Chapter 4

CPD 30103 Plant Maintenance & Inspection UniKL MICET
MICET
Chapter 4
Installation,
Commissioning &
Testing in New Plant
Universiti Kuala Lumpur 1
Malaysian Institute of Chemical and Bioengineering Technology

CPD 30103 Plant Maintenance & Inspection SCET
MICET
Content
4.0 Installation, Commissioning &
Testing in New Process Plant
4.1 New Process Plant Set-Up
4.2 Personnel Requirement
4.3 Certificate of Commissioning
2
MICET
Content
3
New Process Plant Set-up
MICET
Any project will go through four major

phases:
a) Design.
b) Construction & Installation
c) Commissioning.
d) System Start Up, Operation &
Maintenance.
CPD 30103 Plant Maintenance & Inspection (a) Design SCET
MICET
In engineering, design used is to create new

thing or old thing is created in new way..
~ installation basically refers to fix the
new equipment for usage.
~ for new machinery or new plant
In chemical engineering, installation is a

part of plant design..
~ include of mass and energy balance
calculation, site selection, mechanical
design, piping and instrumentation, etc.
(b) Construction & Installation
MICET
The construction of chemical plant will

take from 6 month to 18 month based
on the cost of the project.
Everything that has been detail on the
specification sheet and on the various
diagram must put on place.
~ begin with preparing site, laying
foundation and ends with start up or
commissioning of plant.
Construction - Before
MICET
There are consultation among

the company with appointed
parties (Project Manager, main
contractor, sub-contractors)
Theplant is built as designed
and the contractor keep to time
schedule to complete the task
Construction - Before
MICET
The schedule will form be in form on

CPM/PERT (Critical Path Method/Program
Evaluation and Review Technique) or Gantt
Chart.
Representative (Project Manager) will

handle communication between the company
and Main Contractor for observation of
project and inspection of quality of
contractors work.
PERT/CPM Chart
MICET
Gantt Chart Template
MICET
Construction - During
MICET
many problem will arises

Representative (PM) must find
answer and resolve the problem
try to make certain laborers
are being properly used
(c) Commissioning
MICET
Plant Commissioning is an important

phase within the project life cycle.
Upon completion of plant
installation, commissioning of plant
equipment and system functionality
test will be carried out to ensure
proper functionality of the plant
and optimize its performance.
Commissioning
MICET
a quality-assurance process for new

construction and installations - ensure
that building equipment and integrated
systems perform as company and
designers expect.
implements a systematic process to
verify and cross-check performance
from pre-design through warranty,
increasing the likelihood that a newly
constructed building will meet client
expectations
Commissioning
MICET
In return for investing in

commissioning, the building owner
can save money during construction
and throughout the operation and
maintenance of a quality building.
Designer can be an essential part
of the commissioning process,
helping to facilitate successful
commissioning, and promoting
overall client satisfaction.
Commissioning Goal
MICET
The primary goal is to provide a safe and

healthy facility for all occupants: office
staff, the public, students, faculty,
researchers, and operations and
maintenance staff.
The second goal is to improve energy
performance. Commissioning is the tune-up
that gets the most efficient performance
out of the installed equipment.
The third goal is to reduce operating costs.
Equipment operating improperly is operating
inefficiently.
Commissioning Goal
MICET
The fourth goal is to improve orientation

and training of the operations and
maintenance staff. The complicated
systems being installed will be disabled if
operations and maintenance staff do not
fully understand operation and maintenance
requirements. No matter how well the
equipment and systems are operating at the
outset, systems operation will collapse
without proper care.
Commissioning Goal
MICET
The fifth goal is improved documentation.

Specifications and drawings do not provide
all of the information needed for operation,
troubleshooting, and renovation of the
facility.
Fully documented testing procedures and
results verify the capacity and operating
parameters of the facility and systems, and
facilitate re-commissioning as needed in the
future.
Commissioning Goal
MICET
The final and most important goal

is to meet the clients needs.
When the design and construction
is subjected to systematic
inspection and verification, the
design intent and customer
satisfaction will be achieved.
Commissioning Process
MICET
Commissioning is a strategy that:

Begins early in the design process
Requires special bidding
requirements during contractor
selection
Controls the static and dynamic
testing that acceptance is based
on
Finishes with staff training and
warranty monitoring.
Commissioning Process
MICET
Building systems to be commissioned

include:
Building enclosure and interior
finish materials
HVAC*/mechanical
Electrical
Lighting
Life safety
Plumbing
*HVAC ~heating, ventilating, and air conditioning

Building Commissioning
MICET
isa systematic process of

ensuring that building systems
are designed, installed,
functionally tested, and capable
of being operated and
maintained according to the
owners operational needs.
MICET
The key elements in building commissioning

include:
Thorough documentation of system design
intent, operating sequences, and test
procedures.
Verification of system performance based
on extensive functional testing and
measurement.
Training of building operations staff on
system operation and maintenance
procedures.
Ongoing monitoring of system performance
MICET
Ensure that building systems operate

efficiently, meet the needs of the end
user, function as designed, and
maintain occupant comfort.
The initial costs of commissioning are

recovered many times over through
operating savings, improved staff
performance, and avoidance of costly
construction problems.
Commissioning Phase
MICET
There are three major stages during the

commissioning phases. Each phase
consists of a logical progression of steps
necessary to verify that installed plant
is fully functional and fit for its design
and operational purposes:
a) Pre-Commissioning.
b) Actual Commissioning.
c) Plant Trial Run.
(a) Pre-Commissioning
MICET
System Configuration Check
Verify all pipe work and connections

within the entire system are as per
the approved P & ID and relevant
design drawings.
Perform visual inspections on

equipment and pipe works to ensure
they are clean, properly installed and
with professional finishing.
Pre-Commissioning
MICET
Instrumentation System Check
Verify all alarms settings and signals on

instrumentation are function as
intended.
Verify relevant signals from the field
instrumentation are displayed locally,
and on their corresponding control
panels.
Verify all instrumentation devices are
properly calibrated.
Pre-Commissioning
MICET
Flushing & Cleaning of Lines & Vessels
Do internally clean up all pipe works

and pressure vessels, ensuring no
obstructions, blockages or any
potential contaminants in the process
lines or vessels as a result of poor
house keeping during the construction
phase.
Pre-Commissioning
MICET
Flushing & Cleaning of Lines & Vessels
After flushing, it is important to

ensure all pipelines and equipment are
thoroughly dried off, especially if any
water incompatible chemicals are being
introduced to them during
commissioning.
(This is normally prevented by using
dry air to clean the pipes or vessels,
instead of water).
Pre-Commissioning
MICET
Start-up & Shut-down Protocol
To provide a guide line and

concept for system
isolations, commissioning
sequences, testing period,
etc, prior to actual
commissioning.
(b) Actual Commissioning
MICET
Equipment Testing Energization & Dynamic Testing
Thisinvolves the test of equipment

performances. Equipment such as
pumps, heat exchangers, cooling
towers, etc will be run individually
for certain period of time, and its
performances will be checked
against design specifications.
(b) Actual Commissioning
MICET
System Functional Testing
Individual plant system will be

run and all mechanical &
electrical items within that
particular system will be
checked to ensure the entire
system is function as per its
design concept.
(c) Plant Trial Run
MICET
The entire plant will be put into

operation.
All system involves will be run
concurrently to simulate actual
plant operation condition.
Plant final output will be verified.
MICET
Content
37
Personnel Requirement
MICET
Plant Commissioning is a specialized

area which shall be handled by
qualified personnel.
This is especially so when comes to
commissioning certain specialized
equipment such as gas and steam
turbines, compressors and boilers.
Personnel Requirement
MICET
The following personnel shall participate and

witness the commissioning of plant equipment
and system :
a) The Final Plant Operator (Client).

b) The Main Contractor.
c) The Original Equipment Manufacturer.
d) Local Authority ( Such as BOMBA).
e) Third Party Consultants (Normally
Engaged by Client).
MICET
Content
40
Project Organizational Chart
MICET
41
Contract Document Requirements
MICET
There are three contract documents

required to appropriately incorporate
and coordinate the commissioning
process:
i. the design professional agreement,
ii. the commissioning authority

agreement,
iii. and the construction contract.
Design Professional Agreement
MICET
Design professionals may include the

architect, mechanical design engineer,
electrical design engineer, or other
specialty sub-consultants.
The design professionals scope of
services should include their
assistance in development of the scope
of commissioning services and
participation in the selection of a
commissioning authority.
Design Professional Agreement
MICET
The design professional agreement

must address communication with the
commissioning authority (CA) during
design and construction.
The design professionals must
participate in resolution of problems
and conflicts during construction.
Commissioning Authority Agreement
MICET
The owner must have the full

commitment of the commissioning
authority (CA) during the project.
The scope of services includes:
i. responsibilities during the design and
construction.
ii. a quality-assurance role relative to the
contractors commissioning activities.
iii. witnessing and verifying the results of
systems functional performance tests
Commissioning Authority Agreement
MICET
The commissioning authoritys

agreement should also include:
i. analysis of the functional performance
test results,
ii. review of the contractors proposed
corrective measures when test results
are not acceptable, and
iii. recommendation of alternate or
additional corrective measures, as
appropriate in the commissioning
authoritys scope.
Construction Contract
MICET
Contractors and manufacturers

representatives construct the facility.
They provide, install, start-up, and often
test the buildings systems and their
components.
They are also responsible for providing

system documentation and training building
staff.
Commissioning Lead Qualifications
MICET
Technical knowledge
In all commissioning projects, the
commissioning lead should have experience and
up-to-date technical knowledge in the related
fields of design, construction and building
operations.
Relevant experience
The commissioning lead must have experience
troubleshooting commissioned systems. The
lead should have served in a similar capacity on
at least two other projects with similar needs.
Commissioning Lead Qualifications
MICET
Communication and organizational skills

Diplomacy and an ability to resolve
conflicts are also essential.
References and sample work products
The commissioning lead should provide
references and work products from
other, similar commissioning projects.
Testing & Commissioning Work Objectives
MICET
i. to verify proper functioning of the

equipment/system after installation.
ii. to verify that the performance of the
installed equipment/systems meet with the
specified design intent through a series of
tests and adjustments.
iii. to capture and record performance data of
the whole installation as the baseline for
future operation and maintenance.
Testing & Commissioning Work Scope
MICET
Tests and Inspections during Construction

The purpose of these tests is to ensure that all
components and systems are in a satisfactory
and safe condition before start up.
Functional Performance Tests
The purpose of functional performance tests is
to demonstrate that the equipment/installation
can meet the functional and performance
requirements as specified in the
General/Particular Specifications.
MICET
Commissioning and Statutory Inspections

Commissioning is the advancement of an
installation from the stage of static
completion to full working conditions and
to meet the performance requirements as
specified in the General/Particular
Specification.
Documentation and Deliverables
All inspection and T & C results shall be
recorded in the data record forms
MICET
MICET
MICET
MICET
MICET
Understanding Insulation Resistance Testing
MICET
Why have an insulation testing

program?
A regular program of testing insulation
resistance is strongly recommended to
prevent electrical shocks, assure safety
of personnel and to reduce or eliminate
down time.
primarily to test motor, generator and
transformer insulation
Understanding Insulation Resistance Testing
MICET
What causes insulation failure?

Some of the more common causes of
insulation failure include:
excessive heat or cold,
moisture, dirt, corrosive vapors,
oil, vibration, aging and
nicked wiring.
MICET
CLASSIFICATION OF TESTS
Pump tests should be classified as
follows:
Shop tests are also called laboratory,
manufacturers, or factory acceptance
tests.
They are conducted in the pump
manufacturers plant under geometrically
similar, ideal, and controlled conditions
and are usually assumed to be the most
accurate tests.
MICET
CLASSIFICATION OF TESTS
Pump tests should be classified as follows:
Field tests are made with the pumping unit
installed in its exact environment and
operating under existing field or ultimate
conditions.
The accuracy and reliability of field testing
depend on the instrumentation used,
installation, and advance planning during the
design stages of the installation.
By mutual agreement, field tests can be used as
acceptance tests.
MICET
Commissioning Certificate
MICET
When equipment or a system is

commissioned successfully, a
certificate will be issued to justify its
functionality and performances.
This certificate is normally issued by

the Client ( Final Plant Operator) to
the contractor.
This certificate is referred as

MICET
If local authorities are involve in

the approval process, such as the
plant fire fighting system where
BOMBA will have the final
jurisdiction on the system, this
certificate has to be approved by
them as well.
Provisional Acceptance Certificate (PAC)
MICET
This document is issued by the

clients to the contractor once trial
run is completed successfully.
This certificate is an indication of

accepting the plant temporarily based
on the positive outcomes from the
trial run.
Warranty Period
MICET
For any project, the contractor is

normally contractually obligated to
give warranty on plant equipment and
system performances to its clients, at
a period mutually agreed by both
parties.
The time frame normally ranges from

1 to 3 years, and is referred as
Warranty Period.
Warranty Period
MICET
It is the responsibilities of the

contractor to repair the equipment
and resolve any issues affecting the
plant performances without any cost
to its client, if such occurrences
happen during the warranty period.
CPD 30103 Plant Maintenance & Inspection Hand Over SCET
MICET
Upon completion of the warranty

period, and if there is no issues arise
on the plant operations and
performances, Final Acceptance
Certificate ( FAC) will be issued to
the contractor.
The plant is considered handover

officially to the client.
MICET

Chapter 4

Uploaded by

Document Information

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

Uploaded by

Copyright:

Available Formats

CPD 30103 Plant Maintenance & Inspection UniKL MICET

Malaysian Institute of Chemical and Bioengineering Technology

Any project will go through four major

In engineering, design used is to create new

In chemical engineering, installation is a

The construction of chemical plant will

There are consultation among

The schedule will form be in form on

Representative (Project Manager) will

many problem will arises

Plant Commissioning is an important

a quality-assurance process for new

In return for investing in

The primary goal is to provide a safe and

The fourth goal is to improve orientation

The fifth goal is improved documentation.

The final and most important goal

Commissioning is a strategy that:

Building systems to be commissioned

*HVAC ~heating, ventilating, and air conditioning

isa systematic process of

The key elements in building commissioning

Ensure that building systems operate

The initial costs of commissioning are

There are three major stages during the

System Configuration Check

Verify all pipe work and connections

Perform visual inspections on

Instrumentation System Check

Verify all alarms settings and signals on

Flushing & Cleaning of Lines & Vessels

Do internally clean up all pipe works

Flushing & Cleaning of Lines & Vessels

After flushing, it is important to

Start-up & Shut-down Protocol

To provide a guide line and

Equipment Testing Energization & Dynamic Testing

Thisinvolves the test of equipment

System Functional Testing

Individual plant system will be

The entire plant will be put into

Plant Commissioning is a specialized

The following personnel shall participate and

a) The Final Plant Operator (Client).

There are three contract documents

ii. the commissioning authority

Design professionals may include the

The design professional agreement

The owner must have the full

The commissioning authoritys

Contractors and manufacturers

They are also responsible for providing

Communication and organizational skills

i. to verify proper functioning of the

Tests and Inspections during Construction

Commissioning and Statutory Inspections

Why have an insulation testing

What causes insulation failure?

When equipment or a system is

This certificate is normally issued by

This certificate is referred as

If local authorities are involve in

This document is issued by the