21 Tsrt Pr 21 Mechanical Precommissionng

PT.TAIYO SINAR

MECHANICAL PRECOMMISSIONING

Doc No : TSRT-PR-021

Document Title MECHANICAL PRECOMMISSIONING

Document No. TSRT – PR – 021 Client Doc. No.

Project Code 2014.08.007 PO No.

Project Name :

IFF. PHASE 1 PROJECT

OWNER :

PT.ESSENCE INDONESIA ( IFF )

0 - 05/11/14 Issued for approval IRWAN SUSILO TEBODIN IFF

Rev Status Date DescriptionIssued

byChecked

byApproved

by

Company Approval

PT.TAIYO SINAR IFF. PHASE 1 Project Page | 1

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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 PRE-COMMISSIONING CHECK

3.0 PRECOMMISSIONING TEST


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1.0 INTRODUCTION

Under the generic terminology of Mechanical Pre-commissioning are covered in the present procedure. All pre-commissioning checks and test related to the followings:

- Mechanical equipment

- Piping and general equipment

- Safety Equipment

- Structure and Building

It is also cover the simplified pre-commissioning scope of works applicable to these package with have been subject to an acceptance test at the manufacturer’s and are listed as such in contract.

The pre-commissioning of mechanical equipment, piping, safety equipment, structure and building shall be carried out in accordance with the rule given in Procedure No: COM-SNCL-001.

2.0 PRE-COMMISSIONING CHECK2.1 Check Line index The List shall be indexed as table below: (See Commissioning sequence)

2.2 ProcedureThe Contractor shall carry out equipment check and fill in relevant check list as per the rules given in the Procedure.

2.3 Check List Master FormsRefer to attached following Forms

3.0 PRECOMMISSIONING TEST3.1 Test Sheet IndexThe following Test Sheets available:

- General Purpose

- Vessel and Tank

- Heat Exchanger

- Pipe Work Pressure test

- Pipe Work Flushing

- Valve Pressure test

- NDT Clearance

- Machinery Alignment


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- Piping Pressure Test Index

3.2 Test Procedure3.2.1 Re-testing of Vendor’s Equipment

Vendor supplied Vessel (Equipment) will normally been pressure tested at Vendor’s Works as part of Acceptance Test requirements and shall only require to be re-tested on site if they have been damaged in transit or on site.

The decision to be carried out the Pressure testing will be made by the Company Engineer.

3.2.2 Pipe Work Pressure TestThe Pressure test shall be in accordance with approved piping pressure test as is considered necessary in order to verify the integrity of all pipe work.

The contractor shall monitor all pressure tests by using calibrated pressure gauges and temperature indicator. Contractor shall verify to the satisfaction of the Company that the test Pressure be between 50 to 80 percent of Instrument gauge.

Contractor shall prepare and send a pressure test notice to all parties concerned by witnessing of the test, with complete set of Test Packs.

Inspection clearance certificate indicated that all Inspection Checks and Tests have been carried out on the piping to be tested and that they are satisfactory.

Acceptance certificate for instrument calibration will be used to assess the pressure test.

After successfully test completion, the Contractor shall reinstate the lines and carry out the necessary works to reach the preservation status.

3.2.3 Pipe Work Flushing TestThe Contractor shall perform the Flushing of pipe work as construction proceeds thus avoiding important dismantling and reassembly works.

Flushing operations shall be carried out frequently outside normal construction working hours.

Flushing operation shall be as follows:

- Each flushing operation shall have a reference number

- Contractor shall prepare the flushing of pipe work test sheet. One test sheet for each flushing operation.


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- The contractor shall prepare of a sketch of the network to be clean.

P&ID to be used for this purpose.

- The Contractor shall maintain a set of marked up P&ID’s to show the status of flushed line.

- Approved pipe work flushing test sheet shall be filed in the Pre-commissioning Dossier.

3.2.4 Pressure Test of ValvesValves will normally have been pressure tested at the Valves Vendor work as part of Acceptance Test procedure. They shall only require being pressure tested on site if they have been disassembled, for any reason. The decision to carry out the pressure testing of valves will made by the Company Engineer.

The method of test will vary for valve type, size and service, the Company Engineer will inform the Contractor of his requirement for the test.

3.2.5 NDT Clearance – Test SheetThe NDT clearance form is a record of NDT completion. One test sheet is to be completed for each subsystem.

The Contractor shall complete the test number, line number, spool number, ISO number, a verification of visual inspection, NDT and Post weld heat treatment ( if any ). The original of test sheet will be filed in the pre-commissioning dossier.

3.2.6 Machinery Alignment – Test SheetThe major of rotating equipment e.g. Compressors, Pumps, will have alignment procedure and applicable tolerance by the Manufacturer to which the Contractor shall adhere. In those instances, alignment adjustments will normally be made in the present of or under the direction of Manufacturer’s Engineer.

In order to permit the alignment to be carried out, the contract shall be responsible for the removal and replacement of any work e.g. coupling guard & coupling. Where Manufacturer has not specified specific procedure or on minor items of rotating equipment, the tolerances stated by coupling manufacturer or the figures shall be used, whichever are the less.

The condition of Piping flange bolt during alignment shall be loose and to be verify again after tightening the bolts.


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Prior to checking alignment the coupling hub run out must be checked by mounting the magnetic base of dial indicator on each hub in turn and placing the dial indicators against the coupling periphery and face, keeping the hub on which the magnetic base is mounted and rotating the hub under the dial indicator.

Tolerance:

Coupling periphery – roundness

Maximum 0.125 mm

Coupling face – square ness

Maximum 0.050 mm


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The Contractor must at all times, have all relevant documentation available for review by Company. On completion, originals of the Machinery Alignment Test Sheet shall be form part of the Pre-commissioning Dossier. After final alignment is completed and prior starting the running test of one or four hours (owner requirements) several important checks are to be recorded complementary to Check List, such as:

- Make sure that all greasing points are completed and oil fill level is as per manufacturer recommendation.

- Manually rotate the moving parts (shaft, belt, and gear box input shaft) to make sure that all parts are moving freely of any obstacle.

- Locally start the motors for few seconds to check if direction of the motor and other parts rotation is correct and Emergency Stop button is operating properly.

After above checks are completed and satisfactory accepted all electrical motors are to be run for one hour without any load. During the test running following parameters are to be recorded: vibration, temperature, noise level, current drawing and other checks as require by manufacturer.

Special attention shall be considered when start running the fans. Prior start up the fan’s motor, the inlet valve shall be Fully Closed and shall be slowly open while monitoring the current drawing which shall be less than 25 to 35%.

3.2.7 Pressure Test/ Flushing Test IndexThe pressure test index and as well as Flushing Test index shall provide in order to control the status of each testing.

The following item shall be included on the index but not limited to:

- Priority sequence index (see commissioning sequence)

- P&ID, ISO Drawing No. Line and spool no.

- Testing Sheet No.

- Date of testing

- Etc.


21 Tsrt Pr 21 Mechanical Precommissionng

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