In industries like oil & gas, refining, and petrochemicals, maintaining the reliability and safety of…
Commissioning is a critical phase in the lifecycle of a refinery project, ensuring all systems and equipment are fully functional, safe, and ready for continuous operation. A structured and well-documented commissioning process minimizes start-up risks, enhances plant reliability, and ensures compliance with industry standards. This comprehensive checklist outlines the key steps and verifications required during pre-commissioning, commissioning, and start-up phases—serving as an essential guide for refinery engineers, operators, and project managers.
1. Pre-Commissioning Checklist (Static Checks)
| Area | Activity |
| Documentation | All design documents, P&IDs, loop diagrams, vendor manuals reviewed |
| Mechanical Completion | All piping, equipment, valves, nozzles installed and aligned |
| Welding & NDT | Weld joints inspected as per code (e.g., ASME B31.3) |
| Hydrotesting | Pressure testing of pipelines and vessels completed |
| Electrical Checks | Continuity, insulation resistance, earthing, and breaker tests done |
| Instrumentation | Loop checks, instrument calibration (ISA 5.1 symbols compliance) |
| Flushing & Cleaning | Oil flushing, air blowing, chemical cleaning of process lines |
| Drying & Inerting | Lines purged and dried using nitrogen or air |
| Paint & Insulation | Final coat applied; insulation and cladding checked |
2. Commissioning Checklist (Dynamic Checks)
| System | Activity |
| Utilities | Air, water, nitrogen, steam, and power systems tested under load |
| Control Systems | DCS, SCADA, PLC programs simulated and verified |
| Motor Runs | No-load motor rotation check, vibration testing, alignment |
| Rotating Equipment | Compressors, turbines, pumps tested with lubrication & cooling |
| Safety Systems | ESD, fire & gas systems, alarms, emergency shutdown verified |
| Valve Stroke Test | All MOVs, AOVs, PSV blow-off and stroking checked |
| Communication | Radios, PA systems, SCADA–field device integration tested |
| Line-up Checks | All valves and instruments verified against P&ID for line-up |
| Pre-Start-Up Safety Review (PSSR) | Safety, process, and operational readiness reviewed |
3. Start-Up Readiness Checklist
| Area | Task |
| Permit to Operate | All statutory approvals and permits secured |
| Handover Certification | MC handover from EPC to O&M team completed |
| SOP Availability | Standard Operating Procedures documented and approved |
| Training | Operators trained on procedures and emergency scenarios |
| Startup Plan | Step-by-step startup plan and contingency plans in place |
| Chemicals & Inventory | Chemicals loaded, feedstock available, utilities stabilized |
| Log Book | Control room logs initialized and system checklists updated |
Recommended Documentation
- P&ID Mark-up and Redline Drawings
- Equipment Data Sheets and Calibration Reports
- Inspection Test Plans (ITPs)
- Safety Integrity Level (SIL) Reports
- Loop Folder for Instrumentation
- Pre-Startup Safety Review Report
- Commissioning Dossiers and Punch List Status
Conclusion
A successful refinery commissioning process is vital to achieving long-term operational safety, efficiency, and reliability. By following a detailed checklist covering pre-commissioning, dynamic testing, and start-up readiness, project teams can minimize delays, avoid costly rework, and ensure a smooth transition to full-scale operations. At EngiMates Resources and Energy Pvt Ltd, we bring deep industry expertise and proven methodologies to support safe, compliant, and performance-driven refinery commissioning. Trust us to deliver technical excellence—right from the drawing board to the first barrel.
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