What is Pre-Commissioning and What Does it Include?

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: