verification of media quality

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commissioning
Commissioning means:

The plant systems and sub-systems operate together in an

integrated manner in accordance with the design objective and
meet the performance criteria regarding operational requirements
and occupational safety requirements

The documentation is adequate for full facility operation, describing

accurately the plant and procedures.

Staff skills are appropriate to operate the plant in accordance with

competency requirements, occupational health and safety
requirements.

The new facilities perform as designed

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commissioning

The new facilities interface appropriately with the existing facilities

All Commissioning activities are performed using 'SAFE' fluids with

the exception of Compressor Surge Mapping

Commissioning procedures will be produced and contain detailed

step by step instructions that will be followed when starting for the
first time and placing equipment and systems into operation. Once
the procedure has been successfully completed the system is
deemed to be fully compliant with the design

the commissioning activities will prove the new facilities interface

with all other associated systems and bring the entire plant to a
state of readiness for normal operation and handover.

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Commissioning Items.

Gross Air Leak Testing

Nitrogen or Helium Leak Testing

Installation of temporary systems if required for commissioning use

and start up

Identification and charging of first fills.

Vendor control

Cause and effect logic tests Control logic checks Safety Systems
testing DCS functional testing PLC Functional tests ESD
Functional testing
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Commissioning Items.

Fire & Gas Functional testing

Optimization of room pressure and temperature

Punch Listing

Test Runs

Integrated Runs

Dynamic Instrument testing

Preservation and Maintenance

Surveys

Operator Training
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Start-Up
Start-Up means:

The initial introduction of Hydrocarbons (LIVE fluids) into the

completed systems and ramp up of production to a steady state.

Pre-requisites for Start-Up are;

The state of a system / sub-system where by all Mechanical

Completion Certification has been issued; Pre-Commissioning and
Commissioning activities are complete such as inerting, drying,
function testing of instrument, equipment and safety systems, and
integrity leak testing have been completed.

No open punch list items remain that will be detrimental to the

personnel safety or safe operation of the system.

Start-up Authorization has been received where required from

Operations.

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Start-Up Items.

Initial introduction of Hydrocarbons, stabilization and short running

Check pipe supports, hangers, guides and anchors under running

condition

Check noise levels

Mini shutdown for the removal of temporary strainers and blanks

Restart

Progressive increase of throughput

Phased handover to Operations

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System Example
The following is an example of a system / sub-system breakdown
into system limits.
The primary system is 70A and is made up of sub-system 70A-1,
70A-2, 70A-3, 70A-4, 70A5 and 70A-6 as shown in the extract from
the Work Breakdown Structure below. PI&D's will be used to highlight
the System and Sub-system Limits

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System Durations
Inspection and Testing man-hour can be allocated to each required
ITR thus giving a breakdown of the duration involved for the
Inspection and Testing of all system equipment.
This information is utilized for scheduling each phase of the
Construction and Commissioning activities.
The table below details each Inspection and Test required for the
sample Air Compressor System above.
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ITR
E01-2A
E02A
E09A
101A
103A
105A
106A
S01A
X03A
MOIA
M03-IA
M03-2A
M05A
M08-1A
M12A
M20A
M24A
M29A
M31A
M33A
M30A

Process plant Commissioning and

Startup

ALPHA

No. REQUIRED MANHOURS PER ITR TOTAL

DESCRIPTION
LV CABLE
3
2
6
ELECTRICAL MOTORS
2
4
8
CONTROLPANEL
3
4
12
INST. CABLE
16
4
64
PSV INSP / CAL
4
6
24
INST. INSTALLATION
20
2
40
INST. PANEL/ JB
4
8
32
STRUCTURAL MEMBERS
1
4
4
PAINTING
1
4
4
PRESSURE VESSEL
1
24
24
HEAT EXCH / CLR
2
24
48
AIR COOLER
1
12
12
FILTER
6
a
48
COUPLING ALIGNMENT
2
24
48
I'AISC EQUIPMENT
6
2
12
PACKAGE UNIT
2
24
48
BOLT TENSION
4
4
16
BASE PLATE
2
24
48
EQUIPMENT PACKAGE
1
12
12
EXPANSION VESSEL
1
12
12
VALVES
24
4
96

66

Hamdy Ahmed

ITR
CW01A
CW02A
CW04A
CW05A
CW06A
CW07A
A03A
P01A
P02A
P03A
PO4A
P05A
E05B
E06B
101B
102B
105B

Process plant Commissioning and

Startup

DESCRIPTION
COMPACTION TESTING
CONCRETE POUR
FOUND'N GROUTING
FOUNDATIONS
FOUND'T COATING
FOUND'N PRE-INSPECT
CLADDING / INSULATION
PIPING PKG INDEX
INSTALLATION CHECK
TEST EQUIP. CAL. CERT
FLUSH & TEST
RE-INSTATEMENT
CONTROLPANEL
ELECTRIC MOTORS
VALVES (ON/OFF/ESD)
CALIBRATION PSV
DIGITAL 110 CHECK

No. REQUIRED
2
2
2
2
2
2
1
1
1
1
1
1
1
3
2
4
10

ALPHA
MANHOURS PER
TOTAL
ITR
4
8
4
8
4
8
4
8
4
8
4
8
4
4
3
3
4
4
2
2
4
4
4
4
4
4
8
24
12
24
6
24
4
40

67

Hamdy Ahmed

ALPHA

Process plant Commissioning and

Startup

ANALOGUE 110
106B CHECK
8
6
48
LOOP FUNCTION
107B
1
10
10
TEST
111B MOTOR CONTROL
3
24
72
M01 B PRESSURE VESSEL
2
12
24

M03B HEAT EXCH / CUR

1
12
12
M09-1B COMPRESSOR
2
36
72
M10B GEARBOX UNIT
1
4
4
M25B MISC EQUIPMENT
1
12
12
INSTALLATION
POIB
1
2
2
CHECK
The number of Engineers and Technicians required for the system can

TOTAL
1059

be estimated to be:
Electrical = 2

Instrument = 4

Mechanical = 2

Piping = 2

Civil = 1

Structural = 1

Painting = 1
Total = 14

Architectural = 1
68

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

System Durations

Assuming a 10 hour working day.

The duration for Inspection and Testing activities for the above
system would be 8 days. The commissioning procedure including
vendor support would add a further 4 days to the overall duration
for this system.

Thus giving a total duration of 12 days, which does not include the
time required to complete the hand over process.
69

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Vendor Site Support

Vendor call off for site support will be authorized by the PMT. Vendor
mobilization to site will be according to the stipulations of the
individual Vendors call off contract and the terms and conditions of
The Vendor Service Contract if applicable.
Vendor Site Induction
Upon arrival at site location the Vendor Representative will report to
the Construction or Commissioning Manager who shall organise the
site induction in accordance with rules and regulations applicable.
This induction will include, when relevant, training on the Permit to
Work system.

70

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Vendor Site Support

The Work
The relevant Discipline Commissioning Engineer will be responsible
for the vendor carrying out the work within the time forecast.
The Construction / Commissioning Manager will be responsible for
the
provision of any services or support required by the vendor to carry
out the work in order to ensure there is no delay.
Forecast and Budget
The need for vendor assistance shall be pre-planned and be
facilitated by having in place vendor call-off contracts against those
vendors whose assistance is anticipated, or contingency against

71

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Vendor Site Support

Vendor Site Visit Close-Out
Upon completion of the work to the satisfaction of the relevant
Commissioning Engineer and the Construction / Commissioning
Manager the Vendor Representative shall complete all final time
sheets and reports and obtain the necessary approval signatures.

72

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Commissioning Schedule

The schedule for testing will be according to the construction and

installation program. An extensive inspection and test program is
planned for the new facilities and auxiliary systems. During the
pre-commissioning test phase, testing will be performed as system
MC hand-over from construction allows.

Key systems will be sequenced for completion and testing early

enough to provide necessary auxiliary services for testing and
operation of other systems.

Examples of such key plant systems are the electrical system and
compressed air system.

The sequencing of tests shall be such so that safety of the facility

is never dependent on the performance of untested systems, subsystems and components.

73

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

Preservation and Maintenance

The Preservation and Maintenance of installed, inspected and tested
equipment will remain the responsibility of the project until such a time
as the new facilities are handed over and accepted by Operations.
Equipment Preservation and Maintenance activities will be carried
out by the Commissioning Team and documented using specific ITR's
within the Completions Management system. Preservation and
Maintenance reports will form an integral part of the system hand over
dossier.

74

Hamdy Ahmed

Process plant Commissioning and

Startup

ALPHA

?Any Questions

75