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Mechanical Testing & Commissioning

SSE MULTINATIONAL > Services > Mechanical Testing & Commissioning

Mechanical Testing & Commissioning

Mechanical Testing and Commissioning involve the process of verifying and ensuring that all mechanical systems and equipment, such as pumps, motors, turbines, piping, and HVAC systems, are installed, tested, and functioning according to design specifications. The goal is to confirm that the mechanical systems operate safely, efficiently, and reliably under real-world conditions. This includes checking alignment, integrity, performance, and system integration. Commissioning ensures that all mechanical components are fully operational, meet safety standards, and are ready for handover to the client or end-users.

What We Do

1. Pre-Commissioning Activities

  • Review of Design Documentation: Verify design specifications, drawings, and manuals.
  • Inspection of Equipment: Ensure all equipment (pumps, compressors, turbines, HVAC units, etc.) is delivered according to specifications and is in good condition.
  • Installation Checks: Inspect installation of mechanical systems, including proper alignment, support, and foundation of equipment.
  • System Integrity Checks: Ensure that pipes, vessels, and mechanical components are free of defects and properly welded, bolted, and sealed.
  • Cleaning of Equipment: Clean systems (e.g., piping, heat exchangers) to remove debris, rust, or contaminants that could affect performance.

2. Mechanical System Testing

  • Hydrostatic Testing: Test pressure tolerance of pipelines, tanks, and vessels using water to ensure no leaks or defects.
  • Pneumatic Testing: Test pipelines and vessels using air or nitrogen for leak detection, typically used for systems carrying gases.
  • Torque Testing: Verify the proper torque settings for critical bolts and fasteners, such as flanges and joints, to ensure proper tightness.
  • Pump and Motor Performance Testing: Verify correct operation, capacity, and efficiency of pumps, motors, and associated drives.
  • Flow and Pressure Testing: Measure and verify the performance of pumps, valves, and pipelines for required flow and pressure.
  • Alignment Testing: Ensure that rotating equipment (pumps, compressors, motors) is aligned properly to prevent wear and tear on bearings and shafts.
  • Vibration Monitoring: Measure and analyze vibrations in rotating machinery to identify misalignment or unbalanced parts.

3. Functional Testing

  • Control System Check: Verify that the mechanical systems are integrated with control systems (such as SCADA or DCS), ensuring that they respond to control signals.
  • Start-up Testing: Perform trial runs of systems to verify correct startup sequences, functionality, and safety interlocks.
  • Load Testing: Run the system under varying operational loads to ensure stability and performance.
  • Pressure Relief and Safety Systems Testing: Test safety valves, relief valves, and other pressure control devices to ensure they open/close at correct pressures.
  • Heating and Cooling Systems Commissioning: Test HVAC, refrigeration, and heat exchangers to verify correct operation in maintaining temperature and environmental conditions.

4. System Integration Testing

  • System Interlocks and Safeties: Check the integration of all mechanical interlocks and safety features to ensure safe operation.
  • System Coordination: Ensure smooth coordination between mechanical systems and other disciplines (electrical, instrumentation, etc.) for optimized performance.
  • Noise and Vibration Levels: Verify that noise and vibration levels are within acceptable limits according to regulations and design criteria.

5. Final Commissioning Tasks

  • Performance and Capacity Testing: Validate that the systems perform according to the specified capacity, efficiency, and performance standards.
  • Operational Parameters Verification: Ensure that operational parameters such as temperatures, pressures, flow rates, and speeds are within specified limits.
  • System Documentation: Compile and verify all test records, inspection reports, certificates, and system manuals.
  • Final Inspection: Conduct a final walkthrough to confirm that all equipment is operating correctly and that the site is safe and ready for handover.
  • Client Handover: Provide the final commissioning report to the client, including all test results, certifications, and documentation.

6. Post-Commissioning Activities

  • Training: Provide training for operators and maintenance staff on how to safely operate and maintain the mechanical systems.
  • Maintenance and Support: Offer post-commissioning support, including troubleshooting, repairs, and performance optimization, to ensure long-term reliability

Questions? You’re covered

At SSE Multinational, we believe that clear communication and expertise are key to successful project outcomes. That’s why we’re here to address any questions you may have—whether about our commissioning services, project strategies, or customized solutions. Our team of industry experts is dedicated to providing the insights and guidance you need every step of the way, ensuring confidence and clarity throughout your project journey. Reach out, and let us cover your questions with the answers you deserve.

01. What is the purpose of Mechanical Testing and Commissioning?

The purpose is to ensure that mechanical systems, such as pumps, motors, piping, and HVAC, are installed correctly, tested for performance, and function as intended. The goal is to verify that systems are safe, reliable, efficient, and meet design specifications before they are handed over for full operation.

The first step is typically a review of the design documentation to ensure that all specifications are clear and that the mechanical systems are installed correctly. This may also include inspecting equipment upon arrival and ensuring it is in good condition.

Common tests include:

  • Hydrostatic Testing (for checking leaks in pipes and vessels under pressure).
  • Pneumatic Testing (testing for leaks using air or nitrogen).
  • Pump and Motor Testing (to verify performance, efficiency, and capacity).
  • Alignment Testing (to ensure rotating equipment like pumps and motors are aligned).
  • Vibration Monitoring (to identify any imbalance or misalignment in machinery).

Hydrostatic testing involves filling pipes, tanks, or vessels with water to test for leaks and to verify the structural integrity of the system under pressure. This is a critical safety measure to ensure the system can withstand operating pressures.

Alignment testing is crucial to prevent wear and tear on bearings, shafts, and other rotating components. Proper alignment ensures that the mechanical systems operate efficiently, reducing the risk of equipment failure and extending the lifespan of the machinery.

System integration testing ensures that all mechanical systems, such as pumps, motors, and piping, work together seamlessly. It also includes verifying that the mechanical systems are properly integrated with electrical and control systems and that safety interlocks and control signals function as expected.

Final checks typically include:

  • Performance Testing to verify that the system meets design specifications.
  • Safety Systems Testing to ensure that relief valves and safety interlocks operate correctly.
  • System Documentation to ensure all tests, certifications, and user manuals are completed and available.
  • Client Handover to confirm the system is fully operational and ready for use.

Common challenges include:

  • Delays due to incorrect or incomplete installations.
  • Issues with equipment performance that do not meet specifications.
  • Coordination issues between different disciplines (mechanical, electrical, instrumentation).
  • Difficulty in troubleshooting and resolving problems under tight commissioning schedules.

Safety is ensured by conducting risk assessments, following safety protocols, using proper protective equipment, and ensuring that all safety devices (e.g., pressure relief valves, emergency shutdown systems) are tested and functioning properly. Additionally, personnel are trained on safe operational practices.

All tests, inspections, and certifications are documented in detailed reports, which include test results, operational parameters, and compliance with design specifications. This documentation is crucial for final client handover and future maintenance and troubleshooting. using proper protective equipment, and ensuring that all safety devices (e.g., pressure relief valves, emergency shutdown systems) are tested and functioning properly. Additionally, personnel are trained on safe operational practices.

HVAC systems are tested by checking air and water flow, temperature control, pressure drop across filters and coils, and the overall system’s efficiency. These tests ensure that the system maintains the required environmental conditions as specified in the design.

After commissioning, the system enters the operational phase. Maintenance training is provided to staff, and post-commissioning support may be offered to resolve any issues. Performance monitoring continues to ensure systems remain reliable and efficient throughout their lifecycle.

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