During the project execution and implementation phase, Mechanical completion is defined as the state where all systems including utility and auxiliary facilities have reached the condition “Ready to Use “and are certified by the Construction Chief”. Once the mechanical completion is declared by Construction Chief, pre-commissioning and commissioning activities can be started.
The safety audits are conducted on declaration of “Mechanical completion” of system in various industrial sectors. Safety audit of each level has been conducted with different team. This document contains guidelines for conducting safety audit on a mechanical completion of a project in a professional manner. The methodology to be adopted for carrying out the safety audit is dealt with separately; such audits ensure safe and trouble-free operational safety of industrial sector.
Mechanical completion of a project specifies the essential requirements for safe operation of system, in order to verify the entire installation/system to be operated safely so that any defect, damage or non-compliance can be detected before it results in unacceptable risks. It is important to emphasize here that this safety audit is performed by a team of competent authorized process, maintenance, technologist and all relevant engineers, safety professionals under the able guidance of a competent pre-commissioning/commissioning management personnel.
Mechanical completion of a system includes safety audit of following but not limited to:
- All design and engineering has been completed.
- All installation work for that system including all equipment has been completed in accordance with “Approved for Construction” drawings, specifications, applicable codes and regulations and good engineering practices.
- All instruments have been installed.
- All tie-in connections have been made.
- All factory acceptance tests and all other testing and inspection activities have been completed.
- Ensure that safety studies have been completed and satisfaction of all the ‘Safety Studies’ requirements have been met and all documentation put in place.
- All required documentation including certification documents required by as per the contract have been supplied.
- All operating procedures and maintenance procedures are available well in advance for review.
- All items for which contractor is responsible for obtaining third party, regulatory or company approval have been obtained and confirmation documentation has been provided to Company.
On completion of safety audit for mechanical completion the verification of functional operability of elements within the system, by subjecting them to a set of simulated operational conditions, to achieve a state of readiness for commissioning. Pre-commissioning requires energization of equipment and the introduction of the Permit to Work / LOTO systems.
Pre-commissioning capability consists of checking and testing all functions according to their design parameters in conditions as close as possible to the design conditions, and in bringing them to the status “Ready for Start-Up / Operations Readiness”. Pre-Commissioning is a quality-oriented process for achieving, verifying, and documenting that the performance of facilities, systems, and assemblies meets defined objectives and criteria.
Pre-Commissioning of Modification Works, interconnection and hook-up of facilities, all necessary preparatory work like draining, venting, gas freeing, purging etc. are to be carried out for all the existing facilities required for modification and safe tie-in.
Ready for Commissioning means at this point all systems and equipment shall be at a stage where fluids / hydrocarbons/ injection water can be safely introduced and all equipment can be safely operated with all controls and safety devices in service.
Commissioning is a complex issue, it requires planning, leadership, teamwork, training and communications. Commissioning of the entire system and all modification jobs involve the programmed introduction of fluids, hydrocarbons, injection water and the operation of all systems in the manner intended.
Commissioning is a critical stage in the life of any facility. The process may be thought of as a series of vital checks that are undertaken before actual operation begins. Start-up requires trained personnel, functional equipment and fully tested systems. As a result the management of plant commissioning is a critical point for starting any plant operation successfully and on time.
Commissioning of the process unit shall mean taking the feed, passing it through the normal route, establishing the process control parameters first at turn down and then at design value stipulated in the process package along with supplementary instructions if any from process Company’s representative.