Pre Comm

PRECOMMISSIONING

DEFINITION: Testing of system components for DEFINITION: Testing of system components for continuity, operability and in case of process continuity, operability and in case of process plants, their ability to withstand operating plants, their ability to withstand operating pressures prior to the introduction of feedstock or pressures prior to the introduction of feedstock or other final products into the facilityother final products into the facility

• Activities are indexed/outlined in GI-2.710 Supp. 6Activities are indexed/outlined in GI-2.710 Supp. 6

• Responsibilities are outlined in GI-2.710 Supp. 6Responsibilities are outlined in GI-2.710 Supp. 6

• Precommissioning is divided into 9 categoriesPrecommissioning is divided into 9 categories

NINE TYPES OF PRECOMM ACTIVITIES

• GeneralGeneral

• Civil/StructuralCivil/Structural

• ElectricalElectrical

• PipingPiping

• Mechanical EquipmentMechanical Equipment

• Fire and Safety SystemsFire and Safety Systems

• CommunicationsCommunications

• Instrumentation and Control SystemsInstrumentation and Control Systems

• Catalyst, Chemicals and DesiccantsCatalyst, Chemicals and Desiccants

GENERAL

• ID of Equipment and Unit SystemsID of Equipment and Unit Systems

• Coating, Fireproofing, Insulation & CleanlinessCoating, Fireproofing, Insulation & Cleanliness

• Paving and FencingPaving and Fencing

• Leak Test of Piping & EquipmentLeak Test of Piping & Equipment

CIVIL & STRUCTURAL

• Sewer line and manhole inspectionsSewer line and manhole inspections

• Leak tightness & positive pressure testsLeak tightness & positive pressure tests

• Access platforms, ladders, stairs, walkwaysAccess platforms, ladders, stairs, walkways

• Flood Tests & Flow Tests per GIFlood Tests & Flow Tests per GI

• Access & Egress per SAES-B-054Access & Egress per SAES-B-054

• Valves and Instrument access per SAES-B-054Valves and Instrument access per SAES-B-054

ELECTRICAL

• Tests & Checks of electrical items per SA formsTests & Checks of electrical items per SA forms

• Megger testingMegger testing

• Check & Field Test temporary powerCheck & Field Test temporary power

• Calibrate, Set and Test relays, time delays, etc.Calibrate, Set and Test relays, time delays, etc.

• Operability of emergency systemsOperability of emergency systems

• ID, location and color coding of electrical controlsID, location and color coding of electrical controls

PIPING REQUIREMENTS

• Hydro Testing per SAES-A-004 & SAES-G-116Hydro Testing per SAES-A-004 & SAES-G-116

• Pre HydroPre Hydro

• Hydro TestHydro Test

• ReinstatementReinstatement

• Final Check outFinal Check out

• Identification, tagging and color-codingIdentification, tagging and color-coding

• Inspect hangers, supports, anchors and guidesInspect hangers, supports, anchors and guides

• Install corrosion probesInstall corrosion probes

MECHANICAL EQUIPMENT COVERED

• Air Fin CoolersAir Fin Coolers

• Boilers, Ductwork & StacksBoilers, Ductwork & Stacks

• CompressorsCompressors

• Cooling TowersCooling Towers

• Furnaces & Fixed HeatersFurnaces & Fixed Heaters

• Scales & MetersScales & Meters

• PumpsPumps

• TankageTankage

• TurbinesTurbines

• Vessels, Towers, Drums & ReactorsVessels, Towers, Drums & Reactors

• Heat ExchangersHeat Exchangers

• MixersMixers

• HVAC EquipmentHVAC Equipment

• Pressure Relief & DisposalPressure Relief & Disposal

• Miscellaneous Mechanical EquipmentMiscellaneous Mechanical Equipment

FIRE & SAFETY SYSTEMS

• Relief Valve Testing, Installation and Safety IDRelief Valve Testing, Installation and Safety ID

• Unit and Roadway Markings and IDUnit and Roadway Markings and ID

• Portable Extinguishers, Deluge/Sprinkler SystemsPortable Extinguishers, Deluge/Sprinkler Systems

• Safety Showers & EyewashSafety Showers & Eyewash

• Identification, tagging & mapping of equipmentIdentification, tagging & mapping of equipment

• Gas & Fire Detection & Fire Alarm SystemsGas & Fire Detection & Fire Alarm Systems

• Plant Alarm SystemsPlant Alarm Systems

COMMUNICATIONS

• OSPOSP

• TowerTower

• Buildings and Support UtilitiesBuildings and Support Utilities

• PowerPower

• Equipment, switches, alarmsEquipment, switches, alarms

INSTRUMENTATION & CONTROL

• Test of Piping and tubingTest of Piping and tubing

• Continuity and ID of LoopsContinuity and ID of Loops

• Protect and reinstate inline equipmentProtect and reinstate inline equipment

• Gauge InstallationGauge Installation

• Final Loop ChecksFinal Loop Checks

• Check alarms, computers, digital items & wiringCheck alarms, computers, digital items & wiring

• Analyzers installation and testingAnalyzers installation and testing

Catalyst, Chemicals and Desiccants

• Internal cleanliness checksInternal cleanliness checks

• Chemical Cleaning surveillanceChemical Cleaning surveillance

• Corrosion issuesCorrosion issues

• Lay-up ConcernsLay-up Concerns

• Valves, Pressure Vessels, Storage Tanks, Heat Exchangers, Fin Fan Valves, Pressure Vessels, Storage Tanks, Heat Exchangers, Fin Fan Coolers, Boilers, Compressors, Turbines, Diesel Engines, Pumps, Gears, Coolers, Boilers, Compressors, Turbines, Diesel Engines, Pumps, Gears, Transmitters, Transducers, Switches, Indicators, Orifice Plates, Control Transmitters, Transducers, Switches, Indicators, Orifice Plates, Control Valves, Thermocouples, Detectors, Controllers, Air Lines, Loop Checks, Valves, Thermocouples, Detectors, Controllers, Air Lines, Loop Checks, Instrument & Control Cables, Monitors, HVAC, Auto Transfer Switches, Instrument & Control Cables, Monitors, HVAC, Auto Transfer Switches, Battery System, LV/MV/HV Cables, Circuit Breakers, Transformers, Heat Battery System, LV/MV/HV Cables, Circuit Breakers, Transformers, Heat Tracing, Generators, Grounding System, Lighting, Busses, Motor Control Tracing, Generators, Grounding System, Lighting, Busses, Motor Control Centers & Gear, Relays, Switchgear, Surge Arrestors, Transformers, UPS Centers & Gear, Relays, Switchgear, Surge Arrestors, Transformers, UPS System & Buildings See System & Buildings See http://csd.aramco.com.sa/std/Web_Version.asp

• Outline Inspection responsibilities per ITP & ProceduresOutline Inspection responsibilities per ITP & Procedures

• Ensure adequate Inspection personnel for Precommissioning coverageEnsure adequate Inspection personnel for Precommissioning coverage

• Review/Approve/Verify all Quality Documents/Packages for Content. Review/Approve/Verify all Quality Documents/Packages for Content.

• Ensure installations and testing requiring Inspection coverage are complete Ensure installations and testing requiring Inspection coverage are complete per established checklists.per established checklists.

• Final Review & System Verification per ITP & signoffFinal Review & System Verification per ITP & signoff

• Ensure use of correct Precommissioning forms for Inspection related Ensure use of correct Precommissioning forms for Inspection related activities for Piping, Utilities, activities for Piping, Utilities,

HYDRO TESTING

• Ensure Hydrotest packages contain the requirements of Sch. Q, Att. VI (11 Ensure Hydrotest packages contain the requirements of Sch. Q, Att. VI (11 bullet items) bullet items)

• Ensure approved Hydrotest Procedures and adequate QC records and Ensure approved Hydrotest Procedures and adequate QC records and checklists are approved and followed related to Test Package Preparation checklists are approved and followed related to Test Package Preparation and approve Sample Test Packageand approve Sample Test Package

• Ensure Pre-Hydro Punch listing is organized and follows checklists to Ensure Pre-Hydro Punch listing is organized and follows checklists to assure adequate completeness of system prior to flushing and testing as assure adequate completeness of system prior to flushing and testing as outline in Hydro testing procedure.outline in Hydro testing procedure.

• Ensure lay-up, chemical cleaning and reinstatement procedures and Ensure lay-up, chemical cleaning and reinstatement procedures and checklists are followed.checklists are followed.

• Flanged connection and gasket installation Quality requirements are critical Flanged connection and gasket installation Quality requirements are critical and must strictly follow SAES-L-050 and approved procedures and Quality and must strictly follow SAES-L-050 and approved procedures and Quality Control checklists and formsControl checklists and forms

• Ensure Relief Valve Pop Testing and records prior to installation are Ensure Relief Valve Pop Testing and records prior to installation are complete per Schedule B, SAEP-319 & SA Form 3099 acceptance complete per Schedule B, SAEP-319 & SA Form 3099 acceptance requirements requirements

• Final Package Records Review & System Verification for Completeness Final Package Records Review & System Verification for Completeness before Final Acceptancebefore Final Acceptance

INSTRUMENTATION LOOPS INSTRUMENTATION LOOPS

• Loops to be Tested are Identified Loops to be Tested are Identified

• Development of Loop Package Development of Loop Package

• Review/Approve Sample Loop PackageReview/Approve Sample Loop Package

• Monitor Installation and TestingMonitor Installation and Testing

• Final Review & System Verification per ITPFinal Review & System Verification per ITP

MOTOR RUNSMOTOR RUNS

• Provide List of Motors to be TestedProvide List of Motors to be Tested

• Determine Motor Testing/Preservation Reqmts.Determine Motor Testing/Preservation Reqmts.

• Establish Precommissioning form RequirementsEstablish Precommissioning form Requirements

• Verify Associated Power and Instrumentation Verify Associated Power and Instrumentation Components are installed properly (RTDs, CTs, Components are installed properly (RTDs, CTs, Vibration Monitors, Cabling, etc.) Vibration Monitors, Cabling, etc.)

• Review/Approve Sample Motor Run Test PackageReview/Approve Sample Motor Run Test Package

• Witness 4-hour uncoupled Motor Run TestWitness 4-hour uncoupled Motor Run Test

• Final Review & System Verification per ITPFinal Review & System Verification per ITP

CONDUIT SEALSCONDUIT SEALS

• Provide List of Conduit Seals to be Poured Provide List of Conduit Seals to be Poured

• Share Lessons Learned with Advanced Share Lessons Learned with Advanced Video Presentation to Avoid ReworkVideo Presentation to Avoid Rework

• Review & Approve Special Process Control Review & Approve Special Process Control Procedure for Conduit SealsProcedure for Conduit Seals

• Monitor installation of Conduit SealsMonitor installation of Conduit Seals

• Final Review & System Verification per ITPFinal Review & System Verification per ITP

ENERGIZATION PACKAGESENERGIZATION PACKAGES

• Identify Systems to be Energized Identify Systems to be Energized

• Interface with Contractor to Establish Interface with Contractor to Establish Energization Package Content and Energization Package Content and Precommissioning Form RequirementsPrecommissioning Form Requirements

• Verify Associated Power & Instrumentation Verify Associated Power & Instrumentation Components are properly installed Components are properly installed

• Final Review & System Verification per ITPFinal Review & System Verification per ITP

• Monitor initial EnergizationMonitor initial Energization