Commissioning Checklist

A commissioning checklist is a comprehensive list of tasks, inspections, and tests required to ensure a system or equipment operates according to its design specifications and regulatory standards. It typically includes both pre-commissioning and commissioning activities, with checks for mechanical completion, safety systems, equipment functionality, and control systems. The checklist serves as a critical document to track progress, identify issues, and confirm that all relevant procedures are followed before transitioning to full operation.

Commissioning Procedures

Commissioning procedures outline the systematic steps involved in bringing a system from construction to operational status. These procedures involve the inspection, testing, and verification of equipment and systems to ensure everything functions correctly. This includes the coordination of different disciplines such as mechanical, electrical, and instrumentation to verify that all aspects of the facility meet design intent. A successful commissioning procedure provides the necessary documentation, certifications, and approvals to proceed to operational readiness.

Pre-commissioning for Testing Individual Equipment After Mechanical Completion

Pre-commissioning involves a series of inspections and functional tests to confirm that individual equipment pieces have been correctly installed and are free of defects after mechanical completion. This stage ensures that each component is in proper working order before moving to the next phase of commissioning. Tasks typically include checking alignment, confirming correct installation, verifying electrical connections, and ensuring that safety features are operational. It is an essential step to mitigate issues that could arise during later commissioning phases.

Cold Commissioning

Cold commissioning refers to the process of testing and verifying systems and equipment without the introduction of process fluids or heat. During this stage, components like electrical systems, instrumentation, and control systems are thoroughly tested to confirm their proper functionality. Cold commissioning typically involves checking for correct wiring, testing alarms and shutdown systems, and verifying the integrity of valves, pipes, and controls. This phase ensures that the system is ready to be operated safely when process fluids or energy are introduced in later phases.

Dry Commissioning Without Water or Solvent Control System Sequence Test

Dry commissioning is a phase where the control systems and equipment are tested without the use of process fluids, such as water or solvents. This phase focuses on verifying the sequence and operation of the control systems and ensuring that the systems respond as intended to input signals. Control loop checks, system interlocks, and alarms are tested to ensure that the automation system can control equipment safely and efficiently. It is a crucial stage for identifying and rectifying any issues in control logic before advancing to more complex testing.

Wet Commissioning with Water or Solvent Running Pumps in Closed Loops

Wet commissioning involves introducing process fluids, such as water or solvents, into the system to begin operational testing. This stage focuses on verifying that the system functions under normal operating conditions, including the proper flow of fluids and running pumps in closed loops. The goal is to confirm the integrity of the piping systems, check for leaks, and verify that all pumps, valves, and instrumentation are functioning as expected. Wet commissioning is critical for confirming the system's readiness for full operation with the actual process fluids.

Hot Commissioning (Live or Core Commissioning) by Introducing Design Process Fluid in System and Sub-systems

Hot commissioning, also known as live or core commissioning, is the final stage before a system can be fully operational. It involves introducing the design process fluid into the system and sub-systems, allowing them to operate as they will in production. This phase validates the performance of the entire system under actual operating conditions, including pressure, temperature, and flow parameters. Hot commissioning is essential for confirming the systems ability to perform as intended under normal operating conditions, and it often includes fine-tuning control systems, adjusting set points, and ensuring all systems are synchronized.

Startup and Performance Testing

Startup and performance testing is the phase where the system is gradually brought online and performance is measured against design specifications. This phase involves starting up the system and running it under various load conditions to assess its efficiency, stability, and reliability. Performance testing ensures that all equipment operates at the required capacity, and it helps identify any operational issues that need to be addressed. It includes a full evaluation of power consumption, output, and operational stability to confirm that the system meets its expected performance criteria.

Punchlisting

Punchlisting is the process of identifying and documenting any outstanding tasks, issues, or defects discovered during commissioning or startup. These items are typically minor but must be resolved before the system is considered fully complete and operational. Punchlists include incomplete work, cosmetic issues, missing documentation, and minor mechanical or electrical problems that do not prevent the system from functioning. Punchlisting ensures that any remaining issues are addressed, and the facility can meet all safety and performance standards before final handover to the owner or operator.