19/2/2019 BN-S-UC001C Checklist for Preparation for Start-Up

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BN-S-UC001B Checklist for the Mechanical Completion, incl. pre-commissioning activities

BN-S-UC001C Checklist for

Preparation for Start-Up
30 September 2013

Table of Contents

1. General Procedures (/generalprocedures)

2. Speci c Procedures

1. General Procedures

1.1 Vendor and Service Assistance

    Contractor Client

a. If deemed necessary by Contractor, obtain X  

manufacturer's (vendor) assistance to ensure
satisfactory installation of equipment

b. Obtain manufacturer's (vendor) assistance at X  

Owner's expense if required requested by Owner
for run in

 
1.2 Inspection
a. Provide inspection of the plant to check conformity X  
to ow diagrams, construction drawings, vendor
prints and speci cations

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b. Arrange for any special pre-start-up inspections   X
such as required by insurance or governmental
agencies

c. Perform routine shop inspection X  

d. Witness shop inspection as desired   X

e. Verify completion of work and approve plant. Check   X

any exceptions and note on a separate work order
list (punch list)
Note: Equipment which has been shop inspected will not be reopened for inspection in the eld except as
speci cally noted herein.

1.3 Permits
a. Secure permits and certi cations required in name X  
of Contractor for design work or for erection work

b. Assist Owner at his expense in the procurement of X  

all permits and certi cations required to be secured
in name of Owner for initial operation of the plant

c. Secure at Owner's expense all permits to be issued   X

in name of Owner and required for installation, use,
occupancy and operation of the plant

1.4 Removal of Rust Preventatives

a. Remove rust preventatives and oils used to protect X  
equipment during the construction period

1.5 Maintenance and Spare Parts

a. Protect equipment from normal weather conditions, X  
corrosion or damage prior to plant mechanical
completion

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b. Provide Company with spare parts lists as X  
recommended by vendors

c. Provide spare parts and supplies   X

d. Provide maintenance for equipment, including such   X

items as the cleaning of strainers and the repairing
of steam traps, after plant mechanical completion

 
1.6 Housekeeping
a. Provide construction clean up, including removal of X  
excess materials, temporary facilities and
scaffolding, rough sweeping or raking of job sites
and trash pickup

b. Maintain housekeeping after mechanical completion X X

as required for safe operation

 
1.7 Instructions
a. Transmit to Owner any vendors' or manufacturers' X  
instructions and drawings, as applicable

b. Provide Owner with any special instructions, such as X  

requirements for drying liners

c. Maintain vendor instruction le for ready retrieval   X

 

2. Speci c Procedures

2.1 Electrical Power and Lighting Systems - Account

E
a. Notify Owner of test schedule X  

b. Witness tests when noti ed and record test data if   X

desired

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c. Make insulation test of all wiring using a X  
megohmmeter

d. Check lighting circuits and intensities X  

e. Make insulation tests of motor windings and of X  

transformer windings from phase to phase, and
phase to ground using a megohmmeter

f. Make grounding system tests to determine X  

continuity of connections and value of resistance to
ground

g. Arrange for breakdown tests by manufacturers on X  

oil samples from oil-insulated transformers larger
than 100 kVA. Check oil level of all transformers

h. Make trials and adjustments on all motor control X  

and switchgear equipment

i. Test and set switchgear and motor control center X  

relays for proper functioning

j. Obtain local inspector's/authority approval where X  

required

k. Energize all substations after completion of all tests   X

l. Check phase sequence and polarity X  

m. Run electrical motors uncoupled X  

n. Check bearing, winding temperatures and vibration X  

o. Check installation of emergency and instrument X  

power systems

p. Perform all necessary pre-start up checks on X  

generators in accordance with vendors instruction

q. Assume responsibility for maintenance and   X

operation of energized electrical facilities after
acceptance

r. Provide Owner with record of work completed X  

 

2.2 Instrument Systems - Account K

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a. Make non-operating checks to ensure instrument X  
operability, i.e. remove all shipping stops, check
pointer travels and verify instrument capability to
measure, operate and stroke in the direction and
manner required by the process application

b. Field calibrate instruments with standard test X  

equipment and make all required adjustments and
control point settings

c. Fully pressurize and energize the transmitting and X  

control signal system, open process connections at
primary sensors and nal regulators and make
control mode settings for automatic operation of
equipment as the plant is brought on stream

d. Install and connect all system components and X  

verify their conformance with speci cations and
design criteria for function and range using dummy
transmitted signals as needed

e. Clean all transmission and control tubing by X  

blowing with cooled and ltered clean air prior to
connecting to instrument components

f. Clean all air supply headers by blowing with clean X  

air and check for tightness

g. Leak test pneumatic control circuits in accordance X  

with ISA Recommended Practice RP 7,1

h. Check process lead piping for tightness X  

i. Check all electrical signals and alarm wiring for X  

continuity, correct sources of power and polarity

j. Check thermocouples for proper joining of wires, X  

position of elements in wells, proper polarity and
continuity of receiving instruments

k. Identify ori ce plates by tagging and deliver to X  

Owner

l. Isolate, or remove, if necessary, inline components X  

such as control valves, positive displacement
meters, turbine meters, etc. for pressure testing and
reinstall such items

m. Check bores of ori ce plates   X

n. Install such plates after completion of ushing X  

operations
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o. Isolate or remove in-line components for ushing X  
operations and reinstall them on the completion of
such operations

p. Fill air line lubricators with oil supplied by Owner X  

q. Check designation and function of each isolator and X  

fuse in electric systems

r. Check operation of automatic transfer systems, X  

reset mechanisms, etc.

s. Loop check all instrumentation from eld to control X  

room.

t. Witness all loop checks   X

u. Clean gauge glasses and check illuminators X  

v. Stroke all control valves, on/off valves, lubricate as X  

required

w. Check all analyzers, clean and ush lines to/from X  

arrange for vendor representation for calibration of
analyzers if required (e.g. chromatographs)

x. Test and adjust all safety devices and seals where X  

necessary use vendor if required

y. Install all safety devices e.g. pressure relief valves X  

after testing

z. Assume responsibility for maintenance and   X

operation of all instrument facilities after
acceptance

2.3 Piping - Account C

a. Hydrostatically or pneumatically test all piping as X  
required by the drawings or speci cations

b. Notify Owner of test schedule X  

c. Witness eld pressure tests when noti ed by   X

Contractor

d. Provide at owners expense any special media for X  

test purposes and facilities for their disposal
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e. Check pipehangers, supports, guides and pipe X  
specialities for the removal of all shipping and
erection stops, and for the correctness of cold
settings for the design service. In addition, provide
Owner with instructions for hot settings

f. Check pipehangers, supports, guides and pipe X  

specialities for hot settings and make minor
adjustments as necessary

g. Install carseals on valves where necessary   X

h. Check and record position of all carsealed valves   X

i. Check steam tracing for tightness and continuity X  

(use steam when available) and check proper
tagging of supply and returns

j. Install all strainers (temporary and permanent) X  

spades and spectacle blinds as called for on
drawings.

k. Water ush and/or air-blow small bore piping X  

l. Carry out chemical cleaning as required per job X  

speci cation

m. Operate steam and water systems for ushing,   X

cleaning and tracing

n. Blowdown/clean steam lines with steam e.g. turbine   X

inlets

o. Witness ushing and cleaning   X

p. Clean strainers after ushing and remove if X  

warranted

q. Maintain records of blinds installed   X

r. Obtain Owner's approval and permits and make tie X  

ins as required by applicable speci cation

s. Isolate all systems to allow tie ins to be made   X

t. Remove blinds as required during start up X  

 
2.4 Towers - Account A
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 2.4.1 Shop-fabricated:
19/2/2019 BN-S-UC001C Checklist for Preparation for Start-Up

a. Install all internals not already installed in X  

fabricating shop, including trays, caps, grids,
demisters, internal piping, packing and linings

b. Inspect all internals X  

c. Make necessary corrections to internals, remove all X  

debris and heavy dirt

d. Do chemical cleaning, if required   X

e. Do nal ushing and make tightness tests X  

f. Perform necessary leakage tests on trays X  

g. Carry out nal inspection and formally accept   X

vessel, issue permit to close

h. Final close vessel X  

 
2.4.2 Field-Erected:

a. Supervise construction, code testing and installation X  

of internals

b. Inspect all internals X  

c. Make nal mechanical clean out X  

d. Perform necessary leakage tests on trays X  

e. Do chemical cleaning, if required   X

f. Do nal ushing and tightness test   X

g. Carry out nal inspection and formal accept vessel,   X

issue permit to close

h. Final close vessel X  

 

2.5 Vessels - Account MR

a. Open after erection to place any internals requiring X  
eld installation and inspect at time of installation.
Open external manways on vessels for inspection by
Owner
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b. Clean out debris, etc. X  

c. Witness inspections to the extent desired   X

d. Open after dry out and chemical cleaning and X  

charge materials as chemicals, resins, desiccants
and catalysts (procurement by Owner)

e. Hot bolt vessels after heat up   X

f. Final inspection, and formally accept vessel, issue   X

permit to close if applicable
Note: When vessels have been subjected to a shop test, they will not be further tested in the eld but may be
included as part of a piping system test.

2.6 Tanks - Account M

a. Clean out debris, etc. X  

b. Carry out chemical cleaning as required by job X  

speci cations

c. Cure and dry out any special cement or protective   X

linings in accordance with manufacturers'
speci cations and instructions

d. Test in accordance with applicable specs X  

e. Purge systems and charge chemicals as required   X

f. Final inspection, and formally accept vessel, issue   X

permit to close if applicable

g. Close vessel X  

 
2.7 Shell and Tube Exchangers - Account T
a. If desired, eld inspect exchangers which have been   X
shop inspected

b. If desired, eld test exchangers which have been   X

subjected to a shop test

c. Hot bolt equipment after heat up   X

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2.8 Air-cooled Exchangers - Account T

a. Inspect to ensure that temporary shipping supports X  
and erection material have been removed. Check for
damage

b. If desired, eld test exchangers which have been   X

subjected to a shop test

c. Couple fan to motor after motor has been run X  

uncoupled

d. Test and balance fans as required. Check blade X  

setting

e. Test louvers and controls of same X  

f. Final inspection and formally accept air cooler   X

2.9 Fired heaters - Account H

a. Pressure test in accordance with applicable code, as X  
required

b. Provide all non-operating pre ring checks in X  

accordance with speci cations and manufacturers'
instructions

c. Blow fuel lines, check for cleanliness, and connect X  

burner piping

d. Check proper functioning of registers and dampers, X  

and verify position of indicators

e. Dry refractories during initial ring by following   X

manufacturer's temperature cycles

f. Conduct boilout and chemical cleaning and ushing   X

operations as required

g. Obtain and charge liquid heat transfer media, if   X

required

h. Conduct light off, drying and purging operations   X

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2.10 Pumps, Compressors and Turbine Drivers -

Account P-PC
a. Level baseplates and sole plates and grout all X  
bearing surfaces, cold align units and furnish record
of alignment

b. Check for and remove any excess piping stresses X  

which may be imposed on the equipment

c. Chemically clean the installation of any seal and X  

lube oil system, if speci ed

d. Provide all lubricants required   X

e. Charge the lube and seal oil systems X  

f. Circulate for cleaning purposes any seal oil, lube oil X  

and cooling systems

g. Make vibration tests when driver is coupled. Check X  

temperatures

h. Install mechanical seals, permanent packing and X  

accessories if required

i. Hot align pumps, and turbines etc., and dowel if   X

required

j. Couple units to drivers after motors have been test X  

run

k. Install temporary strainers in suction piping X  

l. Arrange for manufactures representatives to X  

supervise erection and perform test on large
compressors, turbines

m. Loop check auxiliaries on large equipment with X  

vendor representatives

n. Witness all tests, checks and test-runs of large   X

compressors and turbines.

 
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 2.11 Special Equipment - Account G
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(Agitators, mixers, rotary lters, weigh scales, materials handling equipment, vacuum equipment)

a. Fully assemble rotary lters except for nal lter X  

media (cloth or screens)

b. Install all nal lter media (cloth, precoat, etc.) X  

c. Level and calibrate weigh scales with assistance of X  

the manufacturer's representative and set tare
weights where possible

d. Manually check materials handling equipment for X  

freedom and direction of movement

e. Make all nal adjustments during run in and any   X

performance tests required

f. Obtain vendor's service engineer for start up X  

g. Test vacuum equipment, check all joints for leaks X  

2.12 Boilers - Account H

a. Make hydrostatic pressure test in accordance with X  
applicable codes, if required by speci cations

b. Inspect installation for completeness and X  

correctness of installation and make other non-
operating pre- ring checks in accordance with
speci cations and manufacturer's instructions

c. Check proper functioning of registers and dampers X  

and verify position of indicators

d. Blow fuel lines, check for cleanliness and connect X  

burner piping

e. Dry refractories during initial ring by following   X

manufacturer's temperature cycles

f. Purge, ush and drain steam mains as necessary   X

g. Obtain and charge treated water (per speci cations)   X

for boil out and initial operation as required

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h. Commission auxiliaries as detailed elsewhere under X  
the appropriate equipment type

i. Conduct boil out and chemical cleaning and   X

ushing operations as required

j. Conduct initial light off with associated checks and   X

adjustments

k. Conduct all operating tests and obtain required   X

certi cation

2.13 Water Treating Plants

a. Inspect for completeness and correctness of X  
installation and make any non-operating checks
which may be required

b. Install initial charge of ion exchange resins and X  

inert bed material (supply by Owner)

c. Make the necessary operating tests and adjustments   X

to water treatment systems

d. Provide all water treatment chemicals   X

e. Obtain services of water consultant to advise and   X

monitor

2.14 Water Systems

(Service wells, cooling towers, re water, seawater systems, etc.)

a. Inspect for completeness and correctness of X  

installations and make any non-operating checks
required

b. Initially clean cooling tower basin and install X  

screens in suction pit prior to water circulation

c. Test well delivery and ush well piping if wells are X  

furnished by Contractor

d. Flush, drain and clean cooling water basins X  

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e. Clean intake screens X  

f. Operate re pumps to check output of systems   X

g. Fill reservoirs, head towers, etc.   X

h. Arrange for insurance company inspection of re   X

system as required

i. Obtain and install all re ghting chemicals as   X

required and portable equipment such as hoses, re
extinguishers and related equipment

j. Establish water treating program   X

2.15 Waste Disposal

a. Inspect facilities for completeness and correctness X  
of installation and make any non-operating checks
to ensure conformance with speci cations

b. Operate all equipment and supply all chemicals,   X

agents, etc. related to waste treatment

2.16 Buildings and Accessories

a. Check installation of any buildings and accessories X  
including all heating, ventilating and air
conditioning equipment to ensure completeness
and conformance with speci cations

b. Obtain certi cation that all plumbing, wiring and X  

elevator installation are in compliance with local
governmental regulation

c. Test heating, ventilating and air-conditioning units X  

and make all performance tests, if weather permits,
otherwise by Owner

d. Obtain certi cate for occupancy and use, if required   X

 

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 2.17 Insulation and Painting - Accounts N and R
19/2/2019 BN-S-UC001C Checklist for Preparation for Start-Up

a. Inspect and accept all materials and eld   X

workmanship

b. Complete all insulation work as speci ed X*  

c. Complete all painting as speci ed, weather X*  

permitting

       

* This work may extend beyond the date of start up.    

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