COMMISSIONING SERVICES FOR INDUSTRIAL PLANTS AND PETROLEUM REFINERIES
Commissioning Management | Pre-Commissioning | Integrated Testing | Start-Up Support | Operational Handover
SAFE START-UP, VERIFIED SYSTEMS, PLANNED HANDOVER
We provide commissioning management and field execution support for industrial plants, petroleum refineries, petrochemical facilities, storage terminals, power and utility projects, covering the transition from construction completion to safe initial operation and operational handover.
We manage commissioning as a coordinated delivery process that verifies systems against their design intent, approved operating scenarios and acceptance criteria. Through system-based planning, traceable test records and operational readiness reviews, we support a controlled transition into production.
We work with clients, EPC contractors, PMCs, operations, maintenance and manufacturers on new facilities, expansions, upgrades, brownfield integration and post-shutdown recommissioning. Services may include the following activities within the authority and responsibilities defined by the contract.
1. COMMISSIONING MANAGEMENT AND PLANNING
We coordinate construction, commissioning and operations teams around shared handover objectives.
- Development of commissioning strategy, execution plans and organisation structures.
- Definition of systems, subsystems, battery limits and interfaces.
- Systemization and preparation of work, test and turnover packages.
- Definition of Mechanical Completion, Ready for Commissioning and start-up readiness gates.
- Sequencing based on utility availability and process dependencies.
- Detailed commissioning schedules aligned with the master programme and critical path.
- Planning of personnel, specialists, vendor representatives, test equipment and temporary facilities.
- Preparation of procedures, checklists, test sheets and acceptance criteria.
- Daily/weekly coordination, progress reporting, risk and constraint tracking.
- Clear allocation of responsibilities between operations, maintenance, construction and commissioning.
2. MECHANICAL COMPLETION AND SYSTEM TURNOVER
We support controlled transfer of systems from construction to commissioning.
- Field walkdowns against approved drawings and specifications.
- Completion checks for equipment, piping, electrical, instrumentation and control works.
- Review of test certificates, quality records and Mechanical Completion dossiers.
- Punch listing and prioritisation under the project classification system.
- Tracking of items requiring closure before energisation or start-up.
- Verification of system boundaries, blind lists, temporary connections and isolations.
- Recorded turnover and transfer of care, custody and responsibility.
- Review of preservation records and coordination of de-preservation activities.
3. MECHANICAL EQUIPMENT AND ROTATING MACHINERY
We support commissioning preparation and functional testing of pumps, compressors, fans, blowers, turbines, gearboxes and other rotating equipment.
- Verification of manufacturer installation and pre-start checklists.
- Review of alignment, coupling, fastening and mechanical freedom records.
- Readiness checks for lubrication, seal oil, seal gas, cooling and auxiliary systems.
- Monitoring of oil flushing and cleanliness records under approved procedures.
- Coordination of motor rotation checks and required uncoupled/coupled runs.
- Local/remote control, permissive, alarm, trip and protection testing.
- Monitoring of vibration, bearing temperatures, pressures, flows and other operating parameters during initial runs.
- Planning and technical follow-up of vendor-led commissioning activities.
For vessels, columns, heat exchangers, filters, tanks and other static equipment, we coordinate verification of cleanliness, closure, reinstatement, auxiliary connections and operating readiness records with the relevant disciplines.
4. PIPING AND PROCESS LINES
- Review of pressure test packages and completed test records.
- Coordination of cleaning, water flushing, air blowing and chemical cleaning where included.
- Management of steam blowing, oil flushing, drying and specialist cleaning under approved procedures.
- Review of flange, gasket, torque/tensioning and critical joint records.
- Verification of post-test reinstatement, temporary item removal and permanent equipment installation.
- Coordination of leak testing, inerting, purging and drying.
- Checks of valve positions, check valve orientation, vents, drains and sampling points.
- Support for blind/spade registers and start-up line-up verification.
Test media, cleanliness levels and acceptance criteria are selected for the process, materials and equipment. Specialist testing and cleaning are performed by competent providers under approved work packages.
5. ELECTRICAL SYSTEMS
- Power distribution, MV/LV switchgear, MCCs and distribution boards.
- Power and distribution transformers.
- MV/LV motors, motor protection, VFDs and soft starters.
- UPS, DC systems, batteries and chargers.
- Generators, emergency supplies and transfer systems.
- Cables, earthing, bonding and lightning protection systems.
- Normal/emergency lighting and electrical heat tracing.
Within the agreed scope, we support insulation resistance, continuity, phase sequence and appropriate cable tests; protection relay and secondary injection testing; breaker/interlock checks; motor tests; and energisation readiness. Primary injection and specialist advanced testing are delivered through separately defined scopes and competent teams.
Energisation is coordinated with authorised switching personnel, approved switching plans, protection settings and operational permits.
6. INSTRUMENTATION AND CONTROL SYSTEMS
- Pressure, temperature, flow and level instruments.
- Process analysers, sampling and conditioning systems.
- Control valves, SDVs/ESDVs, BDVs, MOVs and actuators.
- Junction boxes, marshalling, remote I/O and control panels.
- DCS, PLC, SCADA, HMI and package control systems.
- SIS, ESD and Fire & Gas systems.
- HART, Fieldbus, Modbus and industrial communication interfaces.
We perform calibration, configuration verification, I/O checks, end-to-end loop checks, valve stroke tests and alarm, trip, permissive, interlock and sequence testing against approved documents. Package interfaces and operator displays are verified as part of the agreed scope.
7. FIRE & GAS, FIREFIGHTING AND EMERGENCY INTERFACES
- Combustible/toxic gas, oxygen, flame, smoke and heat detectors.
- Manual call points, sounders, beacons and warning devices.
- Fire & Gas panels and Cause & Effect functions.
- Firewater pumps, ring mains, hydrants and monitors.
- Deluge, sprinkler, foam and gaseous suppression systems.
- HVAC shutdown, fire/smoke dampers and emergency control interfaces.
We verify device and system functions through individual and integrated tests against approved scenarios. Tests capable of initiating suppression discharge or plant shutdown are performed under approved isolations, permits and coordinated arrangements. Actual discharge tests are separately planned and authorised.
8. UTILITIES AND OFFSITE SYSTEMS
- Instrument air, service air and compressor systems.
- Nitrogen generation/distribution and inert gas systems.
- Steam, condensate, boiler feedwater and associated packages.
- Cooling water, chillers and cooling towers.
- Raw, demineralised, potable and wastewater systems.
- Fuel gas and liquid fuel systems.
- Flare, vent and closed/open drain systems.
- Tank farms, transfer, loading and unloading systems.
- HVAC, ventilation and pressurisation systems.
We plan utility readiness at the conditions and capacities required before process unit commissioning. Package functional testing, alarm/interlock verification and interfaces with main systems are coordinated.
9. TELECOMMUNICATIONS AND OPERATIONAL COMMUNICATIONS
Within the project scope, we support testing and commissioning of PAGA, field telephones, radio infrastructure, CCTV, access control, fibre optic and industrial network systems. Emergency announcements, control room communications and related interfaces are verified against operating scenarios.
10. REFINERY PROCESS UNITS AND INTEGRATED START-UP
We manage commissioning interfaces with licensors, process engineers, operations and vendors for refinery units such as crude and vacuum distillation, hydrotreating, reforming, cracking, hydrogen, amine, sour water and sulphur recovery units.
- Verification of process unit and utility dependencies.
- Tracking of cleaning, drying, inerting and leak-tightness readiness.
- Planning of catalyst, adsorbent and specialist chemical loading with specialist contractors/licensors.
- Coordination of initial power, steam, water, air, nitrogen and fuel introduction.
- Readiness support for first hydrocarbon introduction under operations leadership.
- Monitoring of controlled heating/cooling, circulation, equipment operation and stabilisation.
- Coordination of multidisciplinary resolution of process deviations and equipment issues.
Process operating decisions, chemical dosing, catalyst activation and hydrocarbon introduction remain under the owner's authorised operations team, licensor requirements and approved start-up procedures.
11. SAFE COMMISSIONING AND OPERATIONAL READINESS
- Pre-Start-Up Safety Review — PSSR preparation and action tracking.
- Permit-to-work, LOTO and energy isolation coordination.
- Simultaneous Operations — SIMOPS and field access interface management.
- Coordination of gas testing, work area and temporary equipment readiness.
- Tracking of temporary bypasses, overrides, inhibits and software forcing.
- Restoration of normal configuration and documented close-out after tests.
- Tracking of emergency preparedness and operating procedure delivery.
- Coordination of operator and manufacturer training.
Readiness gaps and critical outstanding items are reported to the responsible authority. Energisation and start-up approvals follow the facility's defined authorisation and acceptance processes.
12. PERFORMANCE TESTING, RELIABILITY RUNS AND ACCEPTANCE
We support measurement of capacity, product quality, energy consumption and equipment performance under approved test protocols. Results are compared with the operating conditions and acceptance criteria defined in the contract.
We coordinate technical records for reliability runs, performance tests, outstanding item closure and provisional/final acceptance. Performance guarantees and formal acceptance decisions remain the responsibility of the relevant contracting parties.
13. COMPLETIONS MANAGEMENT AND HANDOVER DOCUMENTATION
- System and equipment-based completions records.
- ITRs and discipline test sheets.
- Mechanical Completion and Ready for Commissioning packages.
- Calibration, loop check, electrical and mechanical test reports.
- Cause & Effect, SAT and integrated test records.
- Punch list, NCR and corrective action close-outs.
- Protection settings, controller parameters and approved configuration records.
- Temporary modification closure and reinstatement records.
- Red-line/as-built inputs, vendor documentation and O&M dossiers.
- Training records, spare parts lists and system handover certificates.
14. SPECIALIST PERSONNEL AND PROJECT SUPPORT
We provide commissioning managers, system coordinators, discipline engineers, supervisors, technicians, inspection and completions personnel according to the project scope. Participation of competent vendors and specialist testing teams is coordinated where required.
Scope, authority, responsibilities and turnover criteria are defined at the start of each assignment. Engineering design changes, statutory inspections and independent certification services are separately defined where needed.
PREPARE YOUR FACILITY FOR A PLANNED AND CONTROLLED START-UP
We support the transition from construction to operations through system-based planning, multidisciplinary coordination and traceable test records. Contact us to discuss commissioning management, field execution and specialist personnel support for your project.
