Rencana Precommissioning Commissioning & Startup Proyek Petrochemical

1. PROJECT ENGINEERING, PROCUREMENT, AND CONSTRUCTION
AMMONIUM NITRATE 75,000 MTPY
NITRIC ACID 60,000 MTPY
PERFORMANCE TEST
20 MAY 2022

2. Approach to
Approach to Commissioning
Factory Acceptance
Testing (FAT)
Mechanical
Completion
Pre-
Commissioning
Commissioning
Start-Up &
Performance Test
The Commissioning Phase can be split into 5 distinct activities that are usually performed in
chronological order
1
2
3
4
5

3. Factory accep.
Factory Acceptance Testing
The intention of Factory
Acceptance Testing is to
maximize Mechanical
Completion, Pre-
Commissioning,
Commissioning and
Performance testing activities
of Vendor Packaged
equipment, offsite prior to
release and shipment to site
This includes running the
package around a significant
portion of the operating
envelope using simulated
media, temporary supplies
and maximum control
simulation where necessary
in order to confirm that the
package will function correctly
and meet design and field
conditions
Vendor packages will
undergo acceptance testing
at the manufacturer's
premises. These tests will be
attended by members of the
Project and Operations
teams, in accordance with a
FAT Program
1 2 3
QC akan mengumpulkan :
1. MDR (Manufacture Data
Report – yang meliputi
hasil FAT, Prosedure
SAT yang akan
dilakukan, dsbnya)
2. Approval terhadap
pengujian dan catatan
perbaikan yang
dimintakan Owner
Pengujian setiap alat di
lapangan dikenal sebagai
SAT/PreComm dapat
dilakukan dengan beberapa
kondisi untuk menguji kebali
peralatan dengan
pertimbangan konstruksi
belum selesai dilakukan
yakni dengan mencari
workshop yang
menyediakan kondisi yang
sama seperti saat di FAT
atau menyediakan sumber
daya di lapangan
Pengujian yang dilakukan
hanya bersifat uji jalan atau
uji tekan, sehingga baik
pump, vessel, tank, dll
hanya akan dilakukan
pengujian dasar tersebut
dengan beberapa test yang
berhubungan seperti noise,
vibrasi dll
Untuk saat ini yang dapat
dilakukan adalah
membandingkan hasil FAT
dengan desain, dengan
syarat FAT mengikuti
standard yang ada
FAT should be witnessed and
accepted by the discipline QC
& engineers, package
engineers and/or third party
inspection services at the
manufacturers site
4
FAT untuk scope SEDIN
adalah tanggungjawab
SEDIN, sehingga
pelaksanaanya hanya
melibatkan SEDIN dan KAN.
Apakah WIKA mengirimkan
Perwakilan pihak ketiga
untuk melakukan FAT
semua Equipment ?
Sehingga Batasan
tanggungjawab, hasil seperti
apa – QC & Eng.

4. Factory accep.
Factory Acceptance Testing
Copies of the completed
Factory Acceptance Test
(FAT) procedures and
associated acceptance
certification should be made
available to the
Commissioning Manager
complete with all deviation
requests, release notes and
outstanding punchlist items
Manufacturers drawings,
O&M Manuals and
certification books, etc,
should be issued in a timely
manner to support site
installation, commissioning
and handover to operations
5 6
The vendor should provide
SAT procedures that will be
implemented on site and
verify that the
equipment/software has been
assembled/loaded and tested
to the requirements of the
supply contract
The SAT procedure will be
accepted by the respective
commissioning engineers
prior to commencing pre-
commissioning activities on
site
7 8

5. Mechanical Co
Mechanical Completion
Physically Complete Tight Functional Tested
1. Constructed, installed
and connected as per
design
2. Everything is checked,
in working order
3. Lubricants are added to
machinery
4. Equipment is aligned
5. Operability check have
been performed
Safe Clean
Mechanical Completion means the System or Sub-System is:
There is no loss of
pressure or leakage from
equipment, piping, joints,
etc
can operate as intended
Equipment has been
successfully inspected,
tested and certified as
required
The facilities are inherently
safe and all systems for the
protection of
personnel, environment
and property are installed,
operational and
documented
The facilities have been
flushed, are clean, dry and
have the
necessary temporary
equipment installed ready
for Commissioning

6. Mechanical Co
Mechanical Completion Item
MC - Electrical
Activity Example of earth loop tests
Verification of manufacturer's
equipment and certification details
against
Check and inspect the earth system
connections
design specifications including
Hazardous Area and IP ratings
Check for continuity of the main earth
system loop and continuity of the taps
of equipment.
Completeness of Installation against the
approved design
Check earthing resistance.
Insulation Resistance testing Point to
point testing
Check of earthing connection to
equipment rightness.
Protection Relay Tests and lighting
system
Check of adequate mechanical
protection of earth wire (if required).
Continuity testing and attenuation
measurement
Continuity test for earthing mesh
branches.
Earth Loop Impedance tests
Earth grid and ground loop wire sizes
(electric and instrument
grounding system).
Earth Bar resistance checks
Over potential (Hi Pot) testing
Verification of Heat Tracing Installations
Communications equipment testing
MC - Instrumentation / Control / Fire & Gas / ESD
Activity Example
Verification of manufacturer's
equipment and certification details
against design specifications including
Hazardous Area and lP ratings
Instrument tagging
Completeness of installation against the
approved design
Model number and instrument
classification.
Calibration of instrument devices and
equipment
Size and connections.
Attenuation, continuity testing of fibre-
optic cables
Material of construction.
Calibration and cycling of Control Valves Instrument range and calibration.
Continuity testing and attenuation
measurement
Valve action and air/electrical failure
positions
Relief Valve testing
Pressure testing of impulse pipe and
tubing

7. Mechanical Co
Mechanical Completion Item
MC-HVAC MC-MECHANICAL
Verification of manufacturer's equipment and
certification details against design specifications
including Hazardous Area and IP ratings
Verification of manufacturer's equipment and
ancillaries against
design specifications
Completeness of installation against the approved
design
Completeness of installation against the approved
design
Alignment of motor and fan drives Bore scope inspections
Mechanical operation of linkages and damper
blades
Rotational checks
Confirmation of correct airflow direction in pre-
heaters
Equipment alignment checks
Firefighting equipment inspection
Lifting equipment checks

8. Mechanical Co
Mechanical Completion Item
MC - PIPING
Activity Example Vessel Example Pipe
Completeness of installation against the
approved design
Conformity with project documentation. Conformity with P and I flow diagrams.
Non-destructive examination Pressure, temperature, rating. Size
Flange and nozzle alignment checks Nozzles, sizes and orientation.
Pipe: flanges, gaskets, fittings, valves in
conformity with specified piping classes
Bolt tensioning
Internals: types, dimensions, metallurgy
and installation.
High point vents and low point drains.
System flushing Instrument nozzles and types. Instrument nozzles and types.
Hydro-testing
Ladders, platforms, walkways: Location,
size and accessibility.
Pipe supports and spring hangers.
Re-instatement Nameplate information/data.
Flange bolting tightness: nuts, gaskets
and bolts are properly installed
Coating systems checks and pipe
marking
Grounding connections.
Orifice plates in correct location and
direction.
Pipe support checks
Vents, drains, relief valves provided as
specified.
Spacers and spectacles are properly
installed at the open or blind position
3D laser survey results available for
items requiring Dimensional Control
Chemical cleaning
Pickling
Vacuum/air drying
Installation of temporary strainers

9. Mechanical Co
Mechanical Completion Item
FLUSHING OR BLOWING THE PLANT
Small pieces of mill scale, weld rod stabs, weld spatter,
insulation, paper, wood and other debris are sometimes
unavoidably left in piping and equipment on completion of
construction
The P&I Diagrams are used to prepare the flushing sequence
and to follow the progress of flushing. Finally, manual fine
cleaning may be necessary
Use compressed air for piping blow down after flushing
A systematic program for flushing with water or blowing with
air will eliminate most of the debris that might obstruct
control valves and orifice plates restriction orifices or damage
machinery
The fire water circuit should be washed
Special attention must be paid to certain piping systems such
as lubricating oil and mechanical seal circulation systems
where small orifices and openings are present. It may be
necessary to dismantle the piping to clean it mechanically or
by pickling. Once these systems are clean, they must be kept
clean to prevent repetition of the cleaning operations. These
specialized systems are the Supplier responsibility and
normally are cleaned prior to shipment. If further cleaning
has to be done, it shall be conducted by Supplier
representative instructions and responsibility.
The flushing and cleaning entails whatever work is necessary
to obtain a clean unit ready for process operation. Part of this
work can be accomplished after hydraulic test execution and
before final reinstatement of the piping
All control valves should be removed and flushed from both
directions using the bypass and in-line valves, if possible.
Otherwise, open and clean all control valves after flushing are
completed, where will be difficult to remove them
Only fresh water and compressed air should be used
Instruments must be disconnected or isolated. Restriction
orifice and rotameter must be taken away, if have been
installed.
Dirties and debris should be flushed from the unit and not
into it.
Circulated flushing of the piping system within the plant may
be carried out, where it is possible. If water circulated
flushing, using process pumps, is applied for system cleaning,
special care for over load trip must be taken '90due to higher
density than design condition. Provisional strainers are
installed and periodically cleaned. Spraying nozzles must be
installed after relevant lines have been flushed to avoid
clogging. If necessary, take out the flapper of check valves
(previous check of the availability of spare gaskets)
For temporary flushing, use compressed non- asbestos
gaskets. Insert proper gasket only for the final re-assembling
of the unit.
Water is supplied with temporary flexible hoses. Prior to
flushing, make a manual cleaning to minimize obstruction.
All blinds inserted into lines or equipment must be recorded,
and drawn out after flushing. The water should be drained
from every low point
Final reinstatement of piping after flushing/blowing/cleaning
activities shall be supervised by Commissioning Integrated
Team (CIT) engineers to report the conformity with the
design

10. Pre-Commiss
Pre-Commissioning
Physically Complete Tight Functional Tested
The System/Sub-System
has been constructed,
installed and tested
under power in accordance
with the design documents,
Vendor
documents and other
applicable documents as
required.
Safe Clean
There is no loss of
pressure or leakage from
equipment, piping, joints,
etc.. during running
Can operate and running
as intended.
Equipment has been
successfully energized and
tested.
The facilities are inherently
safe and all systems for the
protection of
personnel, environment
and property are installed,
operational and
documented
Everything is tested, in
working order, lubricants
are added to
machinery, equipment is
aligned, operability checks
have been
performed and the
equipment is ready for
Commissioning.

11. Pre-Commiss
Pre-Commissioning
Inspection and testing activities performed to achieve System/Sub
System Acceptance are:
1. Carried out on a single discipline basis.
2. Requires energized checks on systems
3. Include tests by specific discipline.
4. All tests are documented on type "B" ITR’s (Inspection test report) and the status of completion
recorded within and monitored by the Completions & Certification Management System (CCMS).
5. Pre-Commissioning consists of powered up (energized) checks and proves the correct operation of the
equipment under simulation prior to the introduction of utility media

12. Pre-Commiss
Pre-Commissioning Item
Precomm - Electrical
Activity Example of Switchgear & MCC checks
Energize Electrical systems
Complete component and interconnection and cable terminations inspection according to
manufacturer's final approved drawings.
Switchgear & MCC checks and Function Checks Inspection, testing and functional check shall be according to supplier instruction.
Alarm, Trip, ESD and Control Settings Pressure and
Power frequency testing Voltage, polarity and phase
rotation checks
Make all necessary adjustment to switch gear and motor control center equipment
Uncoupled / no load motor runs and performance
tests
Test and calibration of all switch gear relays (using primary and Secondary injection as
applicable), metering, lights, indicators, space heater, and check proper coordination and
setting.
Breaker operation Check the phase sequence and polarity of all equipment
Motor runs Functional check of all motor starters, circuit breakers' incomers, outgoing Feeders and bus ties.
Load Testing and lighting system test.
Perform operational tests on all motor control circuits, interlock system, indicating lights,
meters and all other devices.
Run tests and energized rotation tests of electrically
driven motors
Check circuit breakers, motor starters, relays and other equipment for loose connections (both
mechanical and electrical). Verify that contacts and working parts are correctly aligned and free
from dust and foreign matter.
Auto / Manual operation
Inspect circuit breakers with adjustable trips, checking both thermal (if any) and magnetic
settings for proper protection. Also check thermal overload relay settings according to vendor
documents.
Check and sequence test for alarms, interlocks, auto-transfer, ... etc.
Functional checking of switchgear and MCC from remote locations such as Control Room.
Energizing the substation for readiness of plant commissioning and start-up.

13. Pre-Commiss
Pre-Commissioning Item
Precomm - Instrumentation / Control / Fire & Gas / ESD
Activity Example
Energize Control systems Level DP transmitters.
Loop testing Analogue input / output
tests
Pressure transmitters.
Digital input / output tests Temperature transmitters.
Frequency tests Transducers.
Auto / Manual switching Petitioners.
Control System configuration
After completion of this work QA/QC
stickers should be fixed on the
instruments, then, the check form shall
be signed by all concerned parties.
System integrity testing (i.e.
Communications between Control
Systems)
Control panel functional testing
Precomm-HVAC Precomm-MECHANICAL/PIPING Precomm-COMMON
Damper and actuator Operation Installation of temporary strainers
Package equipment function and
energized tests Removal of internal
preservation
Temperature device operation Load testing of Lifting equipment Removal of temporary bracing
Ductwork Leak Tests
Pre-Commissioning of Lubrication,
Cooling, Fuel, Seal Gas and Hydraulic
systems, including flushing, circulation,
draining and re-filling as required by the
specification
Activation of all piping spring hangers
Air Conditioning equipment operation Coupling of rotating equipment
Testing of Lifting Equipment for 3rd party
inspection Charging of systems
Operation of Fans and Air Handling Units Vibration and Noise testing Loading of Selected Chemicals
Airflow and balance testing Mechanical seal integrity checks Discharge / retention testing
Final inspection of vessels Verification of media quality
Critical Valve Testing
Relief Valve re-setting

14. Commissioning
Commissioning
Commissioning means : Commissioning items :
The plant systems and sub-systems operate together in an integrated
manner in accordance with the design objective and meet the performance
criteria regarding operational requirements and occupational safety
requirements
Gross Air Leak Testing Punch Listing
The documentation is adequate for full facility operation, describing
accurately the plant and procedures.
Nitrogen or Helium Leak Testing Test Runs
Staff skills are appropriate to operate the plant in accordance with
competency requirements, occupational health and safety requirements.
Installation of temporary systems if
required for commissioning use and start
up
Integrated Runs
The new facilities perform as designed Identification and charging of first fills. Dynamic Instrument testing
The new facilities interface appropriately with the existing facilities Vendor control Preservation and Maintenance
All Commissioning activities are performed using 'SAFE' fluids with the
exception of Compressor Surge Mapping
Cause and effect logic tests Control logic
checks Safety Systems testing DCS
functional testing PLC Functional tests
ESD Functional testing
Surveys
Commissioning procedures will be produced and contain detailed step by
step instructions that will be followed when starting for the first time and
placing equipment and systems into operation. Once the procedure has
been successfully completed the system is deemed to be fully compliant
with the design
Fire & Gas Functional testing Operator Training
The commissioning activities will prove the new facilities interface with all
other associated systems and bring the entire plant to a state of readiness
for normal operation and handover
Optimization of room pressure and
temperature

15. Start-Up
Start-Up
Start-up means : Start-up items :
The initial introduction of "LIVE fluids"
into the completed systems and ramp
up of production to a steady state.
Initial introduction of Fluida,
stabilization and short running
Pre-requisites for Start-Up are;
Check pipe supports, hangers, guides
and anchors under running condition
The state of a system / sub-system
where by all Mechanical Completion
Certification has been issued; Pre-
Commissioning and Commissioning
activities are complete such as inerting,
drying, function testing of instrument,
equipment and safety systems, and
integrity leak testing have been
completed
Check noise levels
No open punch list items remain that
will be detrimental to the personnel
safety or safe operation of the system
Mini shutdown for the removal of
temporary strainers and blanks
Start-up Authorization has been
received where required from
Operations.
Restart
Progressive increase of throughput
Phased handover to Operations

16. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up
11
JANUARY
› The schedule for testing will be according to the construction and installation
program. An extensive inspection and test program is planned for the new
facilities and auxiliary systems. During the pre-commissioning test phase,
testing will be performed as system MC hand-over from construction allows.
› Key systems will be sequenced for completion and testing early enough to
provide necessary auxiliary services for testing and operation of other systems
› Examples of such key plant systems are the electrical system and
compressed air system
› The sequencing of tests shall be such so that safety of the facility is never
dependent on the performance of untested systems, sub-systems and
components.

17. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up

18. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up
Vendor Site Support
The Work
The relevant Discipline Commissioning Engineer will be responsible
for the vendor carrying out the work within the time forecast.
The Construction / Commissioning Manager will be responsible for the
provision of any services or support required by the vendor to carry
out the work in order to ensure there is no delay.
Forecast and Budget
The need for vendor assistance shall be pre-planned and be
facilitated by having in place vendor call-off contracts against those
vendors whose assistance is anticipated, or contingency against
those vendors considered desirable.
Vendor Site Visit Close-Out
Upon completion of the work to the satisfaction of the relevant
Commissioning Engineer and the Construction / Commissioning
Manager the Vendor Representative shall complete all final time
sheets and reports and obtain the necessary approval signatures.
Preservation and Maintenance
• The Preservation and Maintenance of installed, inspected and tested
equipment will remain the responsibility of the project until such a
time as the new facilities are handed over and accepted by
Operations.
• Equipment Preservation and Maintenance activities will be carried out
by the Commissioning Team and documented using specific ITR's
within the Completions Management system. Preservation and
Maintenance reports will form an integral part of the system hand
over dossier.

19. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up

20. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up

21. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up

22. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up

23. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up

24. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up

25. Process Plant
Process Plant Pre-commissioning,
Commissioning and Start-Up