What is Commissioning?
Commissioning is a systematic process of verifying the performance of facilities, systems, and assemblies to ensure trouble-free outcomes and mitigate the risk of unplanned outages or downtime. Project managers, contractors, and construction engineers also perform pre-commissioning to confirm that equipment installation and function follows client specifications.
What is a Commissioning Checklist?
A commissioning checklist is used to easily perform comprehensive installation, functional, and operational inspections, resolve any detected failures and prevent costly project delays.
At What Point Does Pre-commissioning End and Commissioning Begin?
There are regional differences when it comes to common parlance in pre-commissioning and commissioning. Pre-commissioning is sometimes referred to as Cold Commissioning, Static Commissioning, or Mechanical Completion; on the other hand, commissioning is sometimes referred to as Hot Commissioning, Live/Dynamic Commissioning, or Start-up. Therefore, commissioning teams experience difficulty in determining the proper procedure. Here is a run-down of what needs to be done during pre-commissioning and commissioning, respectively:
Pre-commissioning Procedure
- Piping and Instrumentation Diagram (P&ID) Check, also known as System Check or Walkdown, should be performed by the commissioning team to identify engineering and construction errors. Create a P&ID Punch List and address identified issues before pre-commissioning.
- Pre-commissioning activities start from mechanical completion, where running-in of equipment such as control system sequence tests (Dry Commissioning), water or solvent introduction to closed-loop pumps (Wet Commissioning), and other operating scenarios where process fluids are NOT YET used.
The Defining Point: Pre-Startup Safety Review (PSSR)
PSSR is a thorough safety inspection of a new or modified facility to be conducted before commissioning. This is the point where pre-commissioning ends and commissioning begins. Correct any system failure, resolve all safety risks, and re-take the PSSR to comply with health and safety regulations prior to commissioning.
Commissioning Procedure
- Commissioning is the overall performance testing of the facility and its systems such as HVAC, pumps, piping, and lighting. Outstanding punch points should be resolved before routine operation. During a manufacturing plant commissioning, process conditions are established and process fluids (the actual raw materials to be used for routine production) are introduced into the system.
- Initial Operation, or the first production run, aims to determine if the production process manufactures output that meets design requirements. Easily identify non-conformance and adjust the system or optimize the process by performing a first article inspection prior to routine production.
FAQs About Commissioning
The usual steps included in a commissioning process are preparation, design, pre-construction, construction, commissioning of services, pre-handover, initial occupancy, and post-occupancy care. More details on what they are and what they mean here.
A commissioning inspection is performed to verify that the end result of a commissioning process is done according to the project’s specifications and based on the requirements of the client. It also proactively identifies any modifications needed through detailed assessment of the commissioning project.
A general commissioning checklist should include the project name, location, inspector, and date of each inspection. The body of the checklist can vary per project but the usual ones include a review of the following:
- HVAC System
- Cabinet and General Installation
- Piping and Coils
- Fans and Dampers
- Compressor and Condenser
- Electrical and Controls
- Testing, Adjusting, and Balancing (TAB)
- Operation
- Pumping System
- Installation
- Electrical and Controls
- VFD
- Testing, Adjusting, and Balancing (TAB)
- Operation
- Piping System
- Installation
- Valves
- Sensors and Gages
- Testing, Adjusting, and Balancing (TAB)
- Lighting System and Controls
- Lighting Fixtures and Switches
- Lighting Controls
