MECHANICAL PRECOMMISSIONING

PT.TAIYO SINAR

PT.TAIYO SINAR

Doc No : TSRT-PR-021

IFF. PHASE 1 Project

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MECHANICAL PRECOMMISSIONING
Doc No : TSRT-PR-021

PT.TAIYO SINAR

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 )

Rev

Status

05/11/14

Date

PT.TAIYO SINAR

Issued for approval

Description

IRWAN

Issued
by

SUSILO

Checked
by

IFF. PHASE 1 Project

TEBODIN

Approved
by

IFF
Com
pany
Appr
oval

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MECHANICAL PRECOMMISSIONING
Doc No : TSRT-PR-021

PT.TAIYO SINAR

TABLE OF CONTENTS

1.0

INTRODUCTION

2.0

PRE-COMMISSIONING CHECK

3.0

PRECOMMISSIONING TEST

PT.TAIYO SINAR

IFF. PHASE 1 Project

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MECHANICAL PRECOMMISSIONING
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1.0

Doc No : TSRT-PR-021

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
manufacturers 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 CHECK
2.1
Check Line index
The List shall be indexed as table below: (See Commissioning sequence)
2.2
Procedure
The 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 Forms
Refer to attached following Forms

3.0

PRECOMMISSIONING TEST
3.1
Test Sheet Index
The 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
- Piping Pressure Test Index
PT.TAIYO SINAR

IFF. PHASE 1 Project

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3.2

Doc No : TSRT-PR-021

Test Procedure
3.2.1 Re-testing of Vendors Equipment
Vendor supplied Vessel (Equipment) will normally been
pressure tested at Vendors 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 Test

The 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 Test

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

PT.TAIYO SINAR

IFF. PHASE 1 Project

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MECHANICAL PRECOMMISSIONING
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Doc No : TSRT-PR-021

P&ID to be used for this purpose.

- The Contractor shall maintain a set of marked up P&IDs 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 Valves

Valves 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 Sheet

The 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 Sheet

The 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 Manufacturers 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.
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

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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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IFF. PHASE 1 Project

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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 fans 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 Index

The 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.

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IFF. PHASE 1 Project

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