Pre-commissioning is a critical project phase that takes place following the construction of piping and process systems, but before those process products are introduced into the systems. The purpose of pre-commissioning is to safeguard the integrity of your systems and ensure they don’t have debris or contaminants that can damage equipment and delay system startup.

Pre-commissioning:

• Helps ensure project ROI
• Reduces startup delays
• Ensures the operability of critical equipment, which maximizes system uptime

In this post, we cover the most common pre-commissioning methods for cleaning your system of mill scale, debris and other contaminants. It’s important to note, when you enlist a service provider to handle pre-commissioning for your system, these techniques should be customized to your system.

Air Blow Cleaning

• In air blowing, air is pumped through your system at more than 1.5 times PSI above normal operation, creating a drag force that removes debris
• The process involves specialty equipment to pressurize the system, including: air receivers, quick-opening valves, oil-free, dry compressed air and fittings and hoses
• Once pressurized, stored energy pushes out debris in a controlled manner so it doesn’t damage expensive equipment downstream
• Air blowing is the simplest, fastest, and least expensive cleaning method

Learn more about our air blowing services.

Steam Blow Cleaning

• Steam blows are necessary for most steam lines and turbine systems
• In this process, high-pressure steam is blown through temporary piping toward steam receivers to remove debris, usually at 1.2 times PSI above normal operation
• There are multiple approaches to steam blows, including the puffing method and the continuous blowing method
• There are significant noise and temperature hazards that require a strong process to control — learn more in this article

Learn more about our steam blowing services

High-Velocity Oil Flushing (HVOF)

• All rotating equipment must be cleaned and prepared before going into operation
• For large-scale operations, a high-velocity oil flush (HVOF) is the most common method
• In this approach, lube oil is run through your systems and filtered out, bringing contaminants with it
• This requires system and turbulent flow analysis as well as a detailed flushing plan to ensure success
• System cleanliness is proven using automatic particle counters or manual microscope analysis on filter paper, depending on the system

Learn more about oil flushing

Hydrostatic/Leak Testing

• Following cleaning of tanks, piping and vessels, it’s crucial to test the system’s structural integrity and ensure there aren’t leaks
• This can include pneumatic testing, hydrotesting, helium leak detection and other approaches

Learn more about hydrostatic testing services

Chemical Cleaning

• Chemical cleaning is used on pipe systems to remove surface contaminants
• It dissolves soluble debris and absorbs them into a solution
• It’s crucial to get this procedure right, as without proper planning, filtration and removal, it’s easy to leave debris behind
• It’s particularly important to select the correct, OEM-approved cleaner for your system

Learn more about the chemical cleaning process from this guide

Fluid Pumping

• High-velocity flushing can also be used on large bore piping to remove debris
• The same approach is used for boiler feed water flushing, glycol flushing and water flushing

Dewatering

• Dewatering is the process of removing water from solid material
• There are several approaches, including: centrifugation, filtration and other liquid separation approaches
• Dewatering is a simple process, but must be handled with care in order to protect the environment from unexpected spills

System Filtration

• Many pre-commissioning services require filtration
• One approach is to set up a slip stream on a live system
• Sometimes, if heavier-duty filtration is required, it’s necessary to connect external filters full bore into the system

Selecting a Pre-Commissioning Service Provider

As pre-commissioning is such a crucial part of a project process, it’s best to use a professional services provider. We recommend selecting a professional partner to:

• Design, manage and execute pre-commissioning strategies
• Achieve cost-effectiveness, scheduling, quality and reduction of project risk
• Bring experience, knowledge and integrity
• Have an experienced, professional team of field staff
• Have experience working with companies like yours

At RIG, we take pride in delivering excellent pre-commissioning services and ensuring our clients’ success.