Pre commissioning &

Commissioning safety

Prepared by: Islam Adel

commissioning Safety :

Mechanical pre-
commissioning &
commissioning

Prepared by: Islam Adel

 commissioning definitions :
• Pre-commissioning A series of verification and activities which
verify function of a competent, or group of components executed
prior to commencing commissioning activities on the portion of the
facilities, the Purpose of which is to prepare the system/subsystem
to be ready for commissioning .

• Commissioning is defined as those function testing activities to be

performed on a multi discipline basis and to bring the system into a
state of RFSU.

Prepared by: Islam Adel

Mechanical commissioning :

Mechanical

a)Pipe c)Rotatin
lines and b)Static g
Piping equipmen equipmen
system t t

Prepared by: Islam Adel

 a) Piping system :

Pre commissioning and

commissioning

Pre commissioning commissioning

Line
Leak test
cleaning

Gross
Chemical Water Air Lube oil Steam Mechanical Commiss
leak
cleaning flushing blowing flushing blowing cleaning leak test
test(GLT)

Prepared by: Islam Adel

 Pre commissioning Line cleaning

► Definition: Cleaning of pipe after pressure test and the

cleaning method is categorized by source of cleaning such as
air blowing, water flushing, steam blowing, chemical cleaning,
manual cleaning.

Prepared by: Islam Adel

1)Chemical cleaning
► Chemical cleaning should be applied to the pipes for which licenser/
vendor specifies or formation of rust is not allowed in the terms of
process
► Hazards related
► Chemical hazard
burns
Asphyxiation
Fire
Environmental damage

Prepared by: Islam Adel

 Control measures
► Permit to work system
► Trained workers
► MSDS for chemicals must be provided at site
► Safety shower and eye wash must be available
► Absorber, counter agent or the other effluent water treating system must be
available
► Barriers and signs
► Proper communications
► Mechanical Isolation control
► Tool box talk
► Suitable PPE

Prepared by: Islam Adel

 2)Water flushing
► Water flushing is applied to the pipes where are services for water or liquid process
line, mainly around pumps

► Hazards related

► Electric hazards resulted from drainage

Of water over electrical properties
► Slipping hazards

Prepared by: Islam Adel

 Control measures
► Protection cover must be provided around discharge area
► Discharge point must be brought down to the ground level
► All electrical equipment must be covered or removed from discharge point
► Sewer system must be capable of handling the discharged water
► Barriers and signs
► Mechanical Isolation control
► Proper communications
► PPE

Prepared by: Islam Adel

 3)Air blowing
► Air blowing is applied to the pipes which are services for air, gas or water
prohibited service
► Hazards related

► Noise
► Injury result from flying parts
► Injury result from sudden Disconnection for hoses

Prepared by: Islam Adel

 Control measures
► Protection cover must be provided around blowing point
► Check for hoses and connections
► Whip check must be provided for connections
► Barriers and signs
► Mechanical Isolation control
► PPE (ear muff)

Prepared by: Islam Adel

 4)Lube oil flushing
► Oil flushing should be applied to the lube oil pipe, seal oil and /or
hydraulic oil pipe fabricated at site for rotating machine.

► Hazards related
► Slipping hazard
► Chemical hazards
burns
Fire
Environmental damage

Prepared by: Islam Adel

 Control measures
► Permit to work system
► Trained workers
► MSDS for oil must be provide at site
► Tool box talk
► Safety shower and eye wash must be available
► Absorber, counter agent or the other effluent water treating system must
be available
► Barriers and signs
► Isolation control
► Suitable PPE
Prepared by: Islam Adel
5)Steam blowing
► Steam blowing should be applied to the pipes of mainly steam line
► Hazards related

► Burns result from

Very high temperature
► Noise

Prepared by: Islam Adel

Control measures
► Protect the area around blowing point
► All the piping where are accessible including temporary piping should
be insulated
► Barriers and signs must be provided
► Attention for line design temperature before start steam blowing
► Silencer must provided to reduce noise level

Prepared by: Islam Adel

 6)Manual cleaning
► Manual cleaning is to manually cleaning a piping by using hand tools,
power tools or other cleaning method

► Hazards related

► Electrical hazards
► Mechanical hazards
► Confined space related hazards

Prepared by: Islam Adel

Control measures
► Trained workers
► Permit to work system
► Mechanical Isolation control
► safe hand and power tools to be used
► PPE

Prepared by: Islam Adel

 commissioning
Leak test

► Pressurizing a system with air, nitrogen, steam or water up to maximum

operating pressure of the system to ensure that there is no external leakage from
relevant connections prior to introduction of flammable fluids into the system for
start up.

Prepared by: Islam Adel

 Leak test

Gross leak test (GLT ) Commissioning leak test (CLT)

leak test by air

leak test by nitrogen (inert gas)

Prepared by: Islam Adel

Leak test
► Hazards related

► Injury resulted from flying parts.

► Injury resulted from sudden disconnection for hoses
► Asphyxiation from nitrogen
► noise

Prepared by: Islam Adel

Control measures

► Permit to work must be provide

► Barriers and sign
► Check for mechanical isolation
► Safe accessibility for checking points
► Inspection for nitrogen tanks, pumps , hoses and pressure gages
and its certificates
► Communication tools should be available
► All threaded connection within the test loop and test connections
to be checked and well tight
► PPE

Prepared by: Islam Adel

b)Static equipment
Pre-commissioning
commissioning

Pre-
commissioning
commissioning

Boxing up Leak test

Catalyst
loading

Prepared by: Islam Adel

Pre-commissioning boxing up
► Boxing up is defined as preparation for static equipment (vessels, tanks etc.) to
be ready for tightness test using hand and power tools

► Hazards related
► Confined space hazards (electrical hazard, mechanical hazards,etc.)

Prepared by: Islam Adel

Control measures
► Permit to work procedure
► Isolation control
► Confined space certificate
► Proper ventilation and sufficient lighting
► Safe hand and power tools
► PPE

Prepared by: Islam Adel

 Commissioning
catalyst loading
► Catalyst loading filling of static equipment by chemical material to purify
hydrocarbons

► Hazards related
► Chemical hazard
burns
Asphyxiation
Fire
Environmental damage

Prepared by: Islam Adel

Control measures
► Permit to work system
► Competent contractor
► MSDS for chemicals must be provide at site
► Safety shower and eye wash must be available
► Tool box talk
► Barriers and signs
► Suitable PPE

Prepared by: Islam Adel

c)Rotating equipment

Commissioning and
pre commissioning

Pre
commissioni
commissioni
ng
ng

Mechanical
Lube oil run test
flushing
(MRT)

Prepared by: Islam Adel

 Rotating equipment commissioning
Mechanical run test(MRT)
► Coupled running of rotating machine with air, nitrogen, water or other applicable
fluids as required to simulate an operating state on the rotating machine. If
necessary, it is to be conducted under supervision of vendor specialist.

Prepared by: Islam Adel

Hazards related
► Electrical hazard
► Injury result from rotating parts

CONTROL MEASURE
► Trained people
► Check for electric connections
► Protect rotating parts
► Isolation control
► PPE

Prepared by: Islam Adel

Prepared by: Islam Adel