SOP-10 Pre Commissioning and Commissioning Activities

हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No.
SP – 10
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Safety Procedure for Pre Commissioning and Page 1 of
Rev No. 0
Commissioning Activities 14
Issue By Approved By
Management Representative DGM-Projects
Revision and Amendment sheet
Page Clause Revisi Revision

Amendment Details
No. No. on No. Date
Note: - As per the procedure for control of document procedure

can be revised up to maximum 5 revisions and after 5 th
revision, new issue of the document with new issue number
shall be issued to all the controlled copy -holders.
हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 10
Issue No.
Rev No. 0
SAFETY PROCEDURE FOR PRE COMMISSIONING AND

COMMISSIONING ACTIVITIES
1.0 Purpose
To encourage and educate personnel on the HPCL sites to

regard Safety First as its prime objective and to be aware of
their commitment, responsibility and statutory obligation.
This procedure will provide information and guidance while
Pre Commissioning and Commissioning Activities . To
identity tendency of unsafe activities and condition and
provide safe work environment.
2.0 Scope
Applicable to all Pipeline Project locations and greenfield

project sites.
3.0 Reference
OISD GDN -192

OISD-141
OISD-105
HSE procedures in practice
4.0 Responsibility
4.1 ROU In-charge / Officer In-charge / Project consultant’s

Safety Officer
4.2 Officer In-Charge / Project consultant’s Safety Officer shall

ensure that all the work is done with proper work permit &
use of proper PPEs.
I. Planning for Pre-commissioning -Contractor shall plan in
advance in consultation with EPMC/Client for Pre-
Issue No.
Rev No. 0
commissioning activities and the schedule for the same shall

be finalized.
II. Supply of operating material such as tools and devices:
Contractor shall supply all required tools and tackles for the
activity.
III. Supply of spare parts during Pre-commissioning: Contractor
shall maintain sufficient stock of spare parts required at work
site for the activity.
IV. Supply of temporary emergency equipment: Contractor shall
arrange temporary equipment like portable fire fighting
equipment, first aid boxes.
V. Mobilization of pre commissioning team including supplier's
engineer/supervisor as required: Contractor shall identify in
advance proper capable personnel for this activity and
depute them for the activity.
VI. Operation of facilities installed: Contractor shall depute
proper skilled personnel to operate the facilities provided for
the activity.
VII. Expense for utility consume/ used up to hand over such as
electricity, telecommunication and fuel for generator: utility
expenses shall borne by Contractor
VIII. Recording the results and reporting on progress of the pre-
commissioning: CONTRACTOR shall depute personnel for
recording of paraMeters and report the progress of the
activity from time to time.
IX. Ensuring safety to personnel, material, equipment and
facilities: CONTRACTORHSE shall be on the job ensuring
safety to the personnel, material, equipment and facilities.
X. Necessary approval from local concerned authorities shall be
taken by Client being custodian / owner of the pipeline and
product therein
XI. Organization chart responsibilities and contact numbers of
EP,C/Client and skid vendors shall be provided by EPMC.
Contractor will attach all this information in procedure.
Issue No.
Rev No. 0
XII. Fire tender shall be made available at all station location by

client.
Ensures that the pre-commissioning team are aware of the

operating parameters,
5.1 Procedure
5.2 Prerequisite before starting work

1. All stakeholders should be informed in advance and take
prior approval as advised and required.
2. Do Job Safety Analysis (JSA) with stakeholders involved in
activities and make JSA as mentioned in OISD-105 and get
signatures of designated person of Client, EPMC, Contractor
and Stackholders for mentioned activities.
3. Job to be supervised by a competent person. Designated
safety person should be present always at site.
4. All person should wear required PPEs.
5. Conduct Tool Box Talk daily and maintain record. Approved
format of Tool Box Talk by Client/EPMC should be used.
6. Sufficient Number of dry chemical type/CO2 type fire
extinguisher, Sand Buckets, DCP Powder etc. shall be made
available by contractor before starting work. Hose-Pipe
connected to Hydrant line, Fire Tender etc. may be made
available while working in the vicinity of existing HPCL
installation.
7. First Aid Box should always be available at site. Regular
inspection should be done by EPMC/Client to ensure that all
medicines are available and expired medicine should be
replaced before expiry date.
8. Only trained personnel to be deployed for this activity.
9. All Measuring & Test Equipment’s used must be well
maintained.
10. All lifting devices & Tools used shall be well maintained
and approved by a competent authority.
Issue No.
Rev No. 0
11. All heavy equipment shall be equipped with an

operational back up alarm.
12. Proper Warning Boards and Safety Boards should be
provided at working site.
5.3 PPEs
Persons working at site shall always wear the appropriate

personal protective equipment which can include the following;
1. Safety Helmets
2. Safety footwear
3. Leather glovers
4. Goggles
5. Face and eye protection with correct grade of shield;
Above mentioned PPEs are minimum required which may include

more PPEs as per work and site conditions.
5.4 Detail of activities
1. Mechanical Completion
I. Mechanical completion is the condition that the individual
facility, system or equipment has been physically installed
in accordance with the drawings, specifications and codes
and regulations to the extent to start the pre
commissioning.
II. Upon the mechanical completion of the pipe line system
Contractor shall submit the following documents along with
the "intimation regarding system completion —FORMAT-1"
to the EPMC/Client .
• Pipe book duly completed in all respects
• List of golden tie-In joints (Tie-in joints which are not
subjected to hydrotesting i.e., for jointing the sections which
Issue No.
Rev No. 0
are already hydro tested) along with inspection reports for

each joint.
• Handing over certificates of land to land owners upon
completion of ROU restoration.
• Final clearance certificate from the respective
local/government authorities upon satisfactory restoration
of ROU crossing of all roads, rail road's, canals, ponds,
rivers, forests etc.
• As-built alignment sheets indicating all the levels, co-
ordinates, changes in route of the pipe line actually laid etc.
• All the test reports pertaining to the pipeline laying, duly
documented.
• OFC handing over report along with link test report to the
telecom vendor and as built sheets for OFC laying.
• Statutory approval for the electrical installations along
with test reports and as-built drawings.
• Final documentation of TCP system.
• Instrument installation and calibration reports.
• Instrument loop checking reports.
• As built drawings for SV Stations.
• As-built pipeline route map.
• All inspection reports as per approved procedures.
Contractor shall prepare and submit Format-1 progressively
for the following systems after completing all activities as
per the scope of contract, except the activities which will
not affect commissioning.
• Pipe line system including scraper facilities, Format-1

shall be prepared section wise
• Telecom system (OFC laying)
• CP works
• Electrical works, Format-I shall be prepared station wise
Issue No.
Rev No. 0
• Instrumentation work, Format-I shall be prepared station

wise
• General civil, structural & architectural works for stations
wise
Upon verification of Format-1 for each of the above systems,
EPMC/Client will arrange for the issue of "Check list" i.e.,
FORMAT-II to Contractor.
Contractor shall comply the above checklist points and
submit, "Ready for pre-commissioning certificate i.e.,
FORMAT-III to EPMC/Client
After completing all Pre-commissioning activities, as
directed by EPMC/Client , Contractor shall submit "Ready for
commissioning certificate" i.e., FORMAT-IV to EPMC/Client .
2. Physical Completion
Physical completion follows the mechanical completion and
when the certificate of physical completion issued by
OWNER
Upon the physical completion, the facilities and pipeline are
fully ready for the pre-commissioning and commissioning.
3. PRE-COMMISSIONING
Pre Commissioning are those activities following the

mechanical completion include such as pre-Commissioning
checks, dewatering and swabbing required to make reach
facilities for filling the Product.
Issue No.
Rev No. 0
Pre-Commissioning activities include but are not limited to

non-operating adjustments,tenderization of electrical
equipment and no load operations tests
• The pre-commissioning will be commenced system by
system/equipment by equipment,once the mechanical
completion of the same has been completed.
Before attempting any Pre-Commissioning activities, the
individual check lists or procedures prepared for each
equipment or system shall be studied along with the
relevant supplier's drawings, instructions/manual and shop
test reports
Commissioning of pipe line is considered completed when

the pipeline in case of availability of product, product has
been charged through the pipe line at normal operating
parameters with all the instruments, controls and interlocks
working satisfactory at normal operating conditions,
In case of non availability of product., line shall be
considered commissioned if the pipeline is ready to be
charged with product at operating pressure and the total
pipeline system shall be filled with corrosion inhibited water
at positive pressure in the filled with corrosion inhibited
water at positive pressure during preservation. The
necessary arrangement like, valves , fittings , fittings,
manpower etc.is kept for maintenance of pressure in the
pipeline during idle time preservation .
The following activities shall be included as a part of

commissioning assistance to be provided by contractor
• Final Drying/Swabbing
• Assistance to Client in valve operation, pig
handling/launching, operation of systems etc. during Pre-
Issue No.
Rev No. 0
Gas in stage and during commissioning at each of the

stations
• This section describes in detail, the details of the system
to be commissioned and activities to be performed as a part
of the commissioning assistance.
• The filtration and pressure reduction unit mounted with
metering skid unit being an integral part of metering skid is
executed from Contractor's scope of operation. As skid is
supplied by client, the vendor to carry out the operation of
valves equipment and instruments at the time of
commissioning to meet the requisite parameters of the
client.
5.5 Hazards involved
1. PRE-COMMISSIONING CHECKS
2. SYSTEM CHECKS
3. INTERNAL INSPECTION OF VESSELS (SCRAPPER

TRAPS & SCRUBBER)
4. OPERABILITY TEST OF VALVES

5. CHECKING OF FIELD INSTRUMENTS
6. SURVEY OF PIPELINE
7. CHECKING OF COMMUNICATION SYSTEM
8. Handling of bentonite / alternative casing filler

Issue No.
Rev No. 0
5.6 Precaution
1. Pre Commissioning Checks

Entire pipeline system shall be checked with respect to latest
P&ID and other design specifications. The pre-commissioning
checks shall be carried out for the pipeline to ascertain that the
pipeline system has been mechanically completed in all
respect. These checks shall cover the main pipeline including
pig launchers/receivers, scrapper near Dispatch station and
Receiving Terminals and sectionalizing valves stations.
2. System checks
i. The entire facilities shall be checked against the latest
P&ID's and other design specification/codes
3. INTERNAL INSPECTION OF VESSELS (SCRAPPER

TRAPS & SCRUBBER)
i. Launchers, receivers and scrubber shall be cleaned internally
and inspected for cleanliness and their internals for proper
installation
4. OPERABILITY TEST OF THE VALVE

i. All sectionalizing valves shall be subjected to an operability
test to check the operation of the valves.
5. CHECKING OF FIELD INSTRUMENTS

i. All field instruments like GOV/HOV, temperature Gauges,
pressure gauges, transmitters etc. shall be checked
physically and also for their intended application by
Issue No.
Rev No. 0
stimulating the operation condition. Contractor shall

coordinate with instrumentation vendors in this respect.
ii. • Actual functional check is a part of pre-commissioning
check, actual operational will be carried out at the time of
Product in.
5. SURVEY OF PIPELINE
i. This shall be performed to confirm that proper fitting /supports,
route markers, fencing around SV stations etc., have been
installed along the pipeline.
6. CHECKING OF COMMUNICATION SYSTEM

i. This is to check that there is proper communication with
adequate back up power to ensure uninterrupted
communication.
ii. Upon completion of the pre-commissioning the pipeline and
facilities are considered ready for the commissioning.
7. OPERATIONAL CHECK AND STABILIZATION
i. SCENARIO-I: NO PRODUCT IS AVAILABLE
Stabilization period shall be 24 hours during which all
parameters such as pressure, flow and temperature etc will
be monitor at control room.
ii. SCENARIO-II: NO PRODUCT IS AVAILABLE
iii. Stabilization period shall be 72 hours during which all

parameters such as pressure„ flow and temperature etc will
be monitor at control room will be recorded accordingly.
SAFETY CHECK
Issue No.
Rev No. 0
• The following points shall be ensured and checked by

safety officer and the same is to be reviewed by Client.
• No hot and cold jobs near the Commissioning area as per
site orientation.
• No naked fire or ignition is permitted in the
Commissioning area.
• Fire Extinguishers fire fighting hoses shall be made
available are to be checked and kept ready well before
starting commissioning.
• Arrangement shall be made for Fire brigade and Fire
engine including Ambulance, so that these can be rushed to
site in case of any emergency.
• All the commissioning personnel shall be informed in detail
about the procedure, chances of accidents involved and
actions to be taken in case of any emergency.
• The area under operation shall be cordoned off with 'No
Entry' sign at a radius suit to site condition from the work
place.
• Communication equipments and gas meters to be used
shall be in good working condition at all the time,
• Special care shall be taken during launching and receiving
of pigs. The pressure in barrel must be zero and there shall
be no valve bye pass, when opening the barrel.
• Running water hoses shall made available all the time
during commissioning.
• Before starting Commissioning, at SV stations and
terminals, security men shall be deployed
• Mobile phones shall not be allowed inside the process
area during Commissioning work.
8. DURING COMMISSIONING, EMERGENCY RESPONSE PLAN OF CLIENT
AVAILABLE AT SITE TO ACCOMMODATE PROCEDURE IN PLACE SHALL BE
FOLLOWED.
i. In case of Injury
Issue No.
Rev No. 0
First aid at site shall be given.

Local emergency -Ambulance, in case of severity if any
shall be called.
Commission In-charge/Manager shall be informed.
CR shall be notified for further assistance if any required.
ii. In case of Gas cut/failure

Intimate CR immediately.
Inform Client representative at place.
Isolate the section / string / loop under commissioning by
closing the valve as directed by Client representatives.
Control flow and back pressure to prevent any surge in
pipeline/section/loop.
iii. In case of fire

Inform Client CR immediately.
Inform fire station/ first aid centre.
Try to douse the fire till help arrives.
Affected area to be cordon off -Safety zebra tape.
After dousing of fire, check damages and reinstatement
the activity.
In case of Explosion
Cut flow of gas.
Inform Client Control Room immediately.
Inform fire station and first aid centre for action.
Cordon off the area by zebra tape immediately.
Start reinstatement after containment the site condition.
Start work, after clearance given by client.
6.0 RECORDS
a. Permit as per OISD-105

b. JSA and Tool Box Talk records as per OISD-105
Issue No.
Rev No. 0
c. Safety Checklists
d. Accident Reports as per OISD-107
e. Safety Training Record
f. Induction Reports

SOP-10 Pre Commissioning and Commissioning Activities

Uploaded by

Copyright:

Available Formats

You might also like

SOP-10 Pre Commissioning and Commissioning Activities

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SOP-10 Pre Commissioning and Commissioning Activities

Uploaded by

Copyright:

Available Formats

हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No.

Management Representative DGM-Projects

Revision and Amendment sheet

Page Clause Revisi Revision

Note: - As per the procedure for control of document procedure

SAFETY PROCEDURE FOR PRE COMMISSIONING AND

To encourage and educate personnel on the HPCL sites to

Applicable to all Pipeline Project locations and greenfield

OISD GDN -192

4.1 ROU In-charge / Officer In-charge / Project consultant’s

4.2 Officer In-Charge / Project consultant’s Safety Officer shall

commissioning activities and the schedule for the same shall

XII. Fire tender shall be made available at all station location by

Ensures that the pre-commissioning team are aware of the

5.2 Prerequisite before starting work

11. All heavy equipment shall be equipped with an

Persons working at site shall always wear the appropriate

Above mentioned PPEs are minimum required which may include

5.4 Detail of activities

are already hydro tested) along with inspection reports for

• Pipe line system including scraper facilities, Format-1

• Instrumentation work, Format-I shall be prepared station

Pre Commissioning are those activities following the

Pre-Commissioning activities include but are not limited to

Commissioning of pipe line is considered completed when

The following activities shall be included as a part of

Gas in stage and during commissioning at each of the

5.5 Hazards involved

3. INTERNAL INSPECTION OF VESSELS (SCRAPPER

4. OPERABILITY TEST OF VALVES

7. CHECKING OF COMMUNICATION SYSTEM

8. Handling of bentonite / alternative casing filler

1. Pre Commissioning Checks

3. INTERNAL INSPECTION OF VESSELS (SCRAPPER

4. OPERABILITY TEST OF THE VALVE

5. CHECKING OF FIELD INSTRUMENTS

stimulating the operation condition. Contractor shall

6. CHECKING OF COMMUNICATION SYSTEM

ii. SCENARIO-II: NO PRODUCT IS AVAILABLE

iii. Stabilization period shall be 72 hours during which all

• The following points shall be ensured and checked by

First aid at site shall be given.

ii. In case of Gas cut/failure

iii. In case of fire

a. Permit as per OISD-105

You might also like