Pre commissioning & Commissioning(SAMPLE)
System , Sub System & ITR Overview
By
QAQC Team
PACKAGE #1. REFINERY & CRACKER
System & Sub System Overview - Sample
SYSTEM SUB SYSTEM SUB SUB SYSTEM
Process Liquid / Process Gas/Gas Compression/ Gas Dew Crude Stabilzation/ PG Separation/ Suction Manifold / Off Gas
Point/Water Injection/ Acid Gas Removal/ Contaminant Removal Compressor/ Gas Dehydration Train/ Water Filtration/ AGRU
100 Process /MRU
Utility Gas/ inert Gas/ Venting/ Produced Water/ Drain/ Process Fuel Gas / Instrument Gas / Nitrogen Generation/ HP &LP Flare/
200 Process Heating/ Chemical Injection or Treatment ATM Vent/ Open Drain/ Closed Drain/ Hot Oil /ETC
Utilities
Fuel & Lubricant/ Compressed Air/ Water/ Steam/ HVAC/ Diesel Fuel / Lubricant Oil/ Instrument Air/ Utility Air/ Potable
300 General Hydraulic Water/ Hot Water / Steam Generation/ AHU/ HPU/ETC
Utilities
Fire Water/ Deluge & Sprinkler / Fire Supression / Fire Extiguiser
Fire Fighting/ Life Saving Equipment
Safety /Etc
400
Power Generation @Supply/ Distribution / UPS/ Small Power & Main Power Generation/ Emergency Power Generation/ ENMS/
Lighting/ Earthing & Lightning Protection / Drives & Controller / PMCS/ Transformer/ Switchboard/ imcs / AC & DC UPS / VSD
500 Power Consumers Controller /ETC
Control & Process Control/ Safe Guarding System DCS/ PMCS/ SIS/ IMSFGS/ HIPPS / Instrument Control
600 Safe Guarding Panel
Telecommuni Main Backbone Link/ Radio Communication system / PAGA/ CCTV / Local Area Network/ PABX and Telephone System
700 cation Voice & Data Communication / Surveillance and Safety & ETC
System
Material Handling / Aviation & Etc Monorail / Trolley Hoist / Pedestal Crane / Helideck/ Etc
800 Miscellaneous
2
ITR Overview- Sample
Mechanical
Construction Pre Commissioning Commissioning
Pressure Vessel
Heat Exchanger Pressure Vessel
Relief valve Heat Exchanger
Air Dryer Package Relief Valve
Filter / Strainer Air Dryer Package
Pressure Vessel
Monorail / Hoist Filter strainer
Monorail/ Hoist
Mixer & agitators Monorail / Hoist
Electric motor piston
Air Compressor Piston Displacement Pump
displacement Pump
Piston Displacement Pump Electric Motor Driven Centrifugal
Electric Motor Driven Centrifugal
Centrifugal Pump Pump
Pump
Equipment Skid Chemical Metering Pump
Chemical Metering Pump
Nitrogen Gas Generator Chemical Injection Package
Chemical Injection Package
Fin Fan Cooler Nitrogen Generator Package
Nitrogen Gas Generator
Base Plate AGRU
AGRU
Load Testing of Lifting Lugs/ MRU
MRU
Monorail Fin Fan Cooler
Etc.
Valve Installation Pulsation Dampener
Pulsation Dampener Coupling Alignment
Coupling Cold Alignment Final Closure Certificate
Storage Tank Booster Compressor
Booster Compressor
ITR A- Construction check-sheets ITR B - Pre Commissioning check-sheets ITR C- Commissioning check-sheets
3
Pump / Compressor
Construction Pre Commissioning
Un Couple Test/ No Load Test ( 1
Install Alignment Check IR & PI Test hours)
DMC Ready for Solo Run
Commissioning Pre Commissioning
Completed Endurance Test ( 72 Hours) Load Test / PTR ( 4 hours)
MC
Ready For
System Run
4
Valve
Valve Leak Test / Install Cleaning/ Flushing Bolt Tightening
Air Seat Test
Commissioning Pre Commissioning Construction
Completed Preserve Reinstatement Leak Test
MC DMC
Ready For
Service
5
ITR Overview - Sample
Piping
Construction Pre Commissioning Commissioning
Pressure Test
Flushing
Re Instatement Work
Blowing/ Drying
Re Instatement Leak Test
Bolt Tensioning / Tourqing
Flanges Management
Chemical Cleaning Nitrogen Purging
Service Test
Service Test
Witness Joint
Pipe Painting/ Coating / Marking
Lube Oil Flushing
Pipe Insulation
Critical Valve Leak Test
ITR A- Construction check-sheets ITR B - Pre Commissioning check-sheets ITR C- Commissioning check-sheets
6
Piping
1 Weld
Metallic( CS/SS/Duplex/ Cutting & Edge
Receiving Glue
Super Duplex) Fit-uP
Non Metallic ( Inspection Preparation
GRE/GRP/PVC/ETC)
Commissioning Pre Commissioning Construction
MC Flanges Management Screw
Utility System
Installation :
DMC Flanges a. Pipe Spool
Alignment b. Valves
HC System
System / Subsystem Nitrogen Reinstatement Leak
Commissioning Purging Test/ Service Test
Painting NDT
External Insulation Bolt Torque/
Pickling(SS) (If Any) Tensioning
Flanges Insulation shall be done after leak test
Chemical PWHT
Touch
Painting Cleaning
Reinstallation work/ Drying/ Conformity
Reinstatement
Blowing Hydrotest Flushing Linewalk NDT
7
ITR Overview - Sample
HVAC
Construction Pre Commissioning Commissioning
Fan Fan
Dampers Air Handling Unit
Air Handling Unit HVAC Static Pressure Test
Duct Work for Vent, Exhaust & HVAC Fire Damper & Panel
Heaters HVAC Damper & Panel
Duct Leak Test HVAC Mist Eliminator and Filter HVAC
Diffuser / Grills/ Louvers/ Hoods HVAC Fans / Motors
Filter / Coalescer HVAC Duct Balance Sheet
Sound Attenuator HVAC Duct Heater
HVAC Duct Heater HVAC Circulation Pump
HVAC HVAC
ITR A- Construction check-sheets ITR B - Pre Commissioning check-sheets ITR C- Commissioning check-sheets
8
ITR Overview - Sample
Electrical
Construction Pre Commissioning Commissioning
ITR A ITR B ITR C
Electrical Network Monitoring Electrical Network Monitoring
and Control System and Control System
Transformer( Dry & Oil Type) Transformer( Dry & Oil Type)
High Voltage Switchgear High Voltage Switchgear / CB/
Low Voltage Switchgear Motor Starter
IMCS Low Voltage Switchgear / CB /
High Voltage Cable Motor Starter
Low Voltage Cable IMCS
Busduct High Voltage Cable
UPS Low Voltage Cable Transformer( Dry & Oil Type)
DC charger Protection Relay / CT / VT High Voltage Switchgear
Battery Busduct Low Voltage Switchgear
Low Voltage DB UPS / DC charger UPS / DC charger
Earthing & Lighning Protection Battery Battery
NER Low Voltage DB VSD
VSD Earthing & Lighning Protection Heater Control Panel
Heater Control Panel NER High Voltage /Low Voltage Motor
High Voltage Motor VSD Electrical Heater
Low Voltage Motor Heater Control Panel Impressed Current Cathodic
Electrical Heater High Voltage /Low Voltage Motor Protection System
Impressed Current Cathodic Electrical Heater MOV
Protection System Impressed Current Cathodic Nomal Lighting
MOV Protection System Emergency Lighting ( Circuit/
Nomal Lighting MOV Fixture)
Emergency Lighting ( Circuit/ Nomal Lighting
Fixture) Emergency Lighting ( Circuit/
Socket ( Welding/ Power / Fixture)
Convinient) Socket ( Welding/ Power /
Push Button/ Safety Switch Convinient)
Junction Box Push Button/ Safety Switch
Cable Ladder Junction Box
Preservation Cable Ladder
Preservation 9
Electric Motor
Construction Pre Commissioning
Un Couple Test/ No Load Test ( LV: 1-
Winding Insulation Test Install IR & PI Test 2 Hours & HV : 4 Hours
DMC Ready for Solo Run
Commissioning
Completed Load Test / PTR ( 4 hours)
MC
Ready For
System Run
10
ITR Overview - Sample
Instrument
Construction Pre Commissioning Commissioning
ITR A ITR B ITR C
Instrument Cable Installation &
Testing
Instrument FO Installation &
Testing
Instrument Calibration
Instrument Installation
Instrument Tubing Installation
& Pressure Testing
Pneumatic Instrument Control Pneumatic Instrument Control
Instrument Panel Installation
Panel/ ESD Station Testing Panel/ ESD Station Testing
Pneumatic Instrument Control
Instrument Closed Loop Check Instrument Closed Loop Check
Panel (ICP) / ESD station
Process Analyzer Test Process Analyzer Test
Installation
Fire & Gas Device Loop Test Fire & Gas Loop Test
CV/BDV/SDV Installation &
Cause & Effect Matrix Cause & Effect Matrix
Calibration
Verification Verification
PSV inspection & Test
Tank Gauging system Testing Tank Gauging system Testing
Process Analyzer Test
Fire & Gas Calibration &
Installation
Fusible Plug Loop & Panel
Installation
Tank Gauging System
Installation
11
Instrument
Construction Pre Commissioning
Tubing Leak Test/ Cable
Calibration Check ( Field Instrument Loop Test
Install Test ( IR/CT ) / Junction Box
/ SDV/ BDV/ CV)
Check
DMC Ready To Energize
Commissioning Pre Commissioning
Completed Cause & Effect Matrix Test( Simulate)
MC
RFSU
12
Instrument / Fire & Gas Panel
Construction Pre Commissioning
Cold Loop Check + Cable Testing +
Loop Check and
Install Earthing Intergrity Check + Installation Power Up
F&G calibration
Inspection
DMC Ready To Energize
Commissioning Pre Commissioning
Perfomance Test ( 7
Completed Matrix Shutdown Test Composite Integrated System Test
days) & Live ESD Test
MC
RFSU
13
Sample of ITR A , B & C
• Mechanical ( ITR A, ITR B & ITR C )
• Piping (ITR A , ITR B & ITR C)
• HVAC ( ITR A, ITR B & ITR C)
• Electrical ( ITR A, ITR B, ITR C)
• Instrument (ITR A, ITR B , ITR C)
• Telecom ( ITR A, ITR B, ITRC )
14
