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Detailed Engineering Solutions

Commissioning and Startup Support

We provide pre commissioning, commissioning and startup advisory for a safe and verified handover

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Technical overview

Commissioning and Startup
Support

Commissioning and startup are the highest risk period in a plant's lifecycle, because incomplete punch items, untested interlocks and inadequately trained operators are the recurring precursors to first year incidents. Our team embeds structured pre startup safety review discipline, manages the system by system turnover process and supports phased process introduction so that your plant enters operation in a verified, documented and safe condition. Our engineers bring hands on experience commissioning process units across oil and gas, chemicals and power generation.

Commissioning and Startup Support Overview
Engineering process

Commissioning and Startup Support workflow

Commissioning Strategy

Define MC, pre commissioning, commissioning, and startup phases, assign system boundaries and completion milestones.

Pre Commissioning

Mechanical completion checks, system flushing, hydrostatic testing, instrument calibration, and preservation verification.

Pre Startup Safety Review (PSSR)

Systematic PSSR per OSHA/CCPS checklist, identify and close punch items before any process introduction.

System Commissioning

Instrument loop checks, interlock and ESD function testing, DCS/SIS configuration verification, and control tuning.

Startup Ramp Up

Phased process introduction against pre agreed ramp schedule, monitor performance, address snags, verify acceptance criteria.

Performance Testing & Handover

Execute contractual acceptance tests, compile as built documentation package, issue formal handover certificate.

Commissioning and Startup Support Scope
Scope of work

Every deliverable from basis to handover

Complete Commissioning and Startup Support scope covering every calculation, drawing, specification, and construction support activity.

We set the commissioning execution strategy with phase definitions, system boundaries and completion milestones
We run pre commissioning through mechanical completion checks, flushing, hydrostatic testing and instrument calibration
We lead the pre startup safety review to OSHA and CCPS practice with systematic checklist and punch list management
We carry out instrument loop checks and emergency shutdown and fire and gas function testing with documented test records
We verify control and safety system configuration against the approved cause and effect matrix
We tune control loops and verify response against the performance acceptance criteria
We support phased process introduction with a ramp schedule, monitoring matrix and hold criteria
We run performance testing against contractual guarantees and compile the formal handover package
Engineering outcomes

Outcomes of Commissioning and Startup Support

Safe Startup and PSSR Completeness
  • We embed pre startup safety review discipline before startup
  • We identify safety gaps before process is introduced
  • We bolster operator readiness
  • We reduce startup incident frequency
OSHA PSM and IEC 61511 Commissioning Defence
  • We track to the OSHA PSM pre startup safety review element
  • We document commissioning to CCPS practice
  • We support performance test acceptance
  • We produce records that stand up to authority inspection
Commissioning Schedule and Punch List Quality
  • We compress startup time and cost
  • We strengthen operator competency
  • We improve first year reliability
  • We build a documented commissioning record
Startup Duration and Rework Cost Reduction
  • We reduce startup delays and rework
  • We help you avoid early life equipment failure
  • We support a faster time to market
  • We strengthen your performance guarantee defence
Standards & references

Codes & standards we work to

CCPS PSSR GuidelinesCII Commissioning Best PracticeOSHA 29 CFR 1910.119(i) (PSSR)API RP 1604IChemE Commissioning GuidanceASME PCC 1 (flanged joint assembly)ISO 10005 (quality plan)IBR 1950 (Indian Boiler Regulations)IS 2825 / 803 / 4503 (BIS Pressure Vessel, Tank, Heat Exchanger)TEMA (Tubular Exchanger)CEA Regulations 2010 (India)NEC India (National Electrical Code)OISD STD 128 (PSSR)IS 12642 (Commissioning)API 653 (Tank Inspection and Reconstruction)
When to engage

Triggers that signal the need

A new facility startupCommissioning of a major modificationA post turnaround restartA brownfield revampPerformance guarantee testingCommissioning during a merger or acquisition integration
Industries served

Where Commissioning and Startup Support applies

Oil & Gas, Upstream

Wellheads, separators, gas compression, FPSO topsides, produced water systems.

UpstreamOffshoreFPSO
Refineries & Petrochemicals

Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.

RefiningPetrochemical
LNG & Gas Processing

Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.

LNGCryogenic
Specialty Chemicals

Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.

ReactiveBatch
Power Generation

Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.

PowerHydrogen
Pharma & Food

Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.

PharmaFood & Bev
What we deliver

Tangible deliverables

  • Commissioning execution plan
  • System turnover tracker
  • Pre startup safety review checklist and report
  • Punch list and clearance log
  • Startup ramp up plan
  • Performance test report
Get Started

Ready to start your project?

Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.

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