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SOP-OPS-001 Commissioning Procedure - Draft
SOP-OPS-001 Commissioning Procedure - Draft
SOP-OPS-001 Commissioning Procedure - Draft
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 1 of 9
SOP-OPS-001
COMMISSIONING PROCEDURE
CONTENTS
1. Introduction
2. Scope
3. Commissioning Procedures
Checklist:
1.0 Introduction
Commissioning Procedure Prepared by: HAH
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 3 of 9
This procedure is prepared for SRS Middle east FZC. It incorporates the relevant
procedures and guidelines from API 700 (Checklist for Plant Completion), Owners Manuals,
Regulations and industry best practices pertaining to commissioning of Petroleum storage
Terminals.
2.0 Scope
The purpose of this manual is to document procedures necessary for the safe
commissioning of SRS terminal & associated facilities at Port of Hamriyah.
This section lists down the procedures to be followed equipment wise in order to make the
facility ready for commissioning. The facility will be considered ready for commissioning when
the facility or any part thereof has been erected in accordance with Drawings, specifications,
instructions and applicable codes and regulations to the extent necessary to permit
commissioning.
3.1 General
Procure all necessary permits and certifications required to start up the facility. Ensure
that application for all necessary permits required for plant use , occupancy and
operation have been made to relevant authorities.
3.1.3 Instructions
Ensure that all rust preventives and oils used to protect the equipment during
construction period are removed before pre-commissioning.
3.1.5 Lubricants
Ensure that all mechanical seals, packings and their accessories as per manufacturer’s
instructions have been provided and properly installed.
Ensure that all temporary supports, bracing or other foreign objects that were installed
during shipping, storage or erection are removed and damages caused if any are
repaired.
Check rotating machinery for correct direction of rotation and freedom of moving parts
before connecting the driver.
Ensure alignment is done as per manufacturers tolerance.
If required ensure presence of factory representative during installation of equipment.
Obtain the schedule of field leak tests or field pressure test on critical equipment’s and
pipelines.
Ensure that all tests are conducted as per applicable codes, specifications and
regulations.
Witness test and/or verify records.
Ensure all test media is disposed as per regulation.
Conduct all operational tightness tests.
3.1.10 Inspection
Commissioning Procedure Prepared by: HAH
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 5 of 9
Inspect the plant to verify that erected facilities confirm to flow diagrams, construction
drawings, vendor prints and specifications.
Verify that specified materials have been installed in the plant and document
verification.
Note any exception on a separate work order list (punch list).
Provide for special inspections such as those required by insurance or governmental
agencies.
Ensure media used for flushing and/or cleaning is disposed off as per regulations.
Ensure that the systems taken over are free of trash and construction debris.
Ensure all temporary strainers are installed and locations marked physically as well as
on drawings.
Remove strainers when system is adequately cleaned and replace/remove with original
ones.
Provide/install and remove all blinds required for flushing or isolation .
3.1.14 Purging/Inerting
3.1.15 Housekeeping
Obtain spare part list as recommended by manufacturer and procure necessary spare
parts.
Ensure environmental surveys are carried out and keep copy of reports. For eg. Noise
surveys for individual equipment.
Ensure Baseplates and soleplates are level and grout all bearing surfaces.
Excess piping stresses imposed on pumps drivers and compressors should be
alleviated.
Chemically clean lube oil/ seal oil system as specified.
Charge the lube oil, seal oil, oil cooling system flushing oil and circulate for cleaning
purposes.
Charge the lube oil, seal oil, and oil cooling systems with the operating oils
recommended by the manufacturer.
Operate the equipment and make vibration, trip, governor and safety devices checks
and any operating tests and adjustments as required.
Obtain assistance of a service engineer for technical advice during installation prestart
up if desired/required.
Conduct any non-operating checks to ensure instrument operability, that is, remove all
shipping stops, check pointer travels and verify instrument capability to measure,
operate and stroke in the right direction.
Ensure all equipment is bench/field calibrated using standard test equipment.
Ensure all transmission and control tubing by blowing with cooled and filtered clean air
before connecting to instrument components.
Check all air supply headers for tightness.
Leak test pneumatic control circuits.
Check piping from instruments to process piping for tightness.
Check all electrical signals and alarm wiring for continuity, correct source of power and
polarity.
Ensure sealing fluids as required are installed
Fully pressurize and energize the transmitting and control signal system(s) by opening
process connections at primary sensors and final regulators and by making control
mode settings for automatic operation of equipment as the process unit is charged and
brought to stream.
Inspect facilities for completeness and correctness of installation and make any
non-operating checks to ensure their conformance to specifications.
Check installation of buildings and accessories including all heating, ventilating and
air- conditioning equipment to ensure their completeness and conformance to
specification.
As required obtain certification that all plumbing, electrical, fire protection and
special materials handling installations comply with local government regulations.
Obtain certificate of occupancy and use if required.
marked on drawing.
2 Pipe resting properly on supports.
3 Pipe clamps, hangers, supports provided as
per drawing.
4 High points have vent and low points have
drain.
5 All vent and drain valves provided with blind
flange.
6 All flanges properly bolted with specified
gaskets.
7 Flange to flange alignment checked.
8 Blinds and spacers inserted as per drawing.
9 Anchors (where applicable) properly
installed.
10 All end flanges in leak proof area.
11 Specified slope provided.
12 Max and Min design limits for Flow, temp,
pressure etc tabulated.
13 Hydrotest reports submitted and verified.
14 Pipe cleaning reports submitted and verified.
15 Material datasheets submitted and verified.
16 All QA/AC documents submitted and verified.
17 Pipe painted as per specification. Check
reports and random DFT.
18 Colour as specified.
19 Proper labelling of pipe and valves done in
specified locations
20 Valve checklist for valves on the pipeline
filled.
23 All as built drawings and documentation
received.
Remarks/ Observations:
Commissioning Procedure Prepared by: HAH
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 10 of 9
Signature :
Date :
Check List For PUMPS
Pump number:
Commissioning Procedure Prepared by: HAH
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 11 of 9
Remarks/ Observations:
Signature :
Date :
Checklist for Pump station
Sno Item To be Checked Status Remarks
1 Safe access provided into the pump station and
located as per drawing
2 Area properly graded and finished.
Commissioning Procedure Prepared by: HAH
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 14 of 9
Signature :
Date :
Checklist for Tank Pit area
Sno Item To be Checked Status Remarks
1 Safe access provided in to the tankpit and located
as per drawing
2 Area properly graded and finished.
Commissioning Procedure Prepared by: HAH
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 15 of 9
Remarks/ Observations
Signature :
Date :
Checklist for Fixed Roof Tanks
1. Calibration table received in both hard & soft copy. Hard copy stamped by relevant
third Parties/authorities.
2. Manuals of all tank fixtures are provided such as, Pivot master. Tank body valves,
Level Gauges, QA/QC documents.
3. PFDs, P&IDs, GADs, detailed drawings of each tank. Tank settlement details.
Commissioning Procedure Prepared by: HAH
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 18 of 9
Remarks/ Observations
Signature :
Date :
Checklist for Internal Floating Roof Tanks
either side.
61 Guide pole brass rollers are free and rotating.
62 Guide pole opening is sealed by brass plate or not.
63 Exposed area between guide pole and brass plate is sealed
with compatible material or not.
64 All roof manholes are closed and properly secured.
65 All manual gauge openings are properly closed/blinded &
secured with gasket.
66 Dip hatch opening provided with compatible rubber seal.
1. Calibration table received in both hard & soft copy. Hard copy stamped by relevant
third Parties/authorities.
2. Manuals of all tank fixtures are provided such as, Pivot master. Tank body valves,
Level Gauges, QA/QC documents.
3. PFDs, P&IDs, GADs, detailed drawings of each tank. Tank settlement details.
4. All Hydrostatic test details.
Commissioning Procedure Prepared by: HAH
Revision: 0
Date: Sept 2019
DOCUMENT NO.: SOP-OPS-001 Page 22 of 9
Remarks/ Observations
Signature :
Date :