Chapter 36: Precommissioning, Commissioning and Guarantee Run

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

Share this post