Commissioning Engineering!

The Commissioning physical scope of work consists of: 

• The dynamic verification of the elementary plant functions 
  
• The running-in and on-line tests of utilities system and the running-in and on-line tests with inert fluid of process system. 
  
• The Piping and Vessels Preparations 
  

From a methodological point of view, the Commissioning scope of work has been divided into four separate activities:

• Preliminary Checks and Pre-Commissioning witnessing 
  
• Functional Tests 
  
• Operational Tests 
  
• Piping and Vessels Preparations. 
  

All operations are organized by subsystem, following a sequence, identical to that of Pre-commissioning, which optimizes the start-up phase. Lastly, depending on the Hand-Over to Field Operation strategy, the Commissioning Team may operate a part of the installation, particularly the utilities.

(1) Preliminary checks 
The Preliminary Checks are the cross verification done by the Commissioning Team. They take place when a subsystem nears or reaches the Ready For Commissioning status, and consist of: 

• A physical check on site of the installation. 
• A thorough review of the Pre-Commissioning Dossier. 
  

At this stage, a number of new punch list items, discovered by the Commissioning team during their cross-checking of the plant are incorporated in the subsystem Punch list (agreed between EPC365 and Company). Once Preliminary Checks have been done, the PRC sheet can be issued (signed by each discipline commissioning representative); the RFC certificate is then countersigned by the commissioning representatives.

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(2) Functional tests 
These are the live tests performed on each instrument, telecommunication, and electrical, elementary function. For commodity, an item or group of items of equipment that performs an elementary function of the plant is named a Basic Function. It is the smallest equipment that can be subject to a commissioning operation. The functional tests are carried out in accordance with technical specifications, the results being recorded on Functional Test Sheets. 
There are no spot or random functional tests: every instrument, electrical, and telecommunication Basic Function of the plant is subject to one functional test, be it part of field or package equipment.

(3) Piping and Vessels Preparations (PVP) 
These are all the specific Commissioning activities required to prepare the piping network before the introduction of the feed stock into the Plant: 

• Leak test 
• Drying-out 
  
• Inerting  
  
• Loading of chemicals 
  

These are covered by specific procedures and reports. It may happen that some of these activities are not related to a single system or subsystem (the leak test, for instance, is carried out by level of pressure rather than by subsystem). A Task report may therefore be created to report the results, which are then referred to in all concerned subsystems commissioning dossiers.

(4) Operational tests 
Once all Basic Functions have been functionally tested, major equipment, system, subsystem or group of subsystems, is subject to an Operational Test, wherever applicable. It consists of bringing the system into operation under conditions as close as possible to normal with inert fluids, not only to live test the automated devices, controls, normal and shutdown sequences, but also to reveal possible mechanical or electrical faults (water tightness, vibrations, overheating, overloading, etc.) which may occur during prolonged normal use. 
Every operational test is a multi-discipline activity, conducted in accordance with an Operational Test Procedure (OTP), which has been established during the Commissioning preparation phase and approved by the GTIM. There is no standard OTP, since they vary with the plant.
Typical subsystems subject to an operational test are: fire water pumps, air compressors, power generation, ESD system, export pumps in recycle, process compressors in recycle (with air or nitrogen if possible, under gas after Start-up if not) etc. 
Prior to the preparation of Operational Test Procedures, acceptance criteria principle shall be defined if there is no contractual requirement (duration of test, number of cycles, etc.) and approved by Company. 
The operational test is the key commissioning activity. In any case, it shall be witnessed, followed, assisted and checked by Company and properly recorded. 

(5) Particularity to be considered for “live” Operational Tests 
Some package Operational Tests are to be performed under oil or gas after Start-up. Those tests shall be carried out under Operator control, with the assistance of the Commissioning Team. This policy should be defined at early stage and specified through the contract. If not, at the beginning of the detailed Engineering phase, the list of systems/package to be performed under oil or gas shall be defined and approved by Company. At the Ready for Start-up (RFSU) the Commissioning team shall identify the remaining Operational Tests to be carried out with hydrocarbons, under the control of the Start Up team / Field Operator. Remaining activities should not be recorded on the Punch List.

(6) Operation and maintenance during Commissioning 
During the Commissioning phase, certain equipments are required to be operated before hand-over to the Operator e.g. air compressors, generators, etc. TENDERER will ensure prior to start-up and to operate those equipments that all safety devices, logics and protections are available and reliable (ESD logic, F&G detection, Fire fighting system, Electrical protection.
Some other equipment need to be mothballed. By default, the Commissioning team shall perform the initial operation, maintenance and equipment preservation with the appropriate resources. Once a package or piece of equipment has been started, it may have to be operated during a short period by the Commissioning team. 
The Commissioning team shall submit the maintenance program to Company for APPROVAL before implementation by the Commissioning Team. This shall include but not limited to: 

• Routine visit 
• Lubrication schedule and substitute lubricant list if applicable 
  
• Fill in of log sheet for routine visit 
  
• Mothballing and de-mothballing procedures and check sheets 
  
• Provision of consumables and spare parts 
  
• Provision of manpower for work on shift if required, etc. 
  

Technical data base
All Basic Functions, grouped by subsystem, discipline and type of Basic Function, are listed in a Technical Data Base, which is therefore the exhaustive description of the physical content of all subsystems. It is the equivalent of the Status Index used for Pre-Commissioning.
The Data Base indicates, for each Basic Function, the type of Commissioning operation required, by reference to the task report form of this operation, and it also gives other relevant information (set points, drawings No., etc.).The completion date of each activity is also recorded, so that it is a working document used to follow up the commissioning progress.The Technical Data Base, main tool of the commissioning preparation and follow up, is established by the Commissioning Team by EPC365 during the preparation phase.

Punch list (during Commissioning)  
The subsystems punch list, once established at the Ready for Commissioning stage, is continually updated during the commissioning and Start-up operations, by adding all newly discovered items and deleting cleared ones. At the time of the Ready for Start-up, those new items discovered by the Commissioning team or the Operator team during their cross-inspection of the plant are included in the Punch list according to the Punch list general principle.

Commissioning dossier   
All documentation pertaining to the commissioning operations is compiled in a specific Dossier, arranged as the Pre-Commissioning dossier by: 

• System 
• Subsystem.