Commissiong - The Final Frontier

Plants Commissioning Main Steps :

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#project #power #testing #precommissioning #commissioning #handover

Commissioning a project involves a series of steps to ensure that all systems and components are properly installed, tested, and verified before commercial operation.

The commissioning manager with his team shall estimate the work done by erection team several months, doing hard work, always with several hours a day to achieve on time the scheduling fixed by the company. At the end, the success is for all the teams. 

The following is a general procedure:

Classify the plant activities:

By system: Example in case of desalination plant: Intake SW, pretreatment, Filtration, Dosing, RO, Remineralization, BOP ( Air compressor, Diesel group, Firefighting system, tanks)

By specialty:

Civil work: Foundations, tanks, buildings, roads, etc.  

Mechanical: pumps, motors, valves, supports, piping, UF skids, RO racks,

Electrical: earthing network, transformers, Motors, GDE, routine cables, electrical panels, lighting,

I&C: Instruments, Junction boxes, instrument piping, DCS panels, valves, loop checks.

Chemical: dosing skids, analyzers, laboratory, chemical products

HSE: FFS, safety measures on site, IEP, ladders, platforms, access  

Quality: certify the assets installation, follow hydraulic test and flushing or blowing activities

Pre-commissioning activities : 

This involves a review of all project documentation, including drawings, hookups, specifications, and procedures. A site inspection is carried out to ensure that all equipment is properly installed and ready for testing.

Testing of individual systems: 

Each system in the plant is tested to ensure that it meets the required specifications. This includes testing of the electrical, mechanical, and control systems.

Every asset shall have its proper inspection point document

Every provider shall communicate the test procedure to follow on every step: cold and hot commissioning

Testing of subsystems: 

After testing of individual systems, subsystems are tested once finished the flushing or blowing required. This involves integrating various systems to ensure that they work together properly. Example, UF skid,

Testing of the entire plant: 

After subsystems are tested, the entire plant is tested to ensure that it is operating correctly. This includes testing of start-up and shutdown procedures, load testing, and testing of emergency systems.

Contractual Performance test

Contractual Reliability test

Verification and acceptance : 

After all testing is completed, the plant is verified and accepted by the owner. This involves documentation of all test results and verification that all requirements have been met.

Handover: 

The plant is then handed over to the owner for operation.

After that, a warranty period is started for a period fixed in the project.