Capability initial flow control

OutputsInputs
Capability - Initial Flow Control(Commissioning)
Aim- To prove the plant under operating conditions and make the Client aware of
plantControl procedures.
To obtain client acceptance certificates and reduce project team
responsibilities.To begin training of operating maintenance personnel.
To prove plant under full load performance conditions.
Responsible- Commissioning Manager
Initial Flow Control
Preparation
Preparation Project Contract
 Project Leader/ Team
 MP Workshop Outputs
 End Users
 Preliminary & Detailed
EngineeringDesigns
 PRIAM Study and
Risks Safety Reports (PHA/
HAZOP) Safety Managment Information
andResponsibilities, e.g. Risk
Assessmentsand Method
Statements Manufacturer's Operating
Procedures Production / Shift Plan or
Schedules

Pre Planning inc. Stores location
andcontrol and/or Laydown Area for
deliveries
 Commissioning Team
PersonnelIdentified inc. Suppliers
 Construction Handover &
CommissioningPlan
 Recruitment and Training
Plan Construction Acceptance Testing
Plan Software loading and testing
Plan Recipe Design and Testing
Plan OEE Targets
 Pre Delivery Inspections at
suppliers
Pre-
commissioning
Work
 Product Quality Control
Procedures Customer Acceptance
Criteria Performance Benchmarking
Criteria Raw Material Supply and Product
Storage Standard Operating Procedures
/Manuals
 Planned Maintenance Strategy
/Schedules
 Maintenance Contract/s
 Spare Parts Inventory
Final Acceptance
and Handover
 Operating & Maintenance
Manual Health & Safety File
 Customer Acceptance Certificate -
FinalHandover
 Project Review
 P& ID and 'as-built' drawings
produced Equipment Specifications re-
assessed
Commissioning
Handover
 Process Commissioning
Plan Plant is clean to required
hygienestandards
 Plant is operating with product to
proveperformance to
specification Operational Training
audited Training Matrix/ Network
produced. Planned production is
considered
Installation
Complete
 Principal Contractor
 Planning Supervisor
 Construction Handover
Procedure Construction Snagging
Report Software Acceptance
 Test Certification (Electrical / Pressure
/Loading Testing etc.
 Construction (Mechanical/
Electrical)Handover Certification
 Construction Safety
Plan Health & Safety File
 Operating Manuals
 Pre-commissioning Plan
 Check for Safety
Defects Removal of Isolations /
Permits Electrical Circuit
Testing
/ Loop Tuning
 Software Installation and
Training Calibration of Instruments
dependingupon type
 Cleaning of Area
 Dry Commissioning
Plan Vibration / Noise
Testing Direction of Rotation Testing
etc
.
 Safety System Testing e.g. e-
stops Running dry without
product Valve Operation
Checks Operating and Maintenance
Instructions
 Wet Commissioning Procedures
andChecklists
 Pressure Testing checks against
suppliercertification
 Final system running tests
withoutproduct
 Safety Systems
Checks 'Hands-on' training and
checks Update P & ID
 Area Clean and Tidy
 Pre-commissioning Plan Complete
andsigned off
 Checklist complete
 Snag list complete and signed off with
orwithout exceptions
 Dry Commissioning Plan Complete
andsigned off
Snag list complete and signed off with
 Dry Commissioning Handover
Certificate
 Wet Commissioning Plan Complete
andsigned off
 Wet commissioning Checklist
&Procedure
 Snag list complete and signed off with
 Wet Commissioning Handover
Certificateand Authority to Introduce
Chemicals
 Process Commissioning Plan
Completeand signed off
 Complete Performance
Benchmarkinginc. OEE figure or previous
experience
Pre-
commissioning
Dry
Commissioning
Process
Commissioning
Wet
Commissioning
Commissioning
Apply 5S principles to commission area
andApply Visual Management Control Stds
and


Inputs OutputsProcess
 Project Contract
 Project Leader, Project Team
 MP Workshop Outputs
 End Users
 Preliminary & Detailed Engineering
Design
 PRIAM Study and Risks
 Safety Reports (PHA/HAZOP)
 Safety Management Information
 Manufacturers Operating Procedures
 Production/Shift Plan or Schedules
 Pre-Planning including Stores location
and or Laydown Area

 Commissioning Team identified
 Construction Handover &
Commissioning Plan
 Recruitment and Training Plan
 Customer Acceptance Testing Plan
 Software loading and Testing Plan
 OEE Targets
 Pre Delivery Inspections (PDIs) at
Suppliers
 Factory Acceptance Tests (FATs)
 Product Quality Control Procedures
 Customer Acceptance Criteria/
Procedure & Forms
 Performance Benchmarking Criteria
 Raw Material Supply & Product
Storage
 Standard Operating Procedures/
Manuals
 Planned Maintenance Strategy/
Schedule
 Maintenance Contract/s
 Spare Parts Inventory
 Main Plant Trial requirement
Preparation
Initial Flow Control Pre-
Commissioning Work
7.1 IFC PREPARATION AND PRE-COMMISSIONING WORK
PURPOSE
The purpose of this stage is to prepare before commissioning
begins - to establish critical success factors, deliverables and key
milestones.
Overview
The preparation incorporates all the requirements for all types of
commissioning e.g. wet, dry or process. During this stage all the various plans and procedures are
written (see checklist) that will ensure that the plant operates to its design criteria.
Commissioning Team
The most important output from this stage is the formulation of a Commissioning team whoare
aware of each others roles and also of the key targets to be met. The Commissioning team must
actively liase with the installation engineers to ensure that they receive handover of each process
area or key process area as soon as possible and to the commissioning schedule or plan.
It is the Commissioning Teams responsibility to decide and agree upon how they are going to divide
the plant up into manageable areas to commission. This can be done in a variety of ways e.g. by
process areas, line operations or by physical location of equipment and plant. Note: the
Commissioning team must be issued with all the latest versions of documentation (P&ID’s, layout
drawings) as soon as they are available.
Main Plant Trial
At this stage it may also be agreed that a Main Plant Trial (MPT) is required. A MPTis normally
carried out on an Innovation Project in whichthe process and/or the product has not been
manufactured before. A MPT is used to validate that the scale up from pilot plant to full factory scale
production can be successfully achieved.
Training
Effective Recruitment and Training of Operations staff is essential if the plant is to meet its
performance criteria or OEE Targets in as short as time possible after start-up. May initially require
recruitment of internal staff from other plants or lines. Training should cover all of the plant
requirements
Safety – Raw Material, Minors or Effluent Handling. This is especially important if new or flammable
ingredients are present.
Quality – changes in paperwork i.e. new start up procedures or new logbooks
Hygienic Awareness – risks involved with process, outside contamination or mixing of process
streams.

Training can be performed in a classroom environment explaining the reasons for the changes and
then consolidated with a tour of the actual plant/ areas applicable. For Software Training simulation
is an excellent tool.
Document Management
It is also important to agree on the document management system that will be in place during the
whole commissioning process. It is best practise to continue with the Document Management
System as described in Section 10. Particular attention should be given to the management of
deviations from specifications or changes to design through the use of a Change Request System.
CHECKLIST
Allocate a Commissioning Team
 Members can include Process and Line Operators, Engineers, Design Team Members and
Installation Team Leaders
Preparation
 Pre Delivery Inspections or Factory Acceptance Tests to be done.
 Raw Material Supply and Product Storage
 Spare Parts Inventory or Commissioning Spares
 Apply 5S principles to commissioning area
 Apply visual management control standards
Plans/ Schedules and Procedures
 Construction Acceptance Test Plan and Handover procedures/ Conditions.
 Commissioning Plan to incorporate whom, when and process section.
 Recruitment and Training Plan for operations Staff. May initially require recruitment of
internal staff from other plants to lead into operational training. Training can cover all of the
plant requirements e.g. Hygiene Awareness, Safety – Raw Material/ Effluent handling and
Software simulation (if possible)
 Software Loading Test Plans.
 Recipe Design and Testing Plan or Main Plant Trial
 Customer Acceptance Criteria and Procedure Forms
 Product Quality Control Test Procedures
 Planned Maintenance Schedules
 Performance Benchmarking Criteria including OEE figures

7.2 CONSTRUCTION HANDOVER MECHANICAL COMPLETION
Purpose
Installation Completion (sometimes referred to as mechanical installation) is the completion of
electrical and mechanical works. It is the responsibility of the construction team.
Overview
In practice the term Installation Completion is used to refer to the point in construction when a
system is sufficiently complete to allow pre-commissioning to begin. When a system is finished it is
handed overfrom the construction team to the commissioning team.
The handover may take the form of a Safety Certificate or Handover Certificate that details the areas
completed and is signed off ‘as completed’ by all interested parties e.g Mechanical/ Electrical Team
Leaders, the Customer, Safety Contact etc. However, handover usually occurs in stages or if a Main
Plant Trial is to be carried out at a certain percentage of Mechanical Completion that will allow the
process plant to function. If this occurs the Handover Certificate becomes an Interim Safety
Certificate.
Once a system as been handed over by the Installation Team to the Commissioning Team it
becomes the Commissioning Teams responsibility to carry out Pre-Commissioning.
 Principal Contractor
 Planning Supervisor
 Construction Handover
Procedure/ Plan
Installation Completion
 TestCertification
 Handover Certificate
 Safety Plan/File
 Health & Safety
 Operating Manuals
 Construction Snagging Report

CHECKLIST
 Construction Snagging Report Complete
 Handover Certificate Complete and signed off
 Including snags/ issues outstanding
Figure 7.1 - Interim Handover Certificate
Interim Safety Inspection
Title/ Description
Project Title Date
Project Leader Location
Customer Customer Contact
Location of System
Discipline Signature Date
Mechanical Engineer
Electrical Engineer
Safety Contact
Line Leader
Line Operator
Line Engineer
Outstanding Issues/ Snagging Accepted Rejected Initials

7.3 PRE-COMMISSIONING
7.3.1.1.1.1.1
Purpose
Pre-commissioning involves the initial checkout and inspection of all items of plant, to ensure that
they are fit for process commissioning.
Overview
The commissioning team physically checks for correct installation of equipment using the P&IDs,
layout drawings and isometric drawings as reference. Any differences or problems between the
drawings and equipment installed are identified as ‘snags’. A ‘snag’ list is drawn up and is given to
the construction team to correct. (See Figure 3).
It is a good idea to prioritise snags according to how crucial they are. For example if a Main Plant
Trial is to be carried out it may be crucial for a particular pump to be operating but not that important
for a temperature probe to be installed.
Pre-commissioning
 Area Clean and Tidy
 Pre-commissioningPlan
Complete and signed off
 ChecklistComplete
 Snag listcomplete and
signed offwith or without
exceptions
 Pre-commissioningPlan
 Check for Safety Defects
 Removal ofIsolations /
Permits
 Electrical CircuitTesting
 Software Installation and
Training
 Calibration ofInstruments
depending upon type
 Cleaning ofArea

Checklist
 P&IDs, Layout Drawings and Isometrics available
 Snags recorded and listed on the snag list
 Instruments calibrated.
 Software Installation and Training begun
 Electrical Circuit Testing begun
Figure 7.2 - Snag ListExample – Taken from ProjectCopperfield 2001
Location Snag Date Actioned Complete Priority
Zone 1 ground
floor
ValveP756 V02 Tagged
as P756 V06
7.2.01 SM C
Zone 3 fourth
floor
Kathon needs to be
returned
15.3.01 JM A
Zone 3 fourth
floor
Perfume needs to be
returned
15.3.01 JM A
Zone 3 fourth
floor
Fresh perfume under tote
lid needs to be sealed
15.3.01 COMM C
Zone 1 ground
floor
V755 vent pipe needs to
be modified
15.3.01 JM/AC D
Zone 3 fourth
floor
Fresh perfume under tote
needs a 1-inch reducer for
flex connection.
15.3.01 COMM C
PRIORITY KEY
A = Essential prior to leak test
B = Essential prior to introduction of chemicals
C = Essential prior to handover to production
D = Discussion required

7.4 DRY COMMISSIONING
Purpose
Dry commissioning is checking the correct operation of all plant items in isolation so that when they
are brought together to function as a system, the system will operate correctly and safely.
Overview
Dry commissioning is done before the introduction of any materials into the plant. It checks the
correct operation of all plant items in isolation. The first stage is inspection of plant and equipment
to verify that the installation is complete and correct. The correct installation of every item is verified
using checklists as a guide. (See Figure 4 Pump Checklist) Again ‘snags’ are identified and given
to the installation team for correction. Once a ‘snag’ has been corrected it should be crossed off the
‘snag’ list.
At this point vibration and noise testing can be carried out as can valveoperation checks. The
operating and maintenance instructions may also be checked and verified.
 Dry Commissioning Plan
 Vibration / Noise Testing
 Direction of Rotation Testing
 Safety SystemTesting e.g. e-
stops
 Running dry withoutproduct
 Valve Operation Checks
 Operating and Maintenance
Instructions
Dry Commissioning
 Dry Commissioning Plan
 Snag listcomplete and
signed offwith or without
exceptions
 Dry Commissioning
Handover Certification

Checklist
 Equipment Dry Commissioning Checklists Complete
 Safety Systems checked
 E-stops
 Fire alarm system
 Explosion Protection
 Pressure Relief Valves
 Gas Detectors
 Rotation Checks Complete
 Noise and Vibration Checks Complete
Figure 7.3 – Dry Commissioning Checklistfor Pumps
CENTRIFUGAL PUMPS
DRY -COMMISSIONING START UP
HISTORY
TAG No PLANT AREA PROCESS FLUID DUTY
EQUIPMENT DETAILS
MAKE TYPE & SIZE SERIAL No SPEED
1. PUMP
2. MOTOR
3.SEAL MECHANISM: MECHANICAL OR GLAND
4.ALIGNMENT MEASUREMENT (if applicable)
DRY-COMMISSIONING START UP CHECKS
1. All outstanding process audit checks complete YES / NO / N/A
2. Referred to procedures in pump manual YES / NO / N/A
3.Check all connections are tight & leak free YES / NO / N/A
4.Check lubrication of pump, motor bearings YES / NO / N/A
5.Check gland is packed or mech seal fitted(refer to manual) YES / NO / N/A
6.Check strainers are fitted and lines are flushed YES / NO / N/A
7.Check all guards are secure YES / NO / N/A
8.Check pump and motor turn freely by hand (if accessible) YES / NO / N/A
9.Check alignment (if applicable) YES / NO / N/A
10.Is the installation safe YES / NO / N/A
START UP PROCEDURES
1.All outstanding pre-commissioning & safety checks completeYES / NO / N/A
2.Check all valves are open & no obstructions in pipework YES / NO / N/A
3.Check all electrical installation has been certified complete YES / NO / N/A
4.Check the rotation is correct YES / NO / N/A
5.Check stop / start operation YES / NO / N/A
6.Check for oil leaks YES / NO / N/A
7.check / adjust seal / packing as appropriate YES / NO / N/A
9.Check pump casing & suction line are filled with liquid YES / NO / N/A
CHECKS COMPLETED BY DATE
CLEARED BY COMMISSIONING ENG DATE

7.5 COMMISSIONING WET COMMISSIONING
Purpose
Wet commissioning involves the introduction of safe materials (usually water) into the plant in order
to verify the correct operation.
Overview
Wet commissioning involves the introduction of safe materials (usually water) into the plant in order
to verify the correct operation i.e. there are no leaks or blockages. Equipment is now longer treated
in isolation but as part of a system. Pressure relief valves are checked to ensure that they are set
correctly, process pump flowrates are checked, flow meters are checked and calibrated. Steam is
introduced to heat exchangers and heating duties checked. The correct operation of every item is
verified using checklists as a guide. (See Figure 5 Pump Checklist)
Again ‘snags’ are identified and given to the installation team for correction. Once a ‘snag’ has been
corrected it should be crossed off the ‘snag’ list.
At this stage another Handover Certificate or Authority to Introduce Chemicals Certificate can be
raised and signed off by all interested parties as a record that the plant and equipment are safe to
operate with chemicals.
Figure 7.4 - Authority to Introduce Chemical Certificate
 Wet Commissioning Procedures
and Checklists
 Pressure Testing checks against
supplier certification
 Final systemrunning tests
withoutproduct
 Safety Systems Checks
 ‘Hands-on’ training and checks
Wet Commissioning
 Wet Commissioning Plan
 Wet commissioning checklist
and procedures
 Snag listcomplete and signed
off with or withoutexceptions
 Wet Commissioning Handover
Certificate and Authority to
Introduce Chemicals

Checklist
 Equipment and Plant Wet Commissioning Checklists Complete
 Safety Systems checked
 E-stops
 Fire alarm system
 Explosion Protection
 Pressure Relief Valves
 Gas Detectors
 Rotation Checks Complete
 Noise and Vibration Checks Complete
Figure 7.5 - WetCommissioningChecklistfor Pumps
PUMP WET COMMISSIONING RUNNING TESTS
(With water)
Tag No
Make
Model
Delivery Pressure ( bar)
Noise Vibration
Levels Acceptable Yes/ No / N/A
Pumps seals free
from leaks Yes/ No / N/A
Pump checks
completed by
Date
PUMP CHECKS

7.6 PROCESS COMMISSIONING
PURPOSE
This is the stage when process materials are introduced into the plant to verify the .
Overview
The plant and the different processes within operate to actually produce product for the first time and
verify that the process plant manufactures as per the design/specification.
Process fluids/ materials are circulated and checked against the design specification and recipe.
This process qualification also proves that the plant performance is repeatable in full scale. The
performance of each plant system is checked in isolation. Performance is checked against
specification and inadequacies are rectified. As each system becomes proven, they will be coupled
up and the plant will be ready for start-up.
 Process Commissioning Plan
 Plantis clean to required
hygiene standards
 Plantis operating with productto
prove performanceto
specification
 Operational Training audited
 Training Matrix/Network
produced
 Planned production is
considered
Process Commissioning
 Process Commissioning
Plan Complete and
signed off
 Complete Performance
Benchmarking inc.OEE
figure or previous
experience

Checklist
 Process materials available
 Space for Process material allocated
 Operational Performance and Training is audited and any changes documented
 Training Matrix produced
 Planned Production has been considered
 All equipment checklists complete and signed off
 Disposal/ storage of final product from trials allowed for

7.7 FINAL ACCEPTANCE AND HANDOVER
Purpose
This is the handover of the plant from the commissioning team to the operating team.
Overview
When a plant is successfully commissioned formal hand-over to the operating personnel takes
place. The operating team formally accepts the responsibility for operating the plant.
This normally takes the form of a final Handover Certificate (see Figure 7.6 Final Handover
Certification). This can or may also list outstanding snags or other issues to be resolved and it is up
to the Plant Leader to decide whether to accept the handover or not.
Final Acceptance and
Handover
 Operating & Maintenance
Manual
 Health & Safety File
 Customer Acceptance
Certificate – Final Handover
 P&ID and ‘as built’ drawings
and documentation
 EquipmentSpecifications re-
assessed

Checklist
 P&ID’s and ‘As-built’ documentation updated and issued
 Health and Safety Plan completed and handed over
 Final Handover Certifications signed and issued
 Equipment Specifications re-issued if changes have been made
 Operating and Maintenance Manuals issued.
 All operating personnel trained or training is as according to plan
Figure7.6 - Final Handover Certification
Handover Certificate
Title/ Description
Project Title Date
Project Leader Location
Customer Customer Contact
Location of System
Discipline Signature Date
Mechanical Engineer
Electrical Engineer
Safety Contact
Environmental Contact
Line 1 Leader
Line 2 Leader
Line 3 Leader
Line 4 Leader
Warehouse Controller
OSE Team Leader
Other
Outstanding Issues/ Snagging Accepted Rejected Initials

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