Commissioning and Startup Training Curriculum

Mod 8 - Equipment Pre-Comm

Module from the Commissioning and Startup Training Curriculum curriculum.

Module 8 — Equipment Precommissioning · Learning Objectives · 1. Precommission centrifugal and positive-displacement pumps including priming and coupling checks. · 2. Precommission centrifugal compressors including barring, warm-up, and minimum-flow confirmation. · 3. Precommission fired heaters including dryout, refractory cure, and burner pilot verification. · 4. Precommission columns and drums including internals inspection and level instrument verification. · 5. Precommission heat exchangers including tube-side and shell-side hydrotest and heatup rates. · Pump Precommissioning Steps

Step	Action
1	Verify alignment within 0.002 in TIR
2	Flush and fill seal plan per API 682
3	Verify rotation direction decoupled
4	Check driver solo run 2 hr (Module 6)
5	Couple; vent casing; prime via bypass
6	Start against closed discharge ≤30 seconds
7	Open discharge; verify flow, NPSHa, bearing temp
8	Run 4 hr with load; log trend data
Compressor Precommissioning
Item	Action
Barring gear	Rotate 10+ revolutions; confirm no rub
Lube / seal oil	Run 24 hr; filter delta-P stable; NAS class met
Dryout / warmup	1.8 °F/min (1 °C/min) max on casing
Minimum flow recycle	Open before rolling to speed
Rotor axial position	Within vendor thrust tolerance
First roll	Slow-roll to check balance piston, seal leak
Surge test	From designed ASV start; verify controller action
Overspeed test	115% rated on turbine driver
Fired Heater Precommissioning
Step	Action
Refractory dryout	Purge + light pilots
Leak check fuel gas	Pressurize burner headers
Pilot light-off	Per light-off permissive
Main burner	One at a time
Firing rate	Stepwise
Tube warmup	Oil in tubes
Column / Drum Precommissioning
Item	Check
Trays / packing	Match internals drawing, anti-jump bars installed
Distributor levelness	±0.125 in across tray
Downcomer clearance	Per vendor
Level instruments	All LTs zero and span verified at static condition
Relief valves	Set pressure sealed; inlet/outlet correct
Manway closure	Final torque witnessed
Internal cleanliness	No rags, tools, debris — signed BEFORE final closure
Heat Exchanger Precommissioning
Item	Check
Hydrotest	Shell and tube sides separately
Tube bundle seating	Per spec, no bow
Expansion joint	Shipping bolts removed
Heatup rate	100 °F/hr typical to avoid thermal shock
Cold side first	Start cold fluid before hot
Vent high points	Remove gas lock before start
Bolt torque	Verified per spec at hot and cold
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Source: Commissioning_and_Startup_Training_Curriculum_v1.xlsx · Sheet: Mod 8 - Equipment Pre-Comm

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