SCOPE

This Project document covers minimum process requirements for plant start-up sequences and
general commissioning procedures for Six Solar T-60 Compressor package , Units and Balance of
Plant . For Solar T-60 Compressor package Units, instructions given by the vendor shall be
followed.
Although, the start-up sequences and commissioning procedures differ to some
extent from equipment to equipment, the basic philosophy and general aspects shall
conform to the concepts of this document .
However, considering the general commissioning and all activities to be
performed prior to initial start-up as outlined in this document , feed introduction to
the Unit shall be according to the stepwise start-up procedure provided by the
Vendor in the Unit Operation Manual.

Definitions:
Commissioning (C)

Is the functional verification of equipment and facilities

that are grouped together in systems.

Mechanical Completion(MC)

The checking and testing of equipment and construction

to confirm that the installation is in accordance with
drawings and specifications and ready for
commissioning in a safe manner and in compliance
with project requirements.

Preservation

The preventive maintenance carried out on equipment

before it is taken into use.

Factory Acceptance Test (FAT)

Testing to be performed at suppliers workshop to verify

the equipment's performance/functionality.

Mechanical Completion Certificate (MCC)

A MC Certificate issued by the Executor to

document that his MC scope has been carried
out. The MC Certificates shall be used per MC
package.

Mechanical Completion Check Record (MCCR)

A discipline checklist for the various equipment.

These records form the basis of the MC
documentation. MC Check Records are prepared

for one or more items for recording of the results

from checking and testing performed during
MC.
Punch List (PL)

A Punch List describes incomplete work or

malfunction of equipment or construction.

Abbreviations:
C
COWR
CR
FAT
MC
MCC
MCCR
MCSI
MSL
PCS
PL
PLR
RFCC

Commissioning
Carry Over Work Register
Check Record
Factory Acceptance Test
Mechanical Completion
Mechanical Completion Certificate
Mechanical Completion Check Record (MCCR)
Mechanical Completion Status Index
Material Status List
Project Completion System
Punch List
Punch List Register
Ready for Commissioning Certificate

Overall Goal
The overall goal of Commissioning is to verify that the system is designed and built to fulfil
its purpose and specified requirements.
Life cycle cost principles and safety should govern all decisions and actions.
Early establishment of commissioning packages is essential for an orderly and effective
project completion. The commissioning plan shall have maximum priority to enable reversed
planning in all project phases. All fabrication and installation planning shall be system
oriented.

COMPLETION PHASES:

Mechanical

Completion

Ready

for Pre Commissioning

Ready

for Commissioning

MECHANICAL COMPLETION
Introduction
This chapter forms the basis for the execution and documentation of mechanical activities.
Mechanical completion takes place through all phases of the project, starting at equipment
supplier and continuing through fabrication up to commissioning phase.

Documentation for a Mechanical Completion Package

The MC package shall consist of an MC Certificate, a MC Status Index and a Punch List as
described below.
A Mechanical Completion Certificate (MCC) is a form completed by the Executor after all
activity is carried out. The MCC is the cover sheet for each MC package. A MC package shall
when signed be ready for start of commissioning.
The Check Records (CR) are the forms on which the Executors record the results of all
checks, inspections and tests carried out for each individual item.
Punch List Register (PLR) shall be prepared by the Executor along with the MC activity. In
each MC package a printout from the PLR shall be included to document the incompleted
work.
Handover at Mechanical completion
Handover at Mechanical completion to commissioning shall be at commissioning package
level, documented by the Ready for Commissioning Certificate (RFCC).
Mechanical Completion Typical Activities .
Mechanical completion of a system include following but not limited to:
All design and engineering has been completed
All installation work for that system including all equipment has been
completed in accordance with Approved for Construction drawings,
specifications, applicable codes and regulations and good engineering
practices.
All instruments have been installed.
All tie-in connections have been made.
All factory acceptance tests and all other testing and inspection activities have
been completed.
Contractor has obtained approvals, which are the responsibility of the
Contractor to obtain.
Safety Studies have been completed and satisfaction of all the Safety Studies
requirements have been met and all documentation put in place.

 All required documentation and certification documents required by the

Contract have been supplied.
All operating procedures and maintenance procedures have been forwarded to
the Company well in advance for review.
All items for which Contractor is responsible for obtaining third party,
regulatory or Company approval have been obtained and confirmation
documentation has been provided to Company.

Ready for Pre-Commissioning

The works are Ready for Pre-Commissioning when the Vendor has issued a
certificate for Mechanical Completion and notification in writing that the Works
is Ready for Pre commissioning.

Pre Commissioning Activities

Pre-commissioning activities are activities to be performed after Mechanical
Completion of a piece of equipment or system to make it safe and ready to receive
hydrocarbons/ injection water and Ready for Commissioning. This include, but
not limited to:
Performance of all remaining works other than commissioning and Performance Tests.
Making operational and commissioning all systems that can be made
operational before fluids are introduced.
The completion and testing of the platform equipment & systems
Testing of all parts and systems of the Works including the communications
systems (if required).
Checking, site modifications.
Internal inspection of the vessels
Flushing/cleaning of vessels & piping
Calibration of PSVs .
Calibration of all the instruments
Loop checking.
Complete checking of the safety system
Checks on electrical system and other vendor packages including DCS etc.
The delivery, storage and cataloguing of all spares
Items for which a defect Notice are issued to be rectified and all defect
Notices shall have been closed out.
The Completion Documents along with all Design Documents to As-Built
The preparation of the commissioning plan and submission to Company for
review.
The hydro testing and pneumatic testing of vessels.
Training and briefing of the Companys and Contractors personnel involved
in commissioning.
Removal of all debris and construction equipment from Site.

PRE-COMMISSIONING CHECKLIST
This checklist represents the absolute minimum of work, which has to be
performed by the Contractor prior to commissioning of the facilities. It is not
intended to be a complete list of activities required. Manufacturers instructions
for pre-commissioning checks/ testing shall be followed for all equipment.
General Procedures
The general work procedures listed below outline the work to be performed by the
Contractor.
.
Packing and Seals
Install mechanical seals, permanent packing and accessories wherever
required.
Adjust and replace mechanical seals, packing and accessories, as
necessary, during pre-commissioning period.
Removal of Temporary Supports
Removal all temporary supports, bracing or other foreign objects that were
installed in vessels, transformers, piping, rotating machinery or other equipment
to prevent damage during shipping, storage and erection.
Alignment of Rotating Equipment
Rotation checks and check rotating machinery for correct direction of rotation
and for freedom of moving parts before connecting driver.
Make cold alignment to the manufacturers tolerances along with Company.
Provide all the alignment readings records to Company. Contractor shall
prepare the formats (unfilled) and submit to Company for approval.
Check all lubricants and their quality, fill etc. before operating the equipment.
Carry out uncoupled run of motors, check bearing temperatures, vibration, no
load currents, over current trips, function of different safety devices and carry
out adjustments as required.
Make hot alignment and any dowelling required after equipment has been put
in operation.
Obtain manufacturer representative for equipment as required during
installation and/or pre-commissioning and commissioning.
Tie-ins at Unit Limits
Prepare all systems for safe tie-ins with bridge connected platform or with
existing operating systems. Contractor shall prepare the systems for Tie-ins in
consultation with Company and will be responsible for safety during tie-ins being
made. Contractor shall gain approval of Company for the safety measures to be
taken by them before any tie-in work is taken up.

 System Check / Inspection

Provide inspection facilities to the Company to check that erected facilities
conform to Process & Instrumentation Diagrams, construction drawings,
vendor drawings and specifications approved for construction.
Verify and approve the facility check. Note exceptions, if any, on a separate
work order list.
Site Modifications
Carry out site modifications as found necessary during system checks and
inspection from the viewpoint of routine operations, maintenance and safety of
the platform. A list of such jobs shall be prepared by the Company and shall be
handed over to the Contractor for execution.
Flushing
Perform flushing and blowing of all piping to remove dirt, welding slag, etc.
Arrange for cleaning media for carrying out flushing/blowing and disposal of the
cleaning media in accordance with minimum procedures to be developed by the
Contractor and approved by the Company.
Temporary Screens, Strainers and Blinds
Provide and install temporary strainers where required. Install permanent
strainers after initial operation.
Clean strainers as required during pre-commissioning and commissioning.
Provide, install and remove all blinds required for flushing or operation.
Change gasket if necessary.
Leak Tests
After completion of all pre-commissioning activities, safety checks and hydro
test, leak test of complete process facilities including piping, equipment,
instrument connections.
Vacuum Test
Rectify any leakage source.
Safety Devices
Provide the Company with a list of settings for safety devices.
Install all safety devices on the equipment.
Test and adjust all safety devices such as PSVs, TSVs at offshore and seal
wherever necessary.

 Purging
Install necessary purge connections and carry out system purging including that of
flare and vent with Nitrogen in accordance with Company approved procedure.
The final Oxygen content in purged systems shall be reduced to an approved safe
limit. Contractor shall arrange & supply the Nitrogen required for purging.
Lubricants and chemicals
Procure and supply initial fill of all lubricants, chemicals, resins, desiccants
and other similar materials, replenish the chemicals consumed during precommissioning
and commissioning.
Inspect vessel interior along with Company / certifying authority before filling
of chemicals for proper cleanliness.
House Keeping
Provide continuous cleanup of the construction and operational area. Remove
excess materials, temporary facilities and scaffolding and pick up trash. Perform
washing for further cleanup as required.
Equipment Protection and Spare Parts
Protect equipment from normal weather conditions, corrosion or damage
before commissioning.
Provide all installation and commissioning spares.
Chemical Cleaning
Perform special chemical cleaning or pickling of the critical piping and
compressor suction piping, etc. in accordance with vendors approved procedures.
Fire Fighting & Life Saving Equipment
Ensure correct installation of all fire fighting and life saving equipment.
Carry out function test of fire detection and suppression system.
Miscellaneous
To carry out any other check/test as required by Company and provide all test
certificate as required by the Company.

Ready for Commissioning

Ready for Commissioning means the point at which the Company issues a
certificate to the Contractor saying that the system is ready for commissioning.
At this point all systems and equipment shall be at a stage where natural gas can be safely
introduced and all equipment can be safely operated with all controls and safety devices in
service.

COMMISSIONING:
Commissioning take place when Mechanical completion is completed for a system or part of
a system.
Commissioning can be divided into three main activities:
Commissioning preparation
Commissioning execution
Commissioning documentation and handover to operation
Establishment of a commissioning network and definition of commissioning packages early
in a Project in order to establish fabrication/installation priorities and milestones.
Definition of commissioning of part systems is essential in order to achieve an early
commissioning completion .
Typical commissioning preparation activities
The preparatory work shall consist of activities such as:

Development of commissioning organisation

Development of system breakdown (part system)
Commissioning packages definition
Commissioning schedules
Commissioning budget including spare parts for commissioning
Commissioning preparation check record.

PERFORMANCE TESTS FOR WORKS

The Commissioning team shall carry out Performance Tests. The Team shall develop a
detailed procedure for the performance tests in accordance with the requirements
of the system .
Maximum Rate Performance Test of Compressor Package and Auxiliaries
A performance test of the turbo compressor package shall be carried out to demonstrate that
everything (including process facilities and utilities) meets its Contract
requirement.
The performance test shall demonstrate that the works meet the requirements of
the Contract. All equipment shall be tested to see that they meet the requirements
specified (including capacities).
The test must successfully demonstrate that all equipment operates to
specification and the shutdown systems for each system and the overall facility,
work as required.
As part of the test, the process simulation model of the process must be updated
and validated against operating data.
The Commissioning team shall develop an extensive test procedure for the above, including
details of all process measurements and analyses to be carried out.
Minimum Rate Performance Test of Compressor Package and Auxiliaries
The test procedure described above shall be repeated at the Design Minimum Rate
The Performance test shall demonstrate the works meets the Design requirements
and demonstrate those things described in above section.

SPECIAL REQUIREMENTS
It shall be Contractors responsibility to install, calibrate and make all laboratory
and workshops equipment operable. Contractor shall involve Companys chemist
and maintenance engineers and impart necessary techniques and know-how
required for operation and maintenance of this equipment.

DOCUMENTS TO BE SUBMITTED

Operating Manual
The Vendor shall prepare a draft start-up and Operating Manual for all of the
Plant facilities that are included in the Works and submit to Company
prior to start of pre-commissioning activities for approval. Quantity of operating
manuals requirement for all equipments shall be provided as per respective
specification given . The related attachments will go with each manual. The following
information shall be included:
Design basis
Description of facilities
Pre-commissioning checks
Start-up, normal operation & shut down procedures for each equipment.
Unit start-up procedure.
Unit normal operation procedure
Unit shut down procedure (normal/emergency)
Vendor instructions for all equipment for normal operation and trouble
shooting.
Emergency procedures.
Operating parameters and set points of different alarms and trip devices
Summary of utilities consumption for each equipment.
Lubrication Schedule
Gas detection system operation, calibration and maintenance procedure.
Life saving devices operation and maintenance procedure.
Routine structural maintenance check.
List of equipment (showing skid size, weight, purchase order no., vendor data
book reference tag no.)
Effluent disposal.
The manual shall have the following attachments as minimum:
Equipment and instrument data sheets in accordance with purchase order
Electrical Single line diagrams, area classification drawings and control
schemes
Pump characteristic curves
Process Flow Diagrams (PFDs) & Piping and Instrumentation Drawings (P &
IDs)
Recommended Performa for recording routine parameters during normal
operation for all equipment.
Equipment Layout
Safety Escape Routes
Field Location Maps.
Layout and Location Maps For Fire And Safety Equipments

YARD CHECKOUT BEFORE LOAD OUT

Prior to load out, the Contractor shall carry out, at the yard, a check of the
facilities for correct erection and installation, operability, maintenance
requirement and safety of plant and personnel during operation in accordance
with accepted international good engineering practices, this will be witnessed by
the Company. The Contractor shall carry out all modifications and corrections in
accordance with the final punch list prepared jointly by the Contractor and the
Company.
SPARES, UTILITIES ETC.
The Contractor shall be responsible for supply of all the spares and consumables
till the complete plant including any modifications are mechanically completed, pre
commissioned/commissioned and handed over to the company.
It shall be Vendors responsibility to supply lubes , chemicals, purging
materials and other pre-commissioning/commissioning aids required till the
station is handed over to the company. It shall be Vendors responsibility to
repair any damage to the system occurred during load out, transportation and
installation and pre-commissioning of the facilities.
HANDING OVER OF MATERIALS
After the mechanical completion and completion of pre-commissioning activities
for all the systems installed by the Vendor/Contractor, the Vendor/Contractor shall hand over to
the company all the materials which shall include but not limited to the following:
- Special tools and tackles
- Commissioning spares
- Spares as specified in relevant functional specifications

ANNEX A
MECHANICAL COMPLETION DOCUMENTATION
(TYPICALS) (INFORMATIVE)
CONTENTS
Documentation for a MC package
MC certificate (MCC)
Piping completion status
MC check record - Instrument installation and inspection
MC check record - Electrical motors
MC check record - Centrifugals/schrewpump, compressor and hydr.motor
Punch list
MC documentation for a Commissioning package
Ready for commissioning certificate (RFCC)