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    Precommissioning & Commissioning Safety

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    mudatha
    Precommissioning and commissioning activities involve preparing equipment for operation after construction and include tasks like flushing, blowing, testing, and inspection that may involve hazards like high temperatures, pressures, noises, and rotating equipment. Safety is paramount for these activities and job safety analyses must be conducted for non-routine tasks. Close coordination is needed between craft and operations as some systems may be live, and permits and isolations are required before work.

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    Precommissioning & Commissioning Safety

    Uploaded by

    mudatha
    4K views3 pages
    Precommissioning and commissioning activities involve preparing equipment for operation after construction and include tasks like flushing, blowing, testing, and inspection that may involve hazards like high temperatures, pressures, noises, and rotating equipment. Safety is paramount for these activities and job safety analyses must be conducted for non-routine tasks. Close coordination is needed between craft and operations as some systems may be live, and permits and isolations are required before work.

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    commissioning

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    Precommissioning and commissioning activities involve preparing equipment for operation after construction and include tasks like flushing, blowing, testing, and inspection that may involve hazards like high temperatures, pressures, noises, and rotating equipment. Safety is paramount for these activities and job safety analyses must be conducted for non-routine tasks. Close coordination is needed between craft and operations as some systems may be live, and permits and isolations are required before work.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    4K views3 pages

    Precommissioning & Commissioning Safety

    Uploaded by

    mudatha
    Precommissioning and commissioning activities involve preparing equipment for operation after construction and include tasks like flushing, blowing, testing, and inspection that may involve hazards like high temperatures, pressures, noises, and rotating equipment. Safety is paramount for these activities and job safety analyses must be conducted for non-routine tasks. Close coordination is needed between craft and operations as some systems may be live, and permits and isolations are required before work.

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    Precommissioning & Commissioning Safety

    Precomm. & comm. tool box meeting. Similarly to the construction safety, the precomm & comm
    safety need to be cascaded and briefed to all involved and affected by the activities.

    Precommissioning and Commissioning is the preparation of equipment for operation after it has
    been constructed. Activities involved in precommissioning are include:

    Precommissioning

    1. Lub oil flushing


    2. Air blowing
    3. Steam blowingWater flushing
    4. Entry for cleaning (large diameter pipe)
    5. Leak testing
    6. Equipment rotation checks
    7. Final alignment
    8. Equipment runs
    9. Loop and function checks
    10. Visual/Video inspection
    11. Tightness tests

    Commissioning
    1. Inerting & purging (nitrogen)
    2. Electrical power energisation.
    3. Electric motor operation
    4. Power generator operation
    5. Compressor operation
    6. Filling the process (hydrocarbon gas, lubricating oils)

    Commissioning can be divided into 2 parts i.e. Cold Commissioning and Hot Commissioning.
    Cold commissioning activities involve cleaning and function testing without gas or liquid
    hydrocarbons e.g. air blowing piping. Hot commissioning activities involve the use of gas or liquid
    hydrocarbons e.g. fired testing of a power generator.

    Precommissioning
    Precommissioning is an essential task of any project and can ensure a smooth transition of
    Construction to Commissioning and Start-Up. Precommissioning activities are activities carried
    out on the plant equipment and systems following completion work to bring them to a state of
    condition where they will function as designed, given the appropriate process conditions.

    The execution of all aspects of precommissioning work must be done with great care to ensure
    no damage to equipment occurs.

    Precommissioning activities will run in conjunction with construction activities (SIMOPS) e.g.
    involve vessel entry, pipe entry, pressurising of systems and other hazardous tasks, it is
    paramount that each task is analysed from safety perspective. A Job Safety Analysis (JSA) shall
    be conducted to all tasks are especially those deemed sufficiently non-routine, to warrant
    additional review before commencement.

    It is imperative that craft and operations work very closely, as part of the plant may be “On
    Stream” and under pressure. All systems or part systems released shall be isolated, blinded and
    tagged by the Operations group prior to the permit being released. Where part of a system or
    equipment remains under pressure “Live line/Equipment” tags shall be installed. No work shall
    be carried out without a valid work permit.

    Commissioning and Start-up


    Commissioning means those activities immediately following Ready For Start up (RFSU),
    including nitrogen purging, and operating plant and/ or equipment.

    Some samples of the precommissioning & commissioning hazards;

    1. Noise (steam blowing – louder than an aircraft jet engine).


    2. Temperature (e.g. steam blowing >400 degree C, LNG <-160 degree C). 3. High speed air,
    water, debris (e.g. air blowing >100km/h).
    4. High voltage (e.g. substation energisation >33,000 Volts).
    5. Hazardous substances (e.g. filling and inerting - hydrocarbon gas, nitrogen).
    6. Pressure (e.g. leak testing >50 Bar).
    7. Oil spills (e.g. oil flushing >2000L).
    8. Rotating equipment (e.g. 7MW electric motors, 21MW generators)

    All of the above is in addition to the existing hazards, e.g. fall from heights etc. recommissioning
    and commissioning is safe provided everyone follows some simple rules. Do not enter
    precommissioning and commissioning areas unless authorised by work permit and trained for
    the task.

    Some sample of specific precommissioning activities & safety control measures.

    Water Flushing

    1. Keep away from Flush-out Area.


    2. All Electrical equipment , welding machines, temporary power supply system to be covered or
    removed.
    3. Water exits at flushing points at high velocity, risk of injury.
    4. Water not drained can cause water hammer –jumping line.
    5. Surface drains and sumps must be free draining to avoid water build up.
    6. Hose couplings, clamps and pipe spools must be tight and secured, whip arrestor to be used.
    7. Take precautions to prevent tools or other objects falling from heights

    Air Blowing

    1. Keep away from Blow-out area.


    2. High noise levels while blowing.
    3. Wearing of ear plugs or ear muffs to be enforced.
    4. Air horns before and after the blow. Three (3) shots blasts - wear ear protection one (1) long
    blast – all clear.
    5. Safety valves to be fitted and sized for low pressure system.
    6. Temporary spool connection using flange or clamp must be tight and secured to prevent
    failure.
    7. Take precautions to prevent tools or other objects falling from heights.
    8. Dust/debris exiting line blowing points at high velocity.
    9. Scaffold impact board to be provided and checked by Scaffold supervisor for 6”margin pipe to
    ensure strong enough.

    Steam Blowing

    1. Keep away from Blow-out area.


    2. Large area evacuated.High noise levels during line blowing.
    3. Piping will get very hot during steam blowing, beware of hot droplet shower.
    4. Wearing of ear plugs or ear muffs to be enforced.
    5. Steam/Dust/debris exiting line blowing points at high velocity.
    6. Temporary spool connection including target plate assembly using flange or clamp must be
    tight and secured to prevent failure.
    7. Take precautions to prevent tools or other objects

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