Chapter 36: Precommissioning, Commissioning and Guarantee Run - Mihir's Handbook of Chemical Process Engineering

36.1	Introduction	3
36.2	Definitions & Stages Involved	3
36.2.1	Definitions	3
36.2.2	Sequence of Activities	5
36.2.3	Management Issues	7
36.2.4	Technical Issues	7
36.2.5	Special Tip	7
36.3	Organogram for Startup	9
36.4	Precommissioning	10
36.5	Documentation Required by Process Engineer	11
36.5.1	Pre-Commissioning Procedures	12
36.5.2	Inspection and Testing	13
36.5.3	Clean Up Of Area	13
36.5.4	Site Preparation, Foundations and Structural Steel	13
36.5.5	Checking Plant against P&ID	13
36.5.6	Vessels and Tanks	14
36.5.7	Columns Inspection and Box Up	15
36.5.8	Heat Exchangers	16
36.5.9	Air Cooled Exchangers	16
36.5.10	Rotating Equipment	17
36.5.11	Electrical Motor Drivers	18
36.5.12	Pumps / Blowers	18
36.5.13	Compressors	19
36.5.14	Instrumentation (General)	19
36.5.15	Hydro Testing	19
36.5.16	Process Piping Flushing/Cleaning	21
36.5.17	Cleaning of lines and equipment	22
36.5.17.1	Flushing	22
36.5.17.2	Flushing Lines	23
36.5.17.3	Air Blowing	24
36.5.17.4	Dynamic Testing With Safe Fluids (Water Run)	24
36.5.17.5	Leak Testing	26
36.5.17.6	Leak Testing Procedure	26
36.5.17.7	Charging of Essential Utilities	27
36.6	Package Unit Pre-Commissioning	31
36.7	Pre-Commissioning of Electrical /Instrumentation Systems	31
36.8	Commissioning activities	31
36.9	Guarantee run	31
36.10	Budget allocation	32
36.10.1	Start Up Budget	32
36.10.2	Preliminary Estimate for Startup Costs	32
36.11	Time involved	34
36.11.1	Estimate for Startup Time	34
36.12	Checklists	34
36.12.1	Responsibility Matrix	34
36.13	Specific Procedures	40
36.14	Pre-Startup / Safety Review Checklist	49
36.15	Machinery Commissioning Checklist	53
36.16	References	56

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