Chapter 4 - Rev A

COMPANY Job N° COMPANY Doc.
N° August 2007
Chapter: 4
Page: 1
QC2-0007 RC2-31-COMT-OPM-00-000-0001 Rev: A
CHAPTER 4
PRELIMINARY OPERATIONS PRIOR TO INITIAL START-UP
CONTENTS
1.
GENERAL 3
2.
PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES 4

2.1
Pre-commissioning Activities 4
2.2
Commissioning Activities 7
3.
PLANT INSPECTION 10
3.1
Equipment Inspection and Cleaning 10

3.1.1
Vessels 10
3.1.2
Pumps 14
3.1.3
Electrical Motors 17
3.1.4
Compressors and Turbines Drivers 18

3.1.5
Air Coolers / Condensers Fans 18

3.2
Piping Inspection 20
COMPANY Job N° COMPANY Doc. N° August 2007
Chapter: 4
Page: 2
3.2.1
Piping Sliding Supports and Anchors 20

3.2.2
Spring Supports 20
3.3
Electrical Equipment Inspection 20

3.4
Instrumentation Preparation 21
3.5
Heating, Ventilation Air Conditioning Equipment 22

3.6
Telecommunications 23
4.
CLEANING OF PIPING AND EQUIPMENT 24

4.1
General 24
4.2
Water Flushing 25
4.3
Air Blowing 27
4.4
Steam Blowing 27
4.5
Chemical Cleaning 28
4.5.1
Cleaning and Pickling of Piping 29

4.5.2
Storage or Installation of Chemically Cleaned Pipework 30

4.5.3
Chapter: 4
Page: 3
Safety Consideration 31
4.6
Lubrication Systems Flushing 31

4.6.1
Preliminary Air Blowing 31

4.6.2
Chemical Cleaning 31
4.6.3
Neutralizing Procedure 32
4.6.4
Flushing with Lubricant Oil 32

4.7
Blinds List 33
5.
TIGHTNESS TESTS 34
5.1
General Procedure 34
5.1.1
Pressure Test 34
5.1.2
Leak Repairs / Tightening 34

5.1.3
Vacuum Test 35
6.
PLANT PURGING AND INERTING 36
7.
SPECIFIC ACTIVITIES 37
7.1
Section 1100 - Storage Area 37

7.1.1
Chapter: 4
Page: 4
Products Storage Drying 37

7.1.2
Fill in of the Fresh Caustic Tank 95-TK-1147 37

7.1.3
Fill in of the Sulfuric Acid Tank 95-TK-1148 37

7.1.4
Fill in of the Wash Oil Tank 95-TK-1149 37

7.1.5
Fill in of the Lube Oil Tank N°1 95-TK-1151 37

7.1.6
Fill in of the Lube Oil Tank N°2 95-TK-1153 37

7.1.7
Fill in of the DMDS Drum 95-D-1120 37

7.1.8
Fill in of the Polymerization Inhibitor Tank 38

7.2
Section 1200 – Utilities 38

7.2.1
Instrument Air and Plant Air 38

7.2.2
Desalinated Water, Fire Water, Fresh Water, Potable Water 38

7.2.3
Demineralized Water and Polished Water 38

7.2.4
Cooling Water 38
7.2.5
Boiler Feed Water 39

7.2.6
Fuel Gas 40
7.2.7
Steam System 40
7.2.8
Flare System 41
Chapter: 4
Page: 5
7.2.9
Thermal Oxidizer 41
7.2.10
Waste Water Treatment 41

7.2.11
Spent Caustic Treatment 41

Chapter: 4
Page: 6
1. GENERAL
This chapter covers activities required to bring the plant to a "ready for start up" condition from the
original construction. The commissioning team, in close coordination with construction forces,
implements this part of precommissioning and commissioning activities.
The preliminary works for initial start-up can basically be divided into the following:
 Plant inspection, checkout of unit.
 Cleaning of piping and equipment.
 Checking of control and safety systems
 Commissioning of utility systems.
 Run-in of drivers and Commissioning of machinery.
 Loading of catalyst.
 Chemical cleaning.
 Air Leak/tightness test.
 Boil-out of steam generating system.
 Dryout of furnace refractories and process systems
 Nitrogen purging.
Although the work will proceed generally in this order, much overlapping may be permitted.
During the preliminary operations, any defect should be disclosed, thus allowing timely
rectification’s to be effected. To obtain complete confidence in the state of the plant and
equipment, site staff must be particularly attentive to systematic checking for possible defects. At
subsequent start-up and partial start-ups, when perhaps only one item of the plant has been isolated
for short maintenance, equal diligence will be applied to appropriate pre-operational checks.
General procedures for preparation are described in the overall plant procedures and only basic
guides are given here. Specific procedures are described in this chapter. For all procedures
described, documentation provided by vendors shall be considered along. This information will
serve as a guide to the plant operators, as commissioning operations will be done using owner
personnel under guidance and supervision of contractor personnel
The result of these activities will be reported on sheets, issued and filled-up on site by
commissioning team. Obviously, some of the static activities hereafter described and implemented
during the construction/mechanical completion phase will be checked/ witnessed by
commissioning team, as they are part of its scope of work and responsibility. So no rigid border
exists between the construction phase and the precommissioning phase, which is achieved with the
Mechanical Completion, system per system.
When Mechanical Completion is reached for a system, the commissioning phase is performed. The
information described hereafter concern the preliminary operations for the first start-up of the new
plant.
In addition, for subsequent start-up, it may happen that some preliminary operations described
hereafter have to be performed or repeated, depending on the current situation (case of shutdowns
for maintenance works, capacities opening, …).
COMPANY Job N° August 2007
COMPANY Doc. N°
Chapter: 4
Page: 7
2. PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES
2.1 Pre-commissioning Activities
SYSTEM N° SYSTEM DESCRIPTION Piping Elec Inst Static Rotating
Eqpt Inspection
PID Check/ PL
Field Instrum.
Internals Load
Chem Treatmt
Motor run-in
Mech. Clean
Oil Flushing
Water Flush
Steam Blow
Loop check
Pre-Commissioning Activity
Oil Filling
Air Blow
Coupling
31 Unit OSBL
31.002 – 01 HP Steam X X X X
31.002 – 02 MP Steam X X X X
31.002 – 03 LP Steam X X X X
31.011 – 01 Boiler 07-B-1207 A X X X X X X X X X X
31.012 – 01 Boiler 07-B-1207 B X X X X X X X X X X
31.013 – 01 Boiler 07-B-1207 C X X X X X X X X X X
31.020 – 01 Water & Condensate Common X X X X
31.020 – 02 Turbine Condensate X X X
31.020 – 03 MP Condensate X X X X X X
31.020 – 04 LP Suspect Condensate X X X X X X X X
31.021 – 01 Remineralization Package X X X X X X X X
31.022 – 01 Demineralization Package X X X X X X X X X
31.022 – 03 Polishing Package X X X X X X X X
31.022 – 04 Polished Water Distribution X X X X X X X X
31.023 – 01 Drinking Water X X X X X X X X
31.023 – 02 Utility Water X X X X X X X X
31.024 – 01 Deaerator X X X X X
31.024 – 02 VHP Boiler Feed Water X X X X X X X X X
31.024 – 04 HP Boiler Feed Water X X X X X X X X X
31.024 – 05 BFW Phosphate Injection Pack. X X (2) X X X X
31.024 – 06 O2 Scavenger Injection Package X X (2) X X X X
31.024 – 07 Amine Injection Package X X (2) X X X X
31.025 – 01 Cooling Water (OSBL, UG ISBL) X X(1) X X X X X X X X
31.025 – 02 Corrosion Inhibitor Injection Pack X X (2) X X X X
31.025 – 03 Sea Water X X(1) X X X X(1)
31.025 – 04 Sea Water Oxidant Package X X (2) X X X X
31.026 – 01 Fire Water (OSBL & UG ISBL) X X X X X X X X
31.026 – 02 Back Up Fire Water X X
31.027 – 01 Desalinated Water Distribution X X X X X X X X
31.037 – 01 Air Generation X X X X X X X X
31.037 – 02 Plant Air X X X X
31.038 – 01 Air Dryers Package X X X X X X
31.038 – 02 Instrument Air X X X X
31.038 – 03 HP Instrument Air X X X X X X X X
31.039 – 01 Nitrogen X X X X
COMPANY Job N° August 2007
COMPANY Doc. N°
Chapter: 4
Page: 8
SYSTEM N° SYSTEM DESCRIPTION Piping Elec Inst Static Rotating
Eqpt Inspection
PID Check/ PL
Field Instrum.
Internals Load
Chem Treatmt
Motor run-in
Mech. Clean
Oil Flushing
Water Flush
Steam Blow
Loop check
Pre-Commissioning Activity
Oil Filling
Air Blow
Coupling
31.040 – 01 FuelGas, Wet Flare Condensates (not used)
31.045 – 01 FuelGas (Boilers, Utilities OSBL) X X X X X
31.045 – 02 Fuel Gas (Furnaces) X X X X X
31.046 – 01 Low Profile Flare Package X X X X X
31.046 – 02 Cold Flare (OSBL) X X X X X
31.046 – 03 Wet Flare (OSBL) X X X X X X X X
31.046 – 04 Cold Drain (OSBL) X X X X
31.050 – 01 Thermal Oxidizer Package X X X X X X X X
31.060 – 01 Waste Water Treatment Package X X X X X X X X X X X
31.060 – 02 Storm Water Treatment Package X X X X X X X X X X
31.060 – 03 Sanitary Water Treatment Pack. X X X X X X X X X X X
31.060 – 04 Effluents X X X X
31.071 – 01 Ethane X X X X X X X
31.072 – 01 Ethylene X X X X X X X X
31.073 – 01 C3/C4 X X X X X X X X
31.074 – 01 Pyrolyse Gasoline Storage & Shipping X X X X X X X X
31.075 – 01 C9+ Storage X X X X X X X X
31.075 – 02 Propane Storage X X X X X
31.075 – 03 Fresh Caustic Storage, Distribut. X X X X X X X X
31.075 – 04 Sulfuric Acid Storage, Distribut. X X X X X X X X
31.075 – 05 Wash Oil Storage & Distribution X X X X X X X X
31.075 – 06 Lube Oil Storage & Distribution X X X X X X X X
31.075 – 07 Mist Oil Storage & Distribution X X X X X X X X
31.080 – 01 Spent Caustic Treatment X X X X X X X X X X
31.080 – 02 Caustic & Acid Close Drains X X X X X X X
31.090 – 01 Oily Water Sewers X X
31.090 – 02 Contamin. Surface Water Sewers X X
31.090 – 03 Clean Roof Water Sewers X X
31.090 – 04 Sanitary Sewers X X X X X X X
31.090 – 05 Methanol, Propanol Inject System X X X X
31.091 – 01 DMDS Storage & Distribution X X X X X X X X
31.092 – 01 Gasoline Station X X X X X X X X
31.092 – 02 Diesel Station X X X X X X X X
31.093 – 01 Emergency Diesel Generator A X X X X X X X X
31.093 – 02 Emergency Diesel Generator B X X X X X X X X
31.096 – 01 Pyrolyse Gasoline Load, Drains X X X X X X X X
31.097 – 01 Ethane Meter Station/ Coalescer X X X X X
Chapter: 4
Page: 9
Notes:
According to the size of lines, Water Flushing can be replaced by Mechanical Cleaning or Air
Blowing.
(1): diameter 60” and above: lines not blown nor washed, to be mechanical cleaned if requested
(2): For displacement pumps, no solo run of motor: replaced by run-in of Pump (refer to
Commissioning part)
COMPANY Job N° August 2007 COMPANY Doc. N°
Chapter: 4
Page: 10
2.2 Commissioning Activities
SYSTEM N° SYSTEM DESCRIPTION Piping Control Syst. Rotating Safety START-UP
Final refractory Dry out

Functional Loop test
Fire Fighting Equpt

Close Circulation
PSSR check list

Air Purge, Inert
Over Sped test

Tightness Test
Commissioning Activity
Run C3, C2=,

Vacuum test
SIS Check
F&G test
Boil Out
Drying
Run-in
31 Unit OSBL
31.002 – 01 HP Steam X X X X
31.002 – 02 MP Steam X X X X
31.002 – 03 LP Steam X X X X
31.011 – 01 Boiler 07-B-1207 A X X X X X X X X X X X X
31.012 – 01 Boiler 07-B-1207 B X X X X X X X X X X X X
31.013 – 01 Boiler 07-B-1207 C X X X X X X X X X X X X
31.020 – 01 Water & Condensate Common (not used)
31.020 – 02 Turbine Condensate X X X
31.020 – 03 MP Condensate X X X
31.020 – 04 LP Suspect Condensate X X X X
31.021 – 01 Remineralization Package X X
31.022 – 01 Demineralization Package X X ? X
31.022 – 03 Polishing Package X X X
31.022 – 04 Polished Water Distribution X X X X
31.023 – 01 Drinking Water X X X
31.023 – 02 Utility Water X X X
31.024 – 01 Deaerator X X X X
31.024 – 02 VHP Boiler Feed Water X X X X X X
31.024 – 04 HP Boiler Feed Water X X X X X X
31.024 – 05 BFW Phosphate Injection Pack. X X
31.024 – 06 O2 Scavenger Injection Package X X
31.024 – 07 Amine Injection Package X X
31.025 – 01 Cooling Water (OSBL, UG ISBL) X (1)
X X X X X X X
31.025 – 02 Corrosion Inhibitor Injection Pack X X
31.025 – 03 Sea Water X X
31.025 – 04 Sea Water Oxidant Package X X
31.026 – 01 Fire Water (OSBL & UG ISBL) X X X X X X X X
31.026 – 02 Back Up Fire Water X
31.027 – 01 Desalinated Water Distribution X X X
31.037 – 01 Air Generation X X X X X X
31.037 – 02 Plant Air X X X
31.038 – 01 Air Dryers Package X X X X X
31.038 – 02 Instrument Air X X X X X
31.038 – 03 HP Instrument Air X X X X X
31.039 – 01 Nitrogen X X X X X
COMPANY Job N° August 2007 COMPANY Doc. N°
Chapter: 4
Page: 11
SYSTEM N° SYSTEM DESCRIPTION Piping Control Syst. Rotating Safety START-UP
Final refractory Dry out

Functional Loop test
Fire Fighting Equpt

Close Circulation
PSSR check list

Air Purge, Inert
Over Sped test

Tightness Test
Commissioning Activity
Run C3, C2=,

Vacuum test
SIS Check
F&G test
Boil Out
Drying
Run-in
31.040 – 01 FuelGas, Wet Flare Condensates (not used)
31.045 – 01 FuelGas (Boilers, Utilities OSBL) X X X X X X X
31.045 – 02 Fuel Gas (Furnaces) X X X X X X X
31.046 – 01 Low Profile Flare Package X X X X X X X
31.046 – 02 Cold Flare (OSBL) X X X X X X X
31.046 – 03 Wet Flare (OSBL) X X X X X X X
31.046 – 04 Cold Drain (OSBL) X X X X
31.050 – 01 Thermal Oxidizer Package X X X X X X X X
31.060 – 01 Waste Water Treatment Package X X X X X
31.060 – 02 Storm Water Treatment Package X X X X X
31.060 – 03 Sanitary Water Treatment Pack. X X X X X
31.060 – 04 Effluents X
31.071 – 01 Ethane X X X X X X X
31.072 – 01 Ethylene X X X X X X X X
31.073 – 01 C3/C4 X X X X X X X X
31.074 – 01 Pyrolyse Gasoline Storage & Shipping X X X X X X X
31.075 – 01 C9+ Storage X X X X X X X
31.075 – 02 Propane Storage X X X X X X X X
31.075 – 03 Fresh Caustic Storage, Distribut. X X X X X
31.075 – 04 Sulfuric Acid Storage, Distribut. X X X X X
31.075 – 05 Wash Oil Storage & Distribution X X X X X X
31.075 – 06 Lube Oil Storage & Distribution X X X X X X
31.075 – 07 Mist Oil Storage & Distribution X X X X X X
31.080 – 01 Spent Caustic Treatment X X X X X
31.080 – 02 Caustic & Acid Close Drains X
31.090 – 01 Oily Water Sewers X
31.090 – 02 Contamin. Surface Water Sewers X
31.090 – 03 Clean Roof Water Sewers X
31.090 – 04 Sanitary Sewers X
31.090 – 05 Methanol, Propanol Inject System X X X X X
31.091 – 01 DMDS Storage & Distribution X X X X X
31.092 – 01 Gasoline Station X X X X X X X
31.092 – 02 Diesel Station X X X X X X X
31.093 – 01 Emergency Diesel Generator A X X X X X X X X
31.093 – 02 Emergency Diesel Generator B X X X X X X X X
31.096 – 01 Pyrolyse Gasoline Load, Drains X X X X X X X X
31.097 – 01 Ethane Meter Station/ Coalescer X X X X X X X
Chapter: 4
Page: 12
Notes:
(1): for the drum area.
Chapter: 4
Page: 13
3. PLANT INSPECTION
The plant should be carefully checked to assure that it is constructed according to the applicable
plans, drawings and specifications. A check-off against the Piping and Instruments Diagrams is
done for piping, equipment and instrumentation. A "punch list" of missing, incomplete, or incorrect
items is then prepared for correction. In addition, temporary identification tags, signs for various
lines, valves and equipment can be installed at this time to assist in subsequent start-up and
operation.
This check is carried out before the end of construction work in order to check that the plant is
satisfactory from an operation point of view. All the individual operations needed for
precommissioning, start-up and shut-down the plant are applied on site.
The work described hereafter is carried out during the final stages of construction work under the
direction of the commissioning team in charge of the plant. Typically, this checking (which can be
called preliminary conformity to PID's check) is useful as soon as construction progress is 70% and
above. Several checks can be made simultaneously depending upon the completeness of each
section or system of plant at that time.
Smooth start-up will depend to a large degree on the thoroughness with which the plant is checked
out beforehand. Every installation details must be checked against the design specifications and
standards and for good construction practice.
3.1 Equipment Inspection and Cleaning
3.1.1 Vessels
a. General Inspection
A general inspection of the vessel is made against the design drawings soon after erection. This
check includes:
 Verification of temperature/ pressure and vacuum rating on nameplate.
 Verification of lining condition (if applicable).
 Nozzles location, size, flanges face
 Thermo well location and length of immersion
 Cleanliness.
When equipment experiences a temperature change it undergoes thermal growth. Supports are
provided to allow and guide this growth. If supports do not function as they are intended, then
damage could result to vessels, columns, heat exchangers nozzles or piping as the case might
be. It is therefore of great importance that all supports are inspected and special attention is
given to large horizontal vessels and heat exchangers.
Chapter: 4
Page: 14
Vessels Sliding Supports

In general thermal growth of horizontal vessels is guided and controlled by anchoring one end
firmly and permitting the other end to slide. To permit movement the sliding end is equipped
with slotted or elongated bolt holes. Occasionally long horizontal vessel may be anchored in the
middle permitting growth towards either end. In any event it is important to see that the vessel
grows in accordance with the design parameters to prevent damage.
 Inspection :
 Check that there is no foreign matter lodged in elongated slots. Any object firmly wedged
between the slot and the bolt could prevent sliding.
 Check that all the bolts in the slots are loose and are located at the correct ambient
position. Even if the bolt is at the correct end of the slot as there should be some
allowance for thermal contraction caused by atmospheric conditions different from those
on the day of inspection.
 Get the approximate thermal growth from figure on following page (Approximate
thermal expansion mm/m of metals versus temperature °C) and establish that the sliding
plate can travel at least this distance and that the slotted holes are large enough to permit
this growth.
 Check that the sliding plate is free to slide and that it will not be obstructed in its travel.
 Check that the sliding plate and base plate are not bonded by rust or other.
Exchanger Sliding Supports
All comments applying to vessels in the above paragraph also apply to exchangers. In addition
all expansion joints should be checked to ascertain that any restraints installed for shipping
purposes have been removed (especially on air cooled exchangers). Especially for air coolers,
ensure that transportation locking device is released to allow dilatation (usually a bolted anchor
on both sides).
Equipment and Structure
Especially in high temperature process, as relative dilation of pipes liaison with structure is
important due to high temperatures:
 Check that relevant lines and expansion joints are free to move in all directions. Be sure
shipping stops are removed on the expansion joints if any.
 Check that the platforms and other structures will not interfere with the free expansion of the
equipment in any direction.
 Check that instrument piping, electrical conduit and other equipment is in no danger of binding.
b. Internal Inspection
Drums and vessels will be inspected internally by observation with a light.
The bottom manhole should be left open in case tools or other materials are accidentally
dropped down.
Check that no scaffolding or trash remains in the vessel.
Chapter: 4
Page: 15
Vessels and tower internals must be inspected carefully and checked against the design
documents to ensure that the installation was properly carried out. This check should include:
 Trays: number, location, type, spacing, levelness, weir height, downcomers, valve number and
operation, support bolting. (Tightness testing is usual for chimneys trays).
 Check that all valves on valve type tray are clean and free to move.
 Check that weep holes, where provided, are not plugged.
 Distributors: location, alignment, size and number of openings.
 Vortex breakers: type, size and orientation
 Demisters : size, material, support
 Check that baffles in the bottom of the columns are correctly fitted, type, orientation and
levelness
 Check that instrument nozzles are clear. Those which are accessible from inside the vessel can
be checked by turning on the aeration air. Those which are accessible only from the outside will
be checked during the air tightness test which will be implemented prior to inerting by
observing that the instrument vent valve is passing air.
Reactors
1. Inlet distributors, quench distributors: metallurgy, type, size, opening sizes, freedom to expand.
2. Vapor / liquid collection and distribution trays: tightness, vertical positioning, liquid tightness of
bubble caps and risers, metallurgy, dimensions, packing, supports, welding, levelness,
cleanliness.
3. Catalyst support grids: metallurgy, grid type and dimensions, screen type and size, supports,
welding.
4. Catalyst unloading nozzles: metallurgy, orientation, length.
5. Thermo wells: orientation, length, and metallurgy.
6. It must be verified that sufficient quantities of bolts, washers and hold downs of the proper size
and metallurgy are available to reassemble any disassembled portions of the reactor internals.
c. Cleaning
All vessels, columns, drums, tanks, etc. have to be inspected and cleaned if required, before
final closure, boxing-up.
The final cleaning is witnessed by the commissioning team, especially if the relevant vessel has
been integrated in a cleaning sequence.
In such case, it is normal practice that the vessel capacity is finally closed/boxed-up after
inspection and information it is clean. If the capacity is used as a buffer capacity, make sure that
air is evacuated from the vessel to lines and not reverse.
When the vessel is used as "collecting device", it must be finally closed only after cleaning.
Vessels’ cleaning is normally done through different ways according to the equipment
materials.
Chapter: 4
Page: 16
Equipment internal materials generally are the following:

 Carbon steel,
 Stainless steel,
 Carbon steel lined with different coating material.
The following procedure will be applied.
Carbon Steel Equipment
Carbon steel equipment will be brushed or wiped when required with brush to remove scale
flakes if any, rust, protection oil, etc. before final closure.
After successful inspection, the equipment will be closed definitely with final gasket.
During precommissioning phase all activities relevant to piping connected with such equipment
will be done with care in order to avoid fulling equipment (piping cleaning will be done by
disconnecting the piping at the flange connections of equipment and the equipment nozzles for
the first cleanings. Flushing will not be directed into vessels or columns containing internals).
Note:
Storage tanks must be clean of any corrosion scales or rust flakes and dust. Depending on the
initial condition of these tanks a cleaning by means of sand blasting may have to be performed.
Afterwards these tanks must be put under nitrogen atmosphere to prevent corrosion (or dry air if
nitrogen is not available).
Stainless Steel Equipment
Stainless steel equipment will be cleaned by using cloth rag before final check (wire brush
should not be used). After successful inspection, the equipment will be closed definitely with
the final gasket.
Carbon Steel with Lining
Such equipment will be cleaned by using a water spray, to prevent lining damages.
Note:
For equipment on which internals have to be installed during precommissioning phase, final
inspection will be done after internals installation.
d. Final Inspection
After hydrotest (on a system / test-pack basis), cleaning and dry-out as required, a final vessel
inspection should be done. When vessels have been shop-tested, they will not be further tested
in the field but may be included as part of a piping system test.
Carefully inspect for cleanliness. After the final inspection, immediately close, after mutual
agreement on "final closure / boxing-up" document.
Note that final boxing-up is done after agreement and checked by the commissioning team.
Vessels final closure (boxing-up) will occur after blowing/ flushing are implemented during the
precommissioning phase.
Therefore, a vessel may be required, after inspection for conformity against design and
drawings, to be closed temporarily by the commissioning team until final inspection.
Chapter: 4
Page: 17
Caution:
Before entering a vessel, the plant safety precautions should be observed. These include the
following: sampling the vessel for toxic vapors and oxygen concentration wearing a safety
harness and having an attendant outside the vessel. AN UNATTENDED VESSEL SHOULD
NEVER BE ENTERED.
3.1.2 Pumps
a. Initial Checking
The most critical period in the life of a pump is during its initial start and several minutes
immediately thereafter. Proper installation and start-up is essential for trouble-free performance.
Before the equipment is ever started, it should be checked as follows:
 Review carefully the manufacturer's operating instructions.
 Check that the overall installation is complete.
 Verify that the pump and driver are properly aligned.
 Verify that cooling water piping is connected and in service where required: pedestals, bearing
jackets, stuffing boxes. etc. Run cooling water through bearing housing, stuffing boxes, etc...
until flushed clear.
 Check gland or seal oil piping. Conventionally packed pumps in hot service are generally
furnished with gland oil. When a pump is furnished with mechanical seals, verify that all
components of the flushing system such as strainers, separators, restriction orifices and coolers
have been correctly installed and are clean. It is very important that the flush system be clean as
the loss or dirty flush can cause the loss of seals.
 Verify that bearings shafts are clean and properly lubricated. All bearings should be flushed
clean and the correct lubricant in the proper quantity must be provided. Records for type of
lubricant used and date of lubrication follow up will be recorded.
 Temporary strainers are provided for the suction of each pump to be installed on the pump side
of the suction block valves. These strainers should be installed after the suction lines are
flushed. These should be cleaned frequently to keep lines free of foreign matter. The strainers
should be cleaned frequently by alternating pumps where possible. Except on severe services
which may require installation of fine mesh on both pumps A and B, it is normally sufficient to
equip only one pump with fine mesh (on all "A" pumps for instance).
Consequently, the "A" pumps will be the ones preferentially started during initial start-up.
Then when temporary strainers are not anymore required they should be removed and only
the permanent strainer installed to prevent further possible pump damage.
 Pumps are not field hydrostatically tested.
b. Running Tests
When piping systems are sufficiently complete, means that a system or sub-system can be
released from construction activity to precommissioning activity for dynamic operations, some
pumps will be put into operation to determine whether they are in good mechanical condition
and to verify proper installation of support systems and test running. Keep in mind that medium
other than the design fluid is not always possible. Typical example is when use of water leads to
adverse effect that may damage mechanical seals and introduce water in a system where drastic
drying is being implemented before start-up.
Chapter: 4
Page: 18
The circulating fluid for test running a pump, when applicable, is often water. Due to
differences in specific gravity between water and the design fluid, care must be taken not to
overload the motors on motor driven pumps. The amperage on motor driven centrifugal pumps
should be monitored. If the amount of current drawn is too high the discharge valve should be
throttled until the amperage drawn by the motor is acceptable, keeping in mind that the pump
minimum flow should always be achieved.
Note: Running test of pumps will be done when applicable only. The selection of the pumps
subject to running test with water will be done by the commissioning team, and the relevant list
will be supplied in the Precommissioning Manual.
Centrifugal Pumps
 The following steps should be adhered to when test running a centrifugal pump:
 Operating personnel should be familiar with the literature furnished by pump and driver
manufacturers and should follow any special instructions therein.
 Open up the suction valve from source.
 Check that the seal does not leak (if packed seal check that packing nuts are not too slack) and
that the seal flushing and cooling water connections are correctly made.
 Rotate centrifugal pump shaft by hand to test for free rotation but never if the starter switch is
not locked.
 Confirm that the alignment check has been made on the pump shaft, driver shaft and coupling.
 Check that the coupling guard is secured over shaft.
 Check that the grounding clip and wire is secured from motor to grounding point.
 Check that a discharge pressure gage is installed and functioning
 Check that the electrician has tacked the pump power supply in substation.
 Check that if a pump is on a closed recirculation loop from a vessel, the vessel is vented to
atmosphere to prevent any possibility of damage by pulling vacuum. A specific procedure will
be issued with marked down PID's for pump running with water prior to actual start-up.
 When a run with water has been planned the loop system should be carefully isolated from the
rest of the sections. The water make-up should be sufficient to fill the whole loop and still leave
a good head available to the pumps.
 Check arrangements to vent the pump for priming, if the pump is not self venting. Verify that
special connections such as bleeds and drains are properly installed.
 Strainers must be installed before aligning pumps. A strainer is provided for each pump suction
line during start-up. To avoid pumps damage during flushing with water the strainers may be
lined temporarily with 20 mesh screens or as specified by the pump manufacturer. Remove this
temporary screen after water flushing is completed and fit the permanent one.
Note:
To prevent equipment damage multistage centrifugal pumps in light product service (specific
gravity less than about 0.8), if any, should not be running with water.
 All valves in the loop should be opened except for control valves (manually closed from the
control room) and the discharge valve of the pumps. The operator at the control panel should
then be informed that the system is ready for operation.
Chapter: 4
Page: 19
 If possible do not start the motor on a centrifugal pump with the discharge valve open as this
also throws an excessive load on the motor (except if specified to start with fully open valve as
auto start cases).
 When a hot pump is being kept hot by circulation of a stream through it from an adjacent pump,
the shaft of the motor may be turning slowly in the direction opposite to normal rotation. If a
pump is running in this manner and is started up, an excessive load is thrown on the motor.
Therefore, if a standby pump is already slowly rotating, cut off or reduce the circulation before
starting up. As a general rule, do not start-up and shutdown any motor more frequently than
necessary since this could cause damage to the motor rotor, especially for high horsepower
motors (not more than 3 starts per hour for medium or high voltage motors are recommended).
 The board operator should be on duty and order the start of the pump. The discharge valve
should then be opened gradually so as not to lose suction. From then, the operation should be
controlled from the control room.
 Ensure the pump is full of liquid after proper casing venting. The pump can now be started.
Crack open the discharge valve and switch on. The pump will come up to speed. The discharge
pressure gage should be checked immediately. If no pressure is shown the pump should be
stopped to find the cause. If discharge pressure is satisfactory, the discharge valve should be
opened slowly to give the desired flow rate. The pump should not be run with the discharge
block valve closed. Note any vibration or abnormal running condition.
 The field operator should check for leaks in the system, overall pump performance and pump
overload.
 The bearings of pumps and drivers should be checked for signs of heating. All oil levels should
be rechecked and the stuffing box should be checked for heating. The packing gland (for non
mechanical seal type pumps) should be loosened or tightened as required. It is desirable to allow
considerable leakage in the stuffing box at the beginning to permit packing to run in. Heating of
pump casing may be attributed to internal rubbing.
 The pump should be run for approximately 1 hour, then shut off to make any adjustment
necessary and to check parts for tightness. Since it is not possible to run the pump at operating
temperature, a final check could be made during normal operating by switching to spare pump.
Reciprocating Pumps/Dosing Pumps
The following steps should be adhered to, when test running a reciprocating pump:
 Check all previous points for centrifugal pumps except hand rotation.
 Check that the correct relief valve has been installed relieving from the discharge line to the
suction line.
 Check that the manually adjustable stroke control is lubricated and moving freely.
 Check that the normal operating level of oil is shown in the sight glass.
 Fully open the discharge valve.
 Switch the reciprocating pump on and off, observe the stroke and listen for any loud rubbing
noises.
Chapter: 4
Page: 20
 All pumps should be watched closely during preliminary circulation and particularly when first
started. When bearings or packing boxes begin to overheat (usually this means hot to the touch)
or other indications of trouble appear, shutdown immediately for inspection. Keep a record of
pump running time, strainer inspections and condition, and final removal of the strainer.
 Never run a reciprocating pump with a closed discharge.
3.1.3 Electrical Motors

In conjunction with final inspection of the electrical construction work the following testing and
preparation is to be carried out in order to perform the initial run-in of electrical motors for
rotational check:
 Open all circuit breakers and switches.
 Check all bus bars to see that they are free of foreign material.
 Check that all electrical equipment vessels and structures are connected to the equipment
grounding system in accordance with the drawings and specifications.
 Check that the cables are correctly installed on the tray supports and that electrical equipment is
properly connected.
 Check grounding systems for continuity and resistance.
 Check piping systems with electrical bonding at flanges for continuity and resistance.
 Close both main transfer primary disconnect switches.
 Close switch gear main circuit breakers.
 Check voltmeter on switch gear for proper voltage.
 Check all thermal overload heaters.
 Close first switchgear feeder circuit breakers, then second, etc
 Close first motor control center main circuit breaker, then close each motor starter circuit breaker
and repeat for each motor control center.
 Check each motor for proper lubrication.
 Check rotation of each motor making sure that the motor driven equipment (i.e pump, compressor,
etc) is either disconnected or free to be turned.
Before switching on any electrical equipment, agreement from an electrical engineer is needed.
When a motor has been started by pressing the starter button, NEVER (except in emergency
conditions) push the stop button until the motor has attained full speed and the amperage has
fallen back to the normal running figure. If a motor is stopped before it has risen to maximum
speed, damage can be done to the switchgear due to the heavy load it is carrying. It is bad
practice and could be dangerous for an operator to press the starter button to see if a motor is
"live" and then immediately press the stop button as soon as the motor turns. Said "bumped test"
is a bad practice.
Chapter: 4
Page: 21
Note:
The run of the electrical motor for rotational check is linked with Mechanical Completion
whereas functional test for several hours with records (amps) may be relevant to
precommissioning activities. Nevertheless, as already mentioned, there should be no border
between construction and precommissioning phases and nothing prevent implementing the
motor test (foreseen a few hours) and the rotation check as soon as the relevant electric supply is
energized.
3.1.4 Compressors and Turbines Drivers

Detailed operating instructions for the compressor and turbine driver are furnished by the
manufacturer. Initial starting and breaking in of the machine should be under the supervision of the
manufacturer's representative (only for first start-up).
The manufacturer's representative will precheck the compressor, driver and lube and seal oil
(centrifugal compressors) system prior to initial machine run-in. Some of the items covered are (but
not limited to):
 Checking compressor driver alignment.
 Checking for proper base grouting and equipment support.
 Removing flushing oils from bearings and seals.
 Checking all seal bearing clearances (done previously when fitting).
 Checking suction and discharge piping for proper vibration support.
 Flushing of lube oil, seal and hydraulic oil network.
 Adjusting centrifugal compressor seal oil system for smooth operation, including alarms and
functional test of trips (witnessed by commissioning team).
 Installing of orifices in the sour oil trap and oil receiver purge lines.
 Running in main and auxiliary lube and seal oil pumps.
 Establishing normal oil levels in all lube and seal oil systems.
Once the precheck is completed, the compressor and driver should be ready for operation. Since
these machines are important and expensive pieces of process equipment, their proper operation
cannot be underestimated. Manufacturer's recommendations should be consulted for a more
thorough discussion of any item mentioned here.
3.1.5 Air Coolers / Condensers Fans

After the motors have been run uncoupled, a static check must be implemented prior to run the fan.
Confirm that the Electrical discipline has test-run the motors uncoupled prior to asking for
operational acceptance. Then make the following checks:
 Check the electrical report for the motor amperage.
 Check that the protection grease has been removed and is replaced by the correct grease.
 Check that the belts are all on the pulley.
 Check that all debris has been removed from the air-coolers area.
 Check that there is no loose or live electrical wiring.
Chapter: 4
Page: 22
 Check that all air fan platform grating is in place and secured.
 Check that all stop and start switches are fully installed.
 Check that the correct motor oil has been put in and the storage protection (light) oil removed if
any.
 Check the fan motor for proper rotation and grounding (never when the motor is energized).
 Set the fan blade pitch as per manufacturer's specification. Once the fan is in operation, if motor
amperage is too high or too low, pitch readjustment may be required.
 Set the vibration shutdown switches to give the permitted safe vibration level.
 If the fan is belt driven adjust the drive belts for proper tension and check belt condition.
 Confirm that the fan safety shields are in place.
 Remove protection plywood that may have been laid on the tubes.
 Check operation of louvers (if any).
 When all above checks have been made, proceed to a 4 hours (except otherwise agreed duration)
test run and check the following points:
 Check that the amperage of the motors is in the normal range.
 Check for any noise from the bearings or other.
 Check for any screeching or abnormal noises from the pulleys (belts may be too tight, which will
affect bearings).
 Check that all belts remain on the pulleys (belts that constantly come off could indicate offset
pulley).
 Check that air fan blades are not making any abnormal noise.
 Check that air fans on the same cell are all turning at approximately the same speed.
 Stop the air fans one by one and stand underneath to observe and check the following:
 Check that no abnormal noise occurs on the rundown.
 Check that the air fans slowly come to a stop in a smooth manner.
 Check by hand that the motor has not overheated (inform the Electrical discipline if it has).
Warning
If the motor is inside the safety screen cover and if motor overheating is suspected or another
intervention on the fan is required never remove the safety screen by yourself. Inform the
Electrical Specialist which will follow the normal safety procedure of electrical isolation in the
substation by tagging off and locking shut the electrical breaker for the motors.
Complete the run-in before using the air cooler condenser for any heat transfer duty.
Chapter: 4
Page: 23
3.2 Piping Inspection
3.2.1 Piping Sliding Supports and Anchors

All comments applying to sliding supports on vessels also apply to piping.
Long straight runs of piping should be checked for bowing when up to temperature. Bowing causes
pipe overstressing and could result in pipe failure. The rule of thumb is that if one can visually
notice bowing then it is excessive. Nevertheless this is not of course the only criteria which had
driven the pipe erection and alignment. The probable cause for bowing is that the line is
unintentionally anchored at each extremity and this should be checked and corrected.
3.2.2 Spring Supports

 Inspection prior to Hydrostatic Testing :
Check that the spring stops are installed. If the stop is not installed on the spring support of a
vapor line, the weight of water in the pipe during hydrostatic testing could deform the spring.
The characteristic of the spring would thus change and its performance may not be as predicted.
Pipe normally transporting water would not be affected as the spring would be designed for the
weight of water but rather than make them an exception it is simpler to state that all spring
supports have their stops installed.
 Inspection after Hydrostatic Testing :
After draining the water and prior to any heating the spring stops should be removed. If the
stops are not removed, the springs will not flex with the pipe thermal growth and nozzles will be
over stressed resulting in possible damage.
After the spring stop is removed, check that the spring pointer is somewhere between the hot
and cold settings stamped on the support. The thermal growth of the pipe will result in the
spring being either compressed or stretched.
If the spring pointer is not between the hot and cold settings, the spring could become fully
compressed or stretched before the full load is imposed on it. At this point, the spring would
cease to function as such, resulting in nozzle over stressing with possible damage.
3.3 Electrical Equipment Inspection

To reach the Mechanical Completion step, part of the Electrical devices have been already
precommissioned, as electrical motors have been initially run (for motor tests and rotational check).
Nevertheless, it may happen that the motors uncoupled tests be implemented during the "readiness
for precommissioning period".
During the actual processing phase, the following functional tests for electrical systems will be
performed:
 For motors where they have more than one control and automatic operation, first check manual
operation, then automatic. Test each control operation to be sure the control is operating in
accordance with process requirements.
 Interlocked control circuits for permissive start and automatic shutdown must be checked to ensure
correct relay and control valve actions from each alarm function. This is deeply linked with
instrumentation loop testing.
 Check emergency power supply is installed for correct operation on power failure.
Chapter: 4
Page: 24
 Close lighting transformer primary circuit breaker.

 Close lighting distribution panels feeders circuit breaker and emergency lighting.
 Check all seal fitting to be sure they are filled with sealing compound.
 Check all explosion-proof, vapor-tight, dust-tight and weather-tight enclosure to be sure that the
enclosure are secured and closed properly.
 Check all nameplates and lighting panel directories to be sure that each circuit breaker controls the
proper circuit.
Electric Motors :
Electric motors are used predominately in the plant as drivers of moving equipment such as pumps,
air coolers, etc. Therefore, it is essential that, before attempting to start any electrically driven
equipment, both the driver (motor) and pump are ready for operation.
Before switching on any electrical equipment, agreement from an electrical engineer is needed.
3.4 Instrumentation Preparation

Commissioning of instruments will be carried out as the plant comes on stream. Most attention will
be directed towards liquid flow measurements: differential pressure instrument piping must be
drained to eliminate accumulated dirt and water and the instrument zero must be adjusted to obtain
a correct zero reading on the scale on the control board instrument. Controllers must be tuned;
interface level transmitters must be zero checked; scale, weld slag and trash must be removed from
striking control valves; other malfunctions must be corrected. Inspection and commissioning of
analyzers should include attention to sample line lengths, analyzer enclosures, auxiliary equipment,
such as carrier gas for chromatography and other items as indicated in the instruction manual for
the particular analyzer.
Analyzers should be inspected, calibrated and commissioned in accordance with procedures and
instructions in the instruction manual for the analyzer. An instrumentation engineer has to review
installation and supervise calibration and initial start-up. A vendor representative might be required
for some specific analyzers. Chromatographs should be inspected to make sure that all external
piping and wiring are complete and that no parts have been lost or damaged in shipment.
Functional test for instrument loops have to be done prior to start-up to ensure correct operation of
safety devices. SIS system interlocks and local / remote actions.
Proceed to the following checking:
First, before energizing field instrumentation and proceed to energized loop checks, confirm that
the following static checks are actually implemented:
 Clean air before connecting to instruments
 Clean the instrument air supply headers by blowing with clean, dry air, and check them for leak
tightness.
 Verify that pneumatic tubing is hooked up, that instrument air is available at the instrument.
 Check piping from instruments to process piping and equipment for leak tightness.
 Isolate or remove in line components such as control valves, positive displacement meters and
turbine meters for pressure and leak testing if specified tight shut off (already done in workshop
normally.)
 Reinstall these items after successful testing of the system.
Chapter: 4
Page: 25
 Check orifice plate bore diameters and Documents.

 Install orifice plates after completion of testing, draining, flushing and cleaning of lines.
 Isolate or remove inline components for flushing and cleaning operations. Reinstall and/or
reconnect after completion of cleaning and flushing operations.
 Verify correct positions and installation of inline instrumentation (control valve flow direction and
fail position, orifice plate installed in correct relation to flow etc).
 Perform all non-operating tests that ensure instrument operability: remove shipping stops, check
pointer travel, verify and adjust the instrument's capability to measure, operate, stroke etc... in the
direction and manner required by the process application (direct or reverse controllers etc).
 Perform functional loop checks and demonstrate correct operation (a precommissioning record
sheet with the relevant loop diagram).
 Fully pressurize and energize the transmitting and control signal systems by opening process
connections at primary sensors and regulators and by making control mode settings for automatic
operation of equipment as the process unit is charged and brought on stream.
 On the DCS check operability of the system and interfaces to other subsystems.
Thermocouple wiring should be inspected for proper polarity at the thermocouple head. Point-
by-point verification or the switch identification at the temperature indicator on the operator's
board can be accomplished by selecting a point to be checked, opening the circuit at the
thermocouple head and checking the temperature indicator to see if it drives upscale or
otherwise indicates an open circuit. The same applies for temperature recorder controller
instruments on the control board. Loop checking involves checking inputs and should be
simulated at the transmitter and the control board instrument should be watched for response.
The controller output should be adjusted manually and the control valve watched for response.
Special attention should be given to split-range loops and complicated systems (machinery/DCS
interface, etc).
3.5 Heating, Ventilation Air Conditioning Equipment

 Verify conformity of the installation with drawings, specifications, safety rules, supplier
instructions.
 Verify the free rotation of fans and motors.
 Verify the correct installation of anti-vibrations mountings and sealing compound of fire dampers,
if any.
 Verify that leakage and blades of dampers run freely.
 Verify that dampers actuators are in good running order.
 Verify that air flow direction in preheater is correct.
 Perform ductwork leak tests.
 Start the unit test sequences, interlocks, vibrations.
 Start air flow and make balancing test (air distribution adjustment).
 Adjust rooms temperature and pressurization.
Chapter: 4
Page: 26
3.6 Telecommunications
Inspection of all telecommunication equipment is performed to ensure compliance with
specifications, drawings, Codes of Practice, regulations and manufacturer's particular requirements.
In general, inspections should ensure satisfactory jointing and continuity of all conductors,
satisfactory alignment and tightness of bolting, acceptance levels of insulation, and a high standard
of cleanliness.
Main telecommunication systems are:
 Message switch system
 Radio communication system
 Telephone network.
Chapter: 4
Page: 27
4. CLEANING OF PIPING AND EQUIPMENT
4.1 General
Lines and equipment cleaning is intended to eliminate welds rods and slags, abrasive dusts, oxides
and in general other substances which might impede the normal unit operation or damage the
equipment (valves, pumps, compressors, turbines, etc.)
Cleaning is usually carried out either by hand cleaning for large equipment and lines having a large
diameter, by water flushing, by air blowing, chemical cleaning or any other cleaning method as
described hereafter.
Inaccessible piping (in terms of impossibility to access inside for hand cleaning) will be cleaned
using fire water or any other hydraulic or power flushing, or by air or steam blowing including
lines to and from storage. When an exchanger is included in a cleaning circuit, the inlet line is first
disconnected and the piping to it cleaned. After sufficient cleaning the exchanger must be
reconnected for washing the outlet piping.
It must be noticed that this is not always possible, as some lines between exchangers are impossible
to disconnect without complete removal of the line. In such case, the identified line has been
subject to joint inspection between the construction team and commissioning team, after or before
hydrotest inspection (drainage of the hydrotest medium) to confirm the line is sufficiently clean for
final installation.
For the circuits that are not equipped with a pump, a fire hose or a capacity (used as a reservoir)
may be used for washing, or as buffer capacity for air blowing.
Flush the pumps suction line through the strainer door/flange.
When the initial washing is completed, reconnect the suction piping of the pumps and continue the
washing of the lines during the running in of the pump (if applicable) until no more collected
fragments in the strainers at the pump suction.
Even if water flushing method would be foreseen, it is impossible to have the proper and required
velocity to clean lines over a certain size with water, without unreasonably sized temporary
facilities (process pumps do not allow such flows).
The cleaning of lines and associated equipment, which forms the various systems to be
mechanically completed then ready for start-up, will be treated during the construction and
precommissioning phases in two steps:
1. During the construction phase, preliminary checking is implemented to avoid pipelines retaining
construction materials until the actual cleaning takes place later, when practically feasibly and
applicable with the required efficiency.
2. Then to reach the readiness for start-up, a cleaning is implemented for each system/subsystem.
This cleaning will use efficient methods that could be implemented only after part of the plant is
available.
As a summary, only above (1) can be implemented at the hydraulic test stage of the work. The
cleaning (2) of course will be performed as soon as the site facilities allow for it, the optimum
being that both cleanings are implemented in sequence.
To make easier the understanding of the sequence of events, the cleaning sequence that will be
applied is the following:
Chapter: 4
Page: 28
 Pipes installation after the prefabricated spools have been transferred to the site must be
checked for removal (by gravity) any foreign material as tools, gloves, etc. (They are placed
vertically before installation).
 For big lines, inspection is carried out by construction group after each spool is welded, and a
manual rubbing/wiping is performed, if necessary.
 After the hydrotest, the hydrotesting medium (mainly water) is drained, through drain valves or
one open flange (if water is dirty, the network is rinsed until clean).
 The relevant pipes are then air-swept to remove free water.
 When the system or part of the hydrotested system (so called Test Pack) is released, a
provisional reinstatement is implemented, with exceptions list agreed by commissioning team
and list given to construction to allow the use of permanent facilities (columns/vessels/pipes
themselves) to perform the actual cleaning to meet the precommissioning cleanliness
requirement.
Some of this cleanings may need the utilities, (such as instrument air, utility air, service
water, etc.), in this case of course utilities should have been precommissioned before with
the normal required checks.
 Above step is the period of time where the plant is actually cleaned and is followed by final
reinstatement and conformity to PIDs checks, air tightness test, etc.
The requirements for start-up are such that a cleaning as per above does not meet, for all
systems, the requirements for readiness for start-up. However, some lines could not be
subject to additional cleaning (such as some columns overhead lines, flare headers, etc.). For
these lines, above steps should be well monitored and controlled, and it is normal practice for
these cases that the commissioning team witnesses and records the status of these lines
before (or after) hydrotest.
4.2 Water Flushing

Water flushing, when applicable, will be performed using clean water. When possible, main and
spare pumps can also be run at the same time and used to circulate water for the purpose of
removing dirt and scale via the pump suction strainers.
The following guidelines should be observed for flushing operations:
 It should be stressed that brackish or salt water must not be used for flushing of systems containing
stainless steel parts. Demineralized water or condensate should be used for stainless steel pipes.
Note:
When stainless steel lines are flushed, what is important is to rinse properly with demineralized
water. Therefore it may happen that some flushing, over a short time, are flushed with utility
water, then rinsed with demineralized water;
 All possible lines should be used during the flushing operation to facilitate complete system clean-
out (main headers first, then subheaders).
 Temporary strainers are to be installed in the suction lines of all pumps before any liquid is allowed
to pass through them from newly constructed lines. If this is not done, scale, weld metal or slag,
stones etc, may freeze or damage centrifugal pump impellers. The screens serve to trap such dirt in
a place where it can be conveniently removed.
Chapter: 4
Page: 29
 When practical, lines should always be flushed away from a vessel rather than into a vessel. Any
vessel that has been flushed or blown into should be opened and manually cleaned following
flushing.
 Flushing should be preferentially from the highest elevation to the lowest elevation. This restrain is
not compulsory for blowing.
 Vessels and systems should be vented when filling or emptying to prevent vacuum pulling.
 During flushing, maximum volume and velocity should be used to ensure through cleaning, the rate
of flushing medium should be regulated at the source.
 Control valves should be rolled out of the piping system during flushing to prevent damage, except
some butterfly valves that can remain installed if wide open.
 Orifice plates should be installed after cleaning is completed.
 Instruments (i.e. pressure gages and transmitters, differential flow meter transmitters, moisture and
other in-line analyzers, etc.) should be positively isolated from the system during cleaning.
 All drains should be flushed through to check for blockage.
 Where possible, open-end lines should be flushed through. This is the case of process units
provided with end flanges for all utilities lines which make easier either flushing / air blowing /
steam blowing. Flow should not be restricted drastically.
 Pump suction and discharge lines should be flushed while protecting the pump casing (by flushing
through the open strainer or a metal plate at pump flange).
 Lines should be flushed in the following sequences, where possible :
 first the main header,
 then each sub-header,
 at last, each branch line.
 Always flush through a by pass when it exists, to an open end before flushing through equipment.
 Lines should not be flushed into exchangers without flushing at the inlet first. Only when the inlet
is checked clean, and when the exchangers is not equipped with a bypass, flushing is allowed to
pass through the exchangers if required to proceed further.
 Flushing should continue in each line or piece of equipment until the water is reasonably clean (or
as clear as the make-up water).
 Unit Piping and Instruments Diagrams should be used as a cleaning check off record to ensure that
lines are flushed cleaned including lines to and from tankage. This marked-up PID set will be
referred as the "Cleaning Master PID Set".
After completion of the flushing operations, the water should be kept in the unit to facilitate
pump run-in if this was not done during the flushing operation and if run-in of pumps with
water is applicable. If pump run-in has been completed or will not follow the flushing operation
immediately, all water should be drained from the unit. If necessary, break flanges at low points
to facilitate drainage and air blow as required to remove as much water as possible.
Chapter: 4
Page: 30
Note:
It is essential that the agreed path flushing procedure is adhered to more personnel it has been
established for in the field. The list of breakpoints should be made known to the construction
group as early as possible to avoid putting final gaskets in place of temporary gaskets and also
to have the required amount of correctly rated and sized gaskets in the hands of the
commissioning team.
The wall charts should be kept up to date and the final gaskets should add up to the same
amount as the temporary gaskets received (ideal situation).
Close follow-up eliminates problems during start-up and identical procedures can be used in
removing all temporary blinds after the completion of the hydrostatic test. A color code system
can be very useful at this stage (for flanges equipped with temporary gaskets).
4.3 Air Blowing

Cleaning of circuits will be carried out by air blowing for lines and pieces of equipment which have
to be kept free from water and for some big piping (for reasons as: unacceptable weight, or too
large quantity of water would be required, or water flushing not efficient).
By experience, the air blowing method is usually also extended and applicable to lines, as this leads
to good results and dry conditions are obtained rapidly.
Air blowing will be carried out with compressed air. Air blowing of a circuit should be performed
by using temporary connection with compressed air network, in a continuous manner for small
lines or by using vessels (drum, column, etc.,) as holdup / buffer capacity to get a quick air release.
The vessel will be pressurized with compressed air, then the air will be released through the circuit
(of course first, check that design pressure of the vessels is in accordance with compressed air
maximum operating pressure). This design pressure is reminded in the specific procedure to be
applied to each system.
In some huge systems, it is sometimes not possible to use valves to blow the relevant lines. In this
case, a bursting disc (made of cardboard or aluminium sheet) can be used to proceed to a sudden
depressurization (ensure that no equipment may be damaged).
Piping system blowing will be considered completed when air at the exit point will appear clear.
(The air has not to be orange dust color).
4.4 Steam Blowing

Cleaning by steam blowing is carried out essentially for steam circuits. Due to problems of
expansion or draining of condensate, this type of cleaning is not used for other circuits except for
small parts and with the utmost care.
Steam blowing will be carried out as follows:
Before putting steam into the system, control valves, turbines meters, instruments, vacuum ejector,
and strainers should be removed or blinded off from the system. The steam headers should be
slowly warned up, one header at a time, while expansion of the line is observed. Special attention
should be given to pipe support shoes. Condensate must be drained manually to prevent steam
hammering. The headers should now be blown using a low pressure, high-velocity sweep as
explained hereafter.
Chapter: 4
Page: 31
When the headers are warm, the drain valves should be opened, blown vigorously for a few
moments before closure. Each lateral to heater, exchangers, or service lines should be blown in the
same manner, usually not more than one at a time. Condensate lines may be cleaned in the same
manner as steam lines, but close observation of the pressure on the condensate line is necessary
since the working pressure and temperature of the condensate lines are generally lower than of the
steam headers. A temporary movable silencer could be used to avoid exceeding noise level
limitations during the steam blowing operation, if necessary. Nevertheless, this minimizes the
efficiency of the steam blowing and steam blowing without silencer is preferable. (Coordination
with people working in the vicinity is required).
When blowing of the steam system is completed, equipment that was removed prior to the blowing
can be reconnected. The system can then be preheated and placed in service, after it has passed the
steam test.
Completion and effectiveness of steam blowing will be determined as follows:
Steam piping at inlet of turbine, desuperheater and outlet of boiler.
An aluminium target located at the vent point will be observed.
Blowing of this piping system will be considered completed and cleaned when on two consecutive
targets, collected after blowing carried out as above described, are present less than two pits per
square cm with a maximum diameter of 0.3 mm.
This is given as a guideline, and waiver can be admitted for boilers outlet.
Targets made from aluminium sheet will be inserted, on temporary vent only after that three - four
blowings (depending on the experience on site) have been carried out and the steam appears to be
clean.
Other steam piping and steam piping to turbine less than 4"
Piping system blowing will be considered completed when steam at the exit of vent point will
appear clean. (The steam has not to be orange dust color).
When blowing of the steam system is completed, traps and other equipment that were removed
prior to the blowing may be reconnected. The system can then be reheated and placed in service,
after it has passed the steam test.
4.5 Chemical Cleaning

Some piping must be cleaned by chemicals when either the product can react with oil left inside of
the piping or in case it can lead to adverse effect to leave even very small parts of debris inside the
piping. Proper neutralizing and flushing of these systems after the chemical attack are of utmost
importance.
This is limited to machinery lube oil pipe system, before final installation, and only in case some
weldings are done on site.
Other pipe network spools (as compressors suction spools), are mechanically brushed / cleaned
before installation.
For this purpose a typical chemical cleaning procedure is appended below. This is only a guideline,
and some vendors could give more specific procedure, if applicable.
Chapter: 4
Page: 32
4.5.1 Cleaning and Pickling of Piping
4.5.1.1 Solution Preparation, Handling and Use

All solutions shall be prepared, handled and used in strict accordance with the manufacturer's
instructions and this specification.
Chemical solutions shall not be introduced into piping systems or equipment unless high point
vents and low point drains are available to ensure proper filling and complete removal of solutions.
4.5.1.2 Detergent Cleaning

All oil, grease, soil, drawing compounds and foreign matter other than rust, scale, and oxides shall
be removed by detergent cleaning as follows:
The piping system shall be force flushed with plant water to remove no adherent foreign matter and
reduce the load on the detergent. Flushing shall be continued until all such foreign matter is
removed.
Detergent cleaning shall include the removal of oil, grease, soil, drawing compounds, and foreign
matter other than rust and scale. Detergent solution shall be circulated through the pipe at the
temperature, concentration, and flow rate recommended by the detergent manufacturer.
When detergent flow rate has not been recommended by the manufacturer, the flow rate shall be
1,5 meter per second.
Surfaces cleaned with detergent must be thoroughly rinsed by warm, fresh water to remove
residues of detergent. To test the effectiveness of rinse, universal pH test paper shall be placed
against the wet steel. The pH of the rinsed surface should be no greater than the pH of the rinse
water.
4.5.1.3 Acid Cleaning

All oil, grease, and soils shall be removed by detergent cleaning. All rust, scale and oxides shall be
removed (to leave bare metal) by citric acid cleaning as follows:
Citric acid solution shall be circulated at the temperature, concentration and flow rate
recommended by manufacturer.
Unless otherwise recommended by manufacturer, solution temperature shall be maintained
between 80°C and 95°C throughout the system during this operation by injecting steam into the
acid solution.
The concentration of citric acid in the cleaning solution shall be monitored and replenished in
accordance with the manufacturer's instructions. Samples shall be taken periodically and titrated to
test for acid and iron content. Cleaning shall be considered complete when acid concentration and
iron content are constant for one hour.
When chemical tests indicate a constant ferric and ferrous ion concentration, the used citric acid
solution shall be displaced by rinse water containing 0.05 percent to 0.10 percent citric acid
solution to ensure all traces of soluble ion are removed. This method of displacing spent cleaning
solution with rinse water shall be used in lieu of draining the spent acid solution and refilling with
rinse water. Circulation of rinse water shall be maintained at least 10 minutes.
Immediately following rinse water circulation, 1.0 percent soda ash solution shall be circulated at
80°C for at least 10 minutes to neutralize the cleaned surfaces. The pH of used soda ash solution
shall be at least 9.5, in order to stop circulation.
Chapter: 4
Page: 33
After the surfaces are clean and dry, the pipe shall be filled with nitrogen and sealed. The nitrogen
pressure shall be 0.1 to 0.2 bar g.
4.5.1.4 Chemical Solution and Rinse Disposal

All spent chemical solutions and rinses will be disposed to sewer, using water for dilution.
Inspection of Cleaned Surfaces
Cleaned surfaces shall be visually examined. Visual examination shall be supplemented with
endoscopes, mirrors, and other aids, as necessary, to properly examine inaccessible or difficult-to-
see surfaces. Lights shall be positioned to prevent glare on the surfaces being examined.
Where visual examination is not practical, a clean, lint free, white cotton cloth or filter paper
moistened (but not saturated) with high purity isopropyl alcohol (rubbing alcohol) may be rubbed
against the surfaces at all openings. The presence of a smudge on the cloth or filter paper is
evidence of incomplete cleaning and the cleaning shall be repeated.
Inspection of Other Surfaces
The internal surfaces of all piping systems shall be visually inspected to verify that all surfaces are
entirely free of weld slag, flux, soil, debris, grease, oil and any foreign matter.
Identification of cleaned pipe (typical)
Cleaned pipe shall be metal tagged to avoid subsequent contamination. Tag shall read "KEEP
SEALED UNTIL USE. INTERNALLY CLEANED (AND PRESSURIZED) ON
(Date) ."
Pipe shall not be marked with paint or ink, in lieu of metal tagging, unless the pipe is finish painted
or insulated.
4.5.2 Storage or Installation of Chemically Cleaned Pipework

Usually, such chemical cleaning is implemented just before installation.
The advise given hereafter is only good sense, to avoid corrosion which may inhibit the work done.
a. The piping should preferably be installed immediately, but if this is impracticable then immediate
steps must be taken to prevent rusting. Generally, a dip or spray coating of light mineral oil will
suffice for storage of less than one month, but if piping is to be placed in outdoor storage for more
than one month, a coating of rust preventive should be used.
b. Unless piping is going to be installed immediately, suitable closures must be placed on the ends
and all openings to prevent entrance of moisture or dirt. Use of steel plate discs and thick gaskets is
recommended for all flanges. Before applying closures, the flange surfaces should be coated with
grease.
c. Before installation, check that no dirt or foreign matter has entered piping and that rusting has
not occurred. If in good condition, then pull through a swab saturated with carbon
tetrachloride. The piping shall not be bolted up until inspected for cleanliness.
Chapter: 4
Page: 34
4.5.3 Safety Consideration

All activities connected with chemical cleaning must be supervised by qualified staff in order to
assure attainment of the required pickling effect and to prevent damage to materials and/or to
health.
Protective gloves, protective boots and aprons in correspondingly acid-resistant material and tightly
sealing protective goggles must be worn for all work involving acids. Acids must always be stirred
carefully in a thin stream of water, never the reverse.
4.6 Lubrication Systems Flushing

Necessary instruction for cleaning the lubricant and seal oil piping systems are given in
manufacturer's data books. They have to be strictly followed to proceed with the cleaning of such
piping systems.
Typically, lubricant oil piping system for machinery can be cleaned as follows;
Preliminary air blowing of the piping and flushing with lubricant oil by circulation.
4.6.1 Preliminary Air Blowing

The piping system will be blown with air in order to remove all dirt, debris. Blowing will be
accomplished with hammering of piping for removal of mill scales.
Air blowing will also remove water or moisture present into the piping system.
4.6.2 Chemical Cleaning

Oil lines, installed in the factory have been flushed and sealed before shipment, then they do not
required any additional chemical cleaning before the final oil flushing. Some other oil
interconnecting piping, which have been fabricated at the erection site, may require chemical
cleaning before installation.
For this purpose two typical chemical cleaning procedures for site prefabricated oil circuits are
appended below.
 CLEANING (OR DEGREASING) PROCEDURE
General
The cleaning of the piping may be carried out by the following recommended procedures.
Procedure for Carbon Steel
Immerse the piping in a caustic bath at a temperature of about 80/90°C for a period of at least 30
minutes, depending on the condition of the material, to remove all grease, dirt, oil or paint.
Piping and/or solution is agitated to ensure the flow of solution through the piping.
The batch may be a solution of 6 % wt of sodium hydroxide in water with detergent.
Remove piping from caustic bath and immediately rinse with cold water.
Procedure for stainless steel
Mechanically clean all welds as required and suitably wash with clean demineralized water to
remove dirt.
Chapter: 4
Page: 35
 PICKLING PROCEDURE
General
Pickling procedure is not required for Stainless Steel Piping.
The pickling (or chemical cleaning) of the carbon steel piping which follows cleaning or
degreasing may be carried out by the following recommended procedure.
Procedure for Carbon Steel
a. Immerse the piping in an acid pickling bath containing a 10 % wt solution of hydrochloric
(muriatic) acid in water. Rodine, Pyridine or other suitable inhibitors should be added to the
solution in accordance with the Supplier's instructions to prevent the piping from rusting quickly
when removed from the acid bath.
The bath temperature should be between 60 and 70°C and the time of immersion required to
remove all scale and rust will depend on the strength of the solution and condition of the
pipe. Normally, 12 to 14 hours are required and 6 hours should be taken as a minimum.
b. Remove piping from acid bath, drain it and immediate wash with cold water to remove all traces
of acid.
4.6.3 Neutralizing Procedure

a. Without allowing the piping to dry, immerse in a hot neutral solution of 0.75 to 1.5 % wt of soda
ash in water maintained at a pH value of 9 or above. The temperature of the bath should be about
70/80 °C.
pH paper may be used to check the wet surface of the piping to determine than an acidity
condition does not exist. If the check shows acidity then the neutralizing treatment must be
repeated.
b. Rinse piping with cold water, drain thoroughly and blow out with service air until dry.
4.6.4 Flushing with Lubricant Oil

The whole lubrication system for a machinery will be assembled as per design.
Bearing house, seal, etc., will be by-passed by temporary connections (i.e. rubber hoses) between
inlet and outlet piping.
Screen mesh will be installed on all flanges between lines (screen with 100 mesh will be used).
When such screen will show to be clean (no presence of dirt, debris or mill scales), a white cotton
cloth will be inserted to finally check the cleanliness of the system. Lubricant oil will be circulated
into the system by using its own lube oil pump and heated up to 60-70°C, by means of console
heater or by a temporary steam connection to the oil coolers.
Chapter: 4
Page: 36
4.7 Blinds List

A blind list of permanent spectacle blinds and temporary blinds on piping and/or equipment must
always be current during the precommissioning and commissioning. It is good practice to double
check not only that the list is accurate but that all blinds necessary for the safety of the plant are in
place. Marking the blinds with brightly colored paint or ribbons also helps to locate installed
blinds.
When commissioning one unit, all blinds on process, fuel gas, closed drain and flare lines at battery
limit should remain closed on other units not in operation or ready to be placed into operation. A
marked-up set of PID will clearly identify the blinds position when initially commission the units.
Until the unit to be started-up is inerted, the following lines must remain positively isolated from
the rest of the plant :
 Flare lines at battery limit must be blinded and the internal headers open to atmosphere, until
nitrogen introduction for inerting to prevent overpressure of these headers.
 Closed drain system and fuel gas must be blinded at battery limit.
 All process lines in and out must be blinded at battery limit.
Chapter: 4
Page: 37
5. TIGHTNESS TESTS
5.1 General Procedure

After hydrostatic pressure testing and flushing, a tightness test must be conducted to check all
flanges and fittings for leaks, especially those opened during hydrostatic tests and flushing.
Unit should be isolated with blinds from every part containing hydrocarbons, nitrogen or steam.
All the relief valves should be in place and their isolation block valves in the current position. The
flare header inside the unit is isolated from the flare header already under hydrocarbon (if any) and
is open to atmosphere (by means of a PSV dismantled for instance) to prevent overpressure during
the air leak test (see above 3.7).
5.1.1 Pressure Test

Tightness test for the process units should be carried out with air (or nitrogen when applicable and
when air is prohibited) at the maximum allowable pressure which doesn't exceed the design
pressure of equipment (check design data). Soap solution should be prepared for the tightness
checking and all flanged connections checked with soap. Bubbling indicates tightening is required.
The pressure raise should be checked on manometers and recorded. The leaks should be carefully
located and tightened. The location should be noted. The tightness test is achieved and deemed
satisfactory when decrease of pressure is no more than 50 mbar per hour during a 4 hours test.
(This figure is of course subject to correction depending on the size of system).
This pressure follow-up gives an indication on the tightness of the system. Nevertheless, it does not
prevent from leak test on each flange with soap.
 Using soap solution check for any sign of soap bubbles being formed.
(Precaution must be taken during windy weather, as soap bubbles can be produced by wind
sweeping over the flange. This can lead to a wrong conclusion that the flange is leaking when it
does not).
 Pressure the system with air (or nitrogen) at the highest possible pressure compatible with the
IA/PA supply, without exceeding the normal operating pressure.
 Check pressure over a length of time. If the test is not satisfactory, every flange and connection
must be inspected with soap solution. After correction of leaks, the test will be repeated until
satisfactory.
Note:
For storage tanks, which cannot be pressurized, the tightness of flanges, manholes, connections,
etc., will be checked as far as possible during cleaning operations.
5.1.2 Leak Repairs / Tightening

In most cases, leaks can be eliminated by tightening the flanges in the correct manner to ensure that
compression on the flange gasket is uniform. If this is not sufficient, the equipment must be
isolated, depressurized, and the gasket replaced.
In most cases, the leakage from a valve bonnet can be eliminated by correct repacking.
Note: The control valves packing must not be tightened when dry until the actual product is
passing through.
Chapter: 4
Page: 38
5.1.3 Vacuum Test

This is used mainly to test systems that normally operate under vacuum.
 Disadvantages
It is difficult to locate small leaks. The results are not always conclusive.
 Advantages
There are no structural stresses (e.g. weight) when the test is carried out on equipment designed
for it.
Vacuum test is usually carried out at 0.2 bar abs. The test is deemed satisfactory when the
pressure increase does not exceed 25 mm Hg per hour. Otherwise, test should be repeated after
leaks repair.
Chapter: 4
Page: 39
6. PLANT PURGING AND INERTING

It is assumed that all pre-start operations including drying have been completed together with the
mechanical check and final inspection of the unit. It is also assumed that all lines have been tested
and washed.
Purging operations are completed by introducing nitrogen into the system. The most effective
procedure for purging plant and equipment is 'pressure purging'. This provides gradual dilution of
the oxygen content of the atmosphere inside the equipment and piping systems and involves
repeated pressurization of the system with nitrogen, followed by blow through and depressurization
down to atmospheric pressure. This procedure is repeated until the oxygen content in the
equipment and lines is reduced down to 0.5 vol%. Once purging has commenced, it should
continue uninterrupted if possible until the oxygen content has been reduced to the desired level.
The quantity of nitrogen required for purging can be established by estimating the volume of the
section to be purged. This can be done with the help of the PID’s which are also used to program
and control the operation.
This procedure can only be done for the first start-up, when the plant is devoid of hydrocarbons or
after a major plant shut-down.
A detailed program of purging operations will be performed by the commissioning team just prior
to start-up and taking into account the above-mentioned points.
Chapter: 4
Page: 40
7. SPECIFIC ACTIVITIES
7.1 Section 1100 - Storage Area
7.1.1 Products Storage Drying

The product storage lines are blown and the storage tanks are wiped. The tanks and the storage
lines are then dried out and blanketed with nitrogen before fill in. The following equipment are
concerned by this drying out:
 Ethane storage sphere 95-TK-1140
 Ethylene storage spheres 95-TK-1146 A/B/C
 C3/C4 storage drum 95-D-1141
 Propane storage 95-D-1145
7.1.2 Fill in of the Fresh Caustic Tank 95-TK-1147

Clean and inert the tank, 95-TK-1147 and upstream lines with nitrogen. Clean unloading line by
blowing with Nitrogen in to the tank. Clean unloading line from truck with fresh caustic during a
short time before connecting it to pipe. Start loading until the level of fresh caustic in the tank is at
90%.
7.1.3 Fill in of the Sulfuric Acid Tank 95-TK-1148

Clean and inert the tank, 95-TK-1148 and upstream lines with nitrogen. Clean unloading line by
blowing with Nitrogen in to the tank.Clean unloading line from truck with sulfuric acid during a
short time before connecting it to pipe. Start loading until the level of sulfuric acid in the tank is at
90%.
7.1.4 Fill in of the Wash Oil Tank 95-TK-1149

Clean and inert the tank, 95-TK-1149 and upstream lines with nitrogen. Clean unloading line from
truck with wash oil during a short time before connecting it to pipe. Start loading until the level of
wash oil in the tank is at 90%.
7.1.5 Fill in of the Lube Oil Tank N°1 95-TK-1151

truck with lube oil during a short time before connecting it to pipe. Start loading until the level of
lube oil in the tank is at 90%.
7.1.6 Fill in of the Lube Oil Tank N°2 95-TK-1153

truck with lube oil during a short time before connecting it to pipe. Start loading until the level of
lube oil in the tank is at 90%.
7.1.7 Fill in of the DMDS Drum 95-D-1120

Clean and inert the drum, 95-D-1120 and upstream lines with nitrogen. Clean unloading line by
blowing with Nitrogen in to the tank Clean unloading line from truck with DMDS during a short
time before connecting it to pipe. Start loading until the level of DMDS in the drum is at 80%.
Chapter: 4
Page: 41
When the drum is close to the working level open nitrogen and put in service the 091-PCV-0005
blanketing.
7.1.8 Fill in of the Polymerization Inhibitor Tank

For 97-PK-1152 tank filling, please refer to the vendor document “Installation & Maintenance &
Operating Instruction Manual All Tags” referenced as RC2-30-00113-OPM-000-0001.
7.2 Section 1200 – Utilities
7.2.1 Instrument Air and Plant Air
7.2.1.1 Networks Flushing

Line air blowing procedure is required for the instrument air and plant air networks.
7.2.1.2 Instrument Air Dryer System

For instrument air dryer system specific operations, please refer to the vendor document
“Installation, Operating and Maintenance Instructions – 97-PK-1222” referenced as RC2-31-
00051-OPM-038-0001.
7.2.2 Desalinated Water, Fire Water, Fresh Water, Potable Water
7.2.2.1 Networks Flushing

Water flushing of the lines is the operation required for these systems.
7.2.2.2 Remineralization Unit

For 97-PK-1226 tanks filling, please refer to the vendor document “Equipment Operating
Manual/Instructions” referenced as RC2-31-00095-OPM-021-0001.
7.2.3 Demineralized Water and Polished Water

Please refer to demineralization/BFW polishing unit vendor’s document “Procedure for Preparation
of Equipment for Commissioning – 97-PK-1201, 97-PK-1206” referenced as “RC2-31-00023-
OPM-022-0010 for the filling of the following equipment :
 Cation exchanger units 35-F-1227 A/B
 Anion exchanger units 35-F-1228 A/B
 Mixed beds units 35-F-1225 A/B/C
 Activated carbon filter 35-F-1207
 Suspect condensate filter unit 35-F-1202
7.2.4 Cooling Water
7.2.4.1 Reduced Cooling Water Network

During the precommissioning activities, a reduced cooling water network will be used to provide
cooling water to the following systems:
 Auxiliary boilers 07-B-1207 A/B/C
Chapter: 4
Page: 42
 Instrument air compressor 16-C-1201 A/B/C

 HP air compressor 16-C-1202 A/B
This reduced cooling water network is obtained by closing the butterfly block valves on lines 32-
HW-925011-14” and 32-CW925012-14” (PID-00-900-0021). A temporary pump and a temporary
cooling tower will be used to provide cooling water into this reduced network.
7.2.4.2 Cooling Water Network Flushing

For the cooling water network flushing, it is expected to by-pass one or two sea water/soft water
exchanger, the other ones being isolated (inlet and outlet butterfly valves closed). During the
flushing, water will not be sent through the users, but temporary lines will be installed to by-pass
the following exchangers :
 41-E-202 A/B
 41-E-301, 41-E-305, 41-E-315 (97-PK-301), 41-E-316
 41-E-505
 41-E-605
 41-801 B, 41-E-807
 41-E-1211
For flushing operation, charge the Cooling Water Buffer Drum 95-D-1227 with desalinated water
treated by the remineralization unit 97-PK-1226. Circulate thanks to the pump 67-P-1205 A/C
(motor driven). These pumps are equipped with a temporary strainer during precommissioning
activities. Flush all the circuit, cleaning the pumps suction strainers as necessary and opening low
point drains periodically to clear out accumulated dirt.
7.2.4.3 Sea Water Lines Flushing

Water flushing is the operation required for the sea water lines. For the flushing, it is expected to
by-pass one or two sea water/soft water exchanger, the other ones being isolated (inlet and outlet
butterfly valves closed).
7.2.4.4 CCCW Corrosion Inhibitor Tank Filling

7.2.4.5 Sea Water Oxidant Tank Filling

7.2.5 Boiler Feed Water
7.2.5.1 Boiler Feed Water Network Flushing

The flushing of Boiler Feed Water system is done with Boiler Feed Water produced by the
demineralization/BFW polishing unit.
The flushing of the Deaerator, 95-D-1223, is realized by gravity removing the suction filter of 67-
P-1202 A/B/C and 67-P-1224 A/B/C. When the equipment is clean, connect the lines to the pumps
Chapter: 4
Page: 43
suction. Next operation is cleaning of discharge lines of pumps 67-P-1202 A/B/C and 67-P-1224
A/B/C. These pumps are equipped with a temporary strainer during this activity.
Start the pumps according to vendor’s instructions.
Start to circulate water trough the pumps, cleaning the pumps suction strainers as necessary. Outlet
line is opened to atmosphere.
Operate only one of these pumps, (67-P-1202 A) driven by an electrical motor, circulating water
trough the line up to the inlet line to the furnaces. The VHP BFW header line is open to the
atmosphere at inlet of each furnace (furnace inlet block valves).
Operate only one of these pumps, (67-P-1224 A) driven by an electrical motor, circulating water
trough the line up to the inlet line to the boilers. The HP BFW header line is open to the
atmosphere at inlet of each boiler (boiler inlet block valves). Circulate water up to desuperheating
valves of the different steam levels.
7.2.5.2 Oxygen Scavenger Tank Filling

7.2.5.3 Volatile Amine Unit Tank Filling

7.2.6 Fuel Gas

Line air blowing procedure is required for this system.
During the precommissioning activities, fuel gas will be imported from OSBL to feed the auxiliary
boilers 07-B-1207 A/B/C only via the drum 95-D-1220. During this phase, the wet flare network
will not be in operation. Consequently, 95-D-1220 pressure control valve and pressure safety valve
will be connected to the atmosphere instead of the wet flare network. All connections to other lines
will be blinded. To avoid sending fuel gas to the atmosphere by high fuel gas pressure, a temporary
safety device will be installed to close EIV at battery limit import fuel gas line.
7.2.7 Steam System
7.2.7.1 Steam System Network Flushing

Steam blowing of steam networks is a necessary procedure to avoid damaging steam turbines and
exchangers. HP steam from boilers 07-B-1207 A/B/C will be used for this purpose.
Targets made of aluminum will be installed to check the effectiveness and completion of steam
blowing for pipes linked with steam turbines. These targets shall be submitted to steam turbine
vendors who will approve the completion of steam blowing up to its machine.
7.2.7.2 Auxiliary Boilers Specific Operations

For auxiliary boilers specific operations, please refer to the paragraph 5.2.3 of the vendor document
“Vendor Documentation Turnover 07-B-1207 A/B/C” referenced as RC2-31-00013-EPM-010-
0002.
Chapter: 4
Page: 44
7.2.7.3 Phosphate Tank Filling

7.2.8 Flare System

Air blowing and inerting of flare network with nitrogen must be done. Before start-up the nitrogen
circulation is switched to a fuel gas circulation to avoid air ingress into the flare system.
For flare 61-FL-1111 specific operations, please refer to the vendor document “Installation,
Operation and maintenance Manuals All Tags” referenced as RC2-31-00079-OPM-046-0001
7.2.9 Thermal Oxidizer

For thermal oxidizer vendor recommendations, please refer to the vendor document “Procedure of
preparation of equipment for commissioning ” referenced as “RC2-31-00154-INM-050-0005.
7.2.10 Waste Water Treatment

For waste water treatment and storm water treatment vendor recommendations, please refer to the
vendor document “Procedure of Preparation of Equipment for Commissioning all tags ” referenced
as RC2-31-00030-INM-060-0005.
For sanitary water treatment vendor recommendations, please refer to the vendor document
“Procedure of Preparation of Equipment for Commissioning all tags ” referenced as RC2-31-
00032-INM-060-0006.
7.2.11 Spent Caustic Treatment

For spent caustic oxidation package vendor’s recommendations, please refer to the vendor
document “Procedure of Preparation of Equipment for Commissioning – 97-PK-301” referenced as
RC2-31-00008-INM-080-0005.

Chapter 4 - Rev A

Uploaded by

Copyright:

Available Formats

You might also like

Chapter 4 - Rev A

Uploaded by

Document Information

Original Description:

Original Title

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

Chapter 4 - Rev A

Uploaded by

Copyright:

Available Formats

COMPANY Job N° COMPANY Doc.

PRELIMINARY OPERATIONS PRIOR TO INITIAL START-UP

PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES 4

Equipment Inspection and Cleaning 10

Compressors and Turbines Drivers 18

Air Coolers / Condensers Fans 18

Piping Sliding Supports and Anchors 20

Electrical Equipment Inspection 20

Heating, Ventilation Air Conditioning Equipment 22

CLEANING OF PIPING AND EQUIPMENT 24

Cleaning and Pickling of Piping 29

Storage or Installation of Chemically Cleaned Pipework 30

Lubrication Systems Flushing 31

Preliminary Air Blowing 31

Flushing with Lubricant Oil 32

Leak Repairs / Tightening 34

PLANT PURGING AND INERTING 36

Section 1100 - Storage Area 37

Products Storage Drying 37

Fill in of the Fresh Caustic Tank 95-TK-1147 37

Fill in of the Sulfuric Acid Tank 95-TK-1148 37

Fill in of the Wash Oil Tank 95-TK-1149 37

Fill in of the Lube Oil Tank N°1 95-TK-1151 37

Fill in of the Lube Oil Tank N°2 95-TK-1153 37

Fill in of the DMDS Drum 95-D-1120 37

Fill in of the Polymerization Inhibitor Tank 38

Section 1200 – Utilities 38

Instrument Air and Plant Air 38

Desalinated Water, Fire Water, Fresh Water, Potable Water 38

Demineralized Water and Polished Water 38

Boiler Feed Water 39

Waste Water Treatment 41

Spent Caustic Treatment 41

2. PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES

2.1 Pre-commissioning Activities

SYSTEM N° SYSTEM DESCRIPTION Piping Elec Inst Static Rotating

SYSTEM N° SYSTEM DESCRIPTION Piping Elec Inst Static Rotating

2.2 Commissioning Activities

SYSTEM N° SYSTEM DESCRIPTION Piping Control Syst. Rotating Safety START-UP

Final refractory Dry out

Fire Fighting Equpt

PSSR check list

Over Sped test

Run C3, C2=,

SYSTEM N° SYSTEM DESCRIPTION Piping Control Syst. Rotating Safety START-UP

Final refractory Dry out

Fire Fighting Equpt

PSSR check list

Over Sped test

Run C3, C2=,

3.1 Equipment Inspection and Cleaning

Vessels Sliding Supports

Equipment internal materials generally are the following:

3.1.3 Electrical Motors

3.1.4 Compressors and Turbines Drivers

3.1.5 Air Coolers / Condensers Fans

3.2 Piping Inspection