Plant Commissioning Start Up Procedure

Slide 1
Plant commissioning & start up

Plant commissioning & start up
procedure
procedure
Slide 2
The Commissioning Process
The Commissioning Process
Key Stages Key Stages
Preparation and planning
Mechanical Completion
and Integrity checking
Performance and
Acceptance testing
Start Up & Initial
Operation
Post Commissioning
Pre-commissioning &
Operational Testing
Slide 3
The Commissioning Process Detail
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1
1
Performance and
Acceptance testing
Start Up & Initial
Operation
Pre-commissioning &
Operational Testing
Appointment of Commissioning Appointment of Commissioning
Manager or Lead Commissioning Manager or Lead Commissioning
Engineer; Engineer;
Appointment of Commissioning Team Appointment of Commissioning Team
Members and Support Staff; Members and Support Staff;
Training; Training;
Information Compilation; Information Compilation;
Safety and Risk Assessment; Safety and Risk Assessment;
Commissioning Strategy Commissioning Strategy
Development; Development;
Procedures and Checklist Procedures and Checklist
Development; Development;
Detailed Plan and Budget Preparation; Detailed Plan and Budget Preparation;
Post Commissioning
Slide 4
Commissioning Strategy
Commissioning Strategy
Equipment Level
Activities
System
Level Activities
Facility/Plant
Level Activities
Commissioning
Strategy
Commissioning Master Plan
Individual item commissioning
plans, procedures and checklists
Slide 5
Facility Commissioning Issues Facility Commissioning Issues
Time phasing construction and commissioning activities Time phasing construction and commissioning activities
Time phasing the commissioning of the various parts of the Time phasing the commissioning of the various parts of the
plant relative to each other; plant relative to each other;
Relationships and timings determining when various systems Relationships and timings determining when various systems
need to be available: need to be available:
Electrical, Steam, Water, Instrumentation Electrical, Steam, Water, Instrumentation
Sequencing of the overall plant startup and shutdown to Sequencing of the overall plant startup and shutdown to
ensure we do not create unsafe conditions; ensure we do not create unsafe conditions;
Initial start up; Initial start up;
Process Control and Shutdown; Process Control and Shutdown;
Performance testing; Performance testing;
Slide 6
Developing Startup Procedures
Developing Startup Procedures
Engineering and construction companies generally follow a Engineering and construction companies generally follow a
systematic procedure where by their startup engineers systematic procedure where by their startup engineers
review the process design several times as it is developed; review the process design several times as it is developed;
After the first review, a preliminary start After the first review, a preliminary start- -up and operations up and operations
procedure is written; procedure is written;
Decide what must be added to the design to make the Decide what must be added to the design to make the
process capable of being started up and operated; process capable of being started up and operated;
By the time the final engineering flow By the time the final engineering flow- -sheets have been sheets have been
released a complete startup and operating instructions released a complete startup and operating instructions
manual should have been completed. manual should have been completed.
Slide 7
Issues considered
Issues considered
Are various part of the process too depend on one Are various part of the process too depend on one
another; another;
Is there enough surge capacity; Is there enough surge capacity;
Are there provisions to prevent abnormal Are there provisions to prevent abnormal
pressures, temperatures and rates of reaction; pressures, temperatures and rates of reaction;
Where are additional valves and bypass lines Where are additional valves and bypass lines
needed; needed;
Special lines to allow equipment to be started up Special lines to allow equipment to be started up
and rerun product/raw materials. and rerun product/raw materials.
Slide 8
System Level Activities
System Level Activities
Utilities systems Utilities systems - - steam, instrument air, process steam, instrument air, process
water, fire water, drainage, condensate return; water, fire water, drainage, condensate return;
Electrical systems; Electrical systems;
Instrumentation and instrumentation systems; Instrumentation and instrumentation systems;
Cleaning and flushing; Cleaning and flushing;
Purging; Purging;
Initial start up and shutdowns; Initial start up and shutdowns;
Performance testing; Performance testing;
Slide 9
Equipment Level Activities Equipment Level Activities
Pressure testing & mechanical integrity testing of Pressure testing & mechanical integrity testing of
vessel, columns and pipe work; vessel, columns and pipe work;
Heat Exchangers, condensers, coolers etc. Heat Exchangers, condensers, coolers etc.
Mechanical equipment and machinery; Mechanical equipment and machinery;
Control Systems and Instrumentation; Control Systems and Instrumentation;
Operational testing; Operational testing;
Proof testing and acceptance. Proof testing and acceptance.
Slide 10
What can be done before mechanical
What can be done before mechanical
completion
completion
Utilities commissioning
Lube and Seal-Oil Systems Cleaned
Instrumentation and Control Loops Proven
Piping, Towers and Vessels Cleaned
Boil-Out, Dry-Out and Acid Cleaning
Turbine, Motor and Pump Run-Ins
Nitrogen Purge and Tightness Testing
Slide 11
Building
Building
Organisational
Organisational
Learning
Learning
Corporate
Knowledge Base
Best Practice
Benchmarking
Industry
Standards
Legislation
Process Design
Specific
Machinery &
Equipment
Procedures and
Check sheets
Improvement
Processes
Experience
Incidents and
Near Misses
Slide 12
Procedures
Procedures
Procedures are written routines/instructions that Procedures are written routines/instructions that
describe the logical sequence of activities required to describe the logical sequence of activities required to
perform a work process and the specific actions perform a work process and the specific actions
required to perform each activity; required to perform each activity;
If there are no written procedures, there is no basis for If there are no written procedures, there is no basis for
monitoring performance, focus for improvement or monitoring performance, focus for improvement or
mechanism by which to capture learning; mechanism by which to capture learning;
The establishment of procedures and routines allow The establishment of procedures and routines allow
more time and mental energy to deal with the more time and mental energy to deal with the
unexpected, which always happen during unexpected, which always happen during
commissioning. commissioning.
Slide 13
Commissioning/Startup Logic
Commissioning/Startup Logic
A Critical Path Network (Plan) with written procedures with A Critical Path Network (Plan) with written procedures with
related documents are required. These should define for the related documents are required. These should define for the
facility, each plant system: facility, each plant system:
The order in which the systems will be started up; The order in which the systems will be started up;
Individual activities at each stage; Individual activities at each stage;
Operation testing requirements; Operation testing requirements;
Durations, waiting times, cooling times; Durations, waiting times, cooling times;
Total duration for starting up each system; Total duration for starting up each system;
Resources required Resources required - - labour labour, materials, equipment, , materials, equipment,
services; services;
Temperatures, pressures, fluid flows used. Temperatures, pressures, fluid flows used.
Slide 14
Commissioning/Startup and Shutdown Issues Commissioning/Startup and Shutdown Issues
At the facility, system and equipment level, we At the facility, system and equipment level, we
want to avoid: want to avoid:
Creation/existence of explosive mixtures, usually Creation/existence of explosive mixtures, usually
because of the presence of air; because of the presence of air;
Water hammer and water based explosion Water hammer and water based explosion
effects, due to contact between water and hot effects, due to contact between water and hot
substances (steam, oil, etc.); substances (steam, oil, etc.);
In particular, during commissioning hot fluids and In particular, during commissioning hot fluids and
gases will be coming into contact with cold gases will be coming into contact with cold
surfaces in places that would be hot under normal surfaces in places that would be hot under normal
operations. operations.
Slide 15
Mechanical Completion and Integrity
Mechanical Completion and Integrity
Checking
Checking
Slide 16
Mechanical Completion and Integrity Mechanical Completion and Integrity
Inspection Inspection
Performance and
Acceptance testing
Start Up & Initial
Operation
Pre-commissioning &
Operational Testing
Pressure testing Pressure testing
Cleaning and Flushing Cleaning and Flushing
Machinery checkout Machinery checkout
Post Commissioning
Slide 17
Categories of Process Equipment
Categories of Process Equipment
Distillation Towers/Fractionation Towers Distillation Towers/Fractionation Towers
Reboilers Reboilers & Other Shell & Tube Heat Exchangers & Other Shell & Tube Heat Exchangers
Boilers and Fired Heaters Boilers and Fired Heaters
Pressure Vessels and Pipe Pressure Vessels and Pipe- -work work
Fin Fin- -Fan Coolers Fan Coolers
Condensers Condensers
Machinery/Rotating Equipment Machinery/Rotating Equipment
Valves Valves
Instrumentation Instrumentation
Electrical Equipment Electrical Equipment
Slide 18
Machinery/ Rotating Equipment
Machinery/ Rotating Equipment
Pumps Pumps
Steam Turbines Steam Turbines
Gas Turbines Gas Turbines
Compressors Compressors
Gas Engines Gas Engines
Electric Motors Electric Motors
Slide 19
Involves checking that everything has been built and it Involves checking that everything has been built and it
there as per specification. Refer: there as per specification. Refer:
Piping Plan Drawings; Piping Plan Drawings;
Layout and construction drawings; Layout and construction drawings;
P & ID P & ID s s
Electrical systems, Instrumentation and control systems Electrical systems, Instrumentation and control systems
checkout down by appropriately qualified personnel checkout down by appropriately qualified personnel
(Electricians and Instrumentation technicians). (Electricians and Instrumentation technicians).
General commissioning engineers generally do not get General commissioning engineers generally do not get
involved in this in a hands involved in this in a hands- -on manner. on manner.
Slide 20
Inspection Procedure Inspection Procedure
Divide plant into manageable areas; Divide plant into manageable areas;
In a large plant, assign individuals or teams to In a large plant, assign individuals or teams to
specific areas; specific areas;
Establish a master set of piping plan drawings and Establish a master set of piping plan drawings and
P&ID P&ID s, mark up areas: s, mark up areas:
Individual commissioning engineers or teams walk Individual commissioning engineers or teams walk
every line and mark up every item that can be every line and mark up every item that can be
confirmed as present on master set of drawings; confirmed as present on master set of drawings;
Use different Use different coloured coloured highlighter highlighter pens to pens to
indicate different services. indicate different services.
Slide 21
Mechanical Completion and Integrity Inspection Mechanical Completion and Integrity Inspection
Every line must be walked! Physically sight everything! Every line must be walked! Physically sight everything!
Slide 22
Inspection Procedure Inspection Procedure - - Hints/Tips Hints/Tips
Ensure pipes, vessels, valves etc. are all in the right Ensure pipes, vessels, valves etc. are all in the right
place; place;
Valves are correct type Valves are correct type - - globe, gate, control; globe, gate, control;
Vents, drains, steam traps etc. Vents, drains, steam traps etc.
Flanges, bolts, types of bolts; Flanges, bolts, types of bolts;
Blind flanges and Blind flanges and swingable swingable blinds in place, blinds in place,
correct rating; correct rating;
Check all tag numbers; Check all tag numbers;
Punchlist Punchlist any non any non- -conformances. conformances.
Slide 23
New Plant
Piping Tie-ins!
Slide 24
Pipe Stressing
Pipe Stressing
Piping should provide adequately for expansion and Piping should provide adequately for expansion and
contraction due to temperature changes, without contraction due to temperature changes, without
placing excessive stresses on equipment; placing excessive stresses on equipment;
Misalignment between matching flanges on pipe Misalignment between matching flanges on pipe- -
work work - - particular where there are changes in particular where there are changes in
direction (elbows) can cause stressing; direction (elbows) can cause stressing;
Misalignments where pipe Misalignments where pipe- -work connects to work connects to
machinery, vessels and other process equipment; machinery, vessels and other process equipment;
Can often be seen visually, or checked with gauges Can often be seen visually, or checked with gauges
using the same procedures we use to align rotating using the same procedures we use to align rotating
equipment. equipment.
Slide 25
Piping and Equipment Supports
Piping and Equipment Supports
Slide 26
Piping and equipment supports
Mobile supports permit and guide the thermal Mobile supports permit and guide the thermal
growth of equipment undergoing temperature growth of equipment undergoing temperature
change; change;
If they do not function correctly, vessels, If they do not function correctly, vessels,
equipment, pipe work, nozzles heat exchangers equipment, pipe work, nozzles heat exchangers
etc. may be damaged. etc. may be damaged.
Slide 27
Typical piping support methods Typical piping support methods
Slide 28
Inspection prior to start up: Inspection prior to start up:
Check that installed according to specification and not jammed; Check that installed according to specification and not jammed;
Inspection during warm up: Inspection during warm up:
Check thermal growth is occurring and supports are responding Check thermal growth is occurring and supports are responding
as per design; as per design;
Check that there is no surface buckling or crimping Check that there is no surface buckling or crimping - - this needs this needs
to be corrected; to be corrected;
Check expansion joints; Check expansion joints;
Check long straight runs of piping for bowing or support shoes Check long straight runs of piping for bowing or support shoes
that may have slipped; that may have slipped;
Rule of thumb Rule of thumb - - bowing is excessive if you can see it. bowing is excessive if you can see it.
Slide 29
Inspection after cool Inspection after cool- -down: down:
Check that sliding supports have returned to Check that sliding supports have returned to
original positions; original positions;
Establish that equipment can expand and Establish that equipment can expand and
contract as required. contract as required.
Slide 30
Inspection of spring supports
Before hydro Before hydro- -testing: testing:
Check that spring stops are installed. (If not, the Check that spring stops are installed. (If not, the
weight of water in pipe will deform the spring). weight of water in pipe will deform the spring).
After hydro After hydro- -testing but before heating: testing but before heating:
Check that stops are removed; Check that stops are removed;
Check that spring pointer is positioned to cold Check that spring pointer is positioned to cold
setting; setting;
Slide 31
During and at end of heating: During and at end of heating:
Check pointer has not exceeded hot setting; Check pointer has not exceeded hot setting;
After cool down: After cool down:
check to establish piping can expand and check to establish piping can expand and
contract as required; contract as required;
establish that springs can absorb loads. establish that springs can absorb loads.
Slide 32
Vessels and Columns
Vessels and Columns
Slide 33
Inspection of Vessels and Columns
The inspection of vessels, columns and reactors The inspection of vessels, columns and reactors
should be scheduled to be completed before should be scheduled to be completed before
construction has closed them up; construction has closed them up;
Other inspections Other inspections - - e.g. for completeness or piping, e.g. for completeness or piping,
insulation, safety etc. can be scheduled later; insulation, safety etc. can be scheduled later;
If a vessel has been sealed up by construction, it is If a vessel has been sealed up by construction, it is
your duty to inspect it, even it construction resist. your duty to inspect it, even it construction resist.
Slide 34
Check that distributors have been installed Check that distributors have been installed
correctly; correctly;
De De- -misters installed correctly and of correct misters installed correctly and of correct
materials, design, type; materials, design, type;
Vortex breakers in place; Vortex breakers in place;
Trays Trays - - packed or packed or bubble bubble- -cap cap are correct: are correct:
Bubble caps not jammed or damaged, down Bubble caps not jammed or damaged, down
comers clear, supports all OK. comers clear, supports all OK.
Slide 35
Pressure Testing
Pressure Testing
Slide 36
Pressure Testing
Pressure Testing
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-
Objectives
Objectives
The objective of pressure testing is to confirm the The objective of pressure testing is to confirm the
mechanical integrity of the plant; mechanical integrity of the plant;
Verifying capability of containing the pressures it has Verifying capability of containing the pressures it has
been designed to hold; been designed to hold;
Ensure there are no leaks and verify that the plant can Ensure there are no leaks and verify that the plant can
be reliably made leak free; be reliably made leak free;
Identify any vulnerabilities well before the plant is Identify any vulnerabilities well before the plant is
placed into service; placed into service;
Meet the requirements of legislation, local, Meet the requirements of legislation, local,
international and industry standards. international and industry standards.
Slide 37
Pressure Testing
Pressure Testing
-
-
responsibilities
responsibilities
Pressure tests of tanks, reactors and piping for Pressure tests of tanks, reactors and piping for
mechanical strength and tightness of joints is mechanical strength and tightness of joints is
usually done by the construction team; usually done by the construction team;
Commissioning team representatives should Commissioning team representatives should
witness and certify the tests; witness and certify the tests;
Need to verify that all necessary safety precautions Need to verify that all necessary safety precautions
have been taken; have been taken;
Slide 38
Pressure Testing
Pressure Testing
-
-
procedures
procedures
Water for testing and flushing should contain a rust Water for testing and flushing should contain a rust
inhibitor inhibitor - - one low in chloride content for stainless one low in chloride content for stainless
steel lines; steel lines;
After testing, water should be drained completely After testing, water should be drained completely
from all lines that do not normally carry water, from all lines that do not normally carry water,
steam or steam condensate; steam or steam condensate;
All low points should be checked for presence of All low points should be checked for presence of
water; water;
Lines should be dried by blowing hot air, dry inert Lines should be dried by blowing hot air, dry inert
gas or instrument air. gas or instrument air.
Slide 39
Pressure Testing
Pressure Testing
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-
Vacuum Systems
Vacuum Systems
Final checks of vacuum systems are best Final checks of vacuum systems are best
performed by pulling a vacuum and observing the performed by pulling a vacuum and observing the
rate of pressure rise in the blocked in system; rate of pressure rise in the blocked in system;
Excessive leaks can then be located by applying a Excessive leaks can then be located by applying a
mild positive pressure and testing each flange with mild positive pressure and testing each flange with
bubble solution. bubble solution.
Slide 40
Pressure Testing
Pressure Testing
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-
Procedures 2
Procedures 2
Isometric drawings of all systems to be tested should be Isometric drawings of all systems to be tested should be
displayed on a board and marked up as each section is displayed on a board and marked up as each section is
tested; tested;
Hydrotesting Hydrotesting of piping and equipment according to code of piping and equipment according to code
requirements to confirm mechanical strength should be requirements to confirm mechanical strength should be
carried out on groups of equipment naturally suggested by carried out on groups of equipment naturally suggested by
design pressure and function; design pressure and function;
All water, steam, condensate, oil, gas and process steam All water, steam, condensate, oil, gas and process steam
piping should be hydrotested; piping should be hydrotested;
Major equipment that has already been tested as part of Major equipment that has already been tested as part of
manufacturing may be isolated by blanks. manufacturing may be isolated by blanks.
Slide 41
Cleaning and Flushing
Slide 42
Need to ensure no construction debris is left in Need to ensure no construction debris is left in
pipes of vessels pipes of vessels - - welding rods, bolts, gloves, rags welding rods, bolts, gloves, rags
etc. etc.
Large debris (lumber, cable, packaging) should Large debris (lumber, cable, packaging) should
have been removed during mechanical integrity have been removed during mechanical integrity
inspections; inspections;
Small debris (rags, nuts, dirt) must be flushed out Small debris (rags, nuts, dirt) must be flushed out
of all pipe and vessels; of all pipe and vessels;
Where oil coatings must be removed, chemical Where oil coatings must be removed, chemical
cleaning is necessary. cleaning is necessary.
Slide 43
Before flushing is started, check the process Before flushing is started, check the process
thoroughly to ensure: thoroughly to ensure:
Screens have been installed in front of pump Screens have been installed in front of pump
suctions; suctions;
Blinds in front of equipment such as Blinds in front of equipment such as
compressors and turbines; compressors and turbines;
Jumper Jumper spool pieces to allow for continuity of spool pieces to allow for continuity of
flow. flow.
Slide 44
Flushing
Flushing
Can be handled by geographic plant area; Can be handled by geographic plant area;
Sections too large for water flushing: Sections too large for water flushing:
Pipes greater than 30 in diameter (0.75 m), or Pipes greater than 30 in diameter (0.75 m), or
Pipes that should not be touched with water; Pipes that should not be touched with water;
Should all be blown out with air or inert gas. Should all be blown out with air or inert gas.
Slide 45
Flushing
Flushing
Regardless of whether pipes are cleaned with Regardless of whether pipes are cleaned with
water, steam, air or nitrogen, flow velocities water, steam, air or nitrogen, flow velocities
should be high enough to ensure that pipes will should be high enough to ensure that pipes will
be suitably scoured; be suitably scoured;
Need to ensure that the debris from one piece of Need to ensure that the debris from one piece of
equipment will not simply be flushed into equipment will not simply be flushed into
another; another;
Water velocities should be at least 12 ft/sec Water velocities should be at least 12 ft/sec
(approx. 3.75 m/sec); (approx. 3.75 m/sec);
Air velocities a minimum of 200 ft/sec (approx. Air velocities a minimum of 200 ft/sec (approx.
65 m/sec); 65 m/sec);
Slide 46
Pre
Pre
-
-
commissioning and Operational
commissioning and Operational
Testing
Testing
Slide 47
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-
3
3
Performance and
Acceptance testing
Start Up & Initial
Operation
Steam and other utilities Steam and other utilities
commissioned and introduced; commissioned and introduced;
Dry running trials; Dry running trials;
Hot running trials; Hot running trials;
Safe Safe- -fluid dynamic testing; fluid dynamic testing;
Solvent dynamic testing; Solvent dynamic testing;
Process fluid tests. Process fluid tests.
Pre-commissioning &
Operational Testing
Post Commissioning
Slide 48
Commissioning Utilities
Slide 49
Utilities commissioning usually represents the first Utilities commissioning usually represents the first
phase of commissioning, as these usually need to phase of commissioning, as these usually need to
operational first, before the rest of the plant can be operational first, before the rest of the plant can be
commissioned; commissioned;
The steps for commissioning each utility should be The steps for commissioning each utility should be
planned in detail; planned in detail;
Provides planning practice for planning the startup Provides planning practice for planning the startup
of the main plant. of the main plant.
Slide 50
Commissioning Utilities Commissioning Utilities - - Broad Guidelines Broad Guidelines
Check supply pressures of all services Check supply pressures of all services - - steam, cooling water, steam, cooling water,
instrument air, nitrogen etc. instrument air, nitrogen etc.
At the most distant points, open drains, vent valves or pipe At the most distant points, open drains, vent valves or pipe
flanges and purge until fluids come out clean and rust free; flanges and purge until fluids come out clean and rust free;
Purge/blow out lines to each piece of equipment; Purge/blow out lines to each piece of equipment;
Check that instrument air is clean and dry, and at correct Check that instrument air is clean and dry, and at correct
pressure; pressure;
Circulate water to waste water system until water lines clear an Circulate water to waste water system until water lines clear and d
clean; clean;
Flush waste water and drain systems to ensure no blockages; Flush waste water and drain systems to ensure no blockages;
Check operation of steam traps; Check operation of steam traps;
Drain condensate to waste water until is is clean. Drain condensate to waste water until is is clean.
Slide 51
Commissioning Utilities Commissioning Utilities
Introducing Steam Introducing Steam
Steam usually represents the first Steam usually represents the first hazardous hazardous fluid fluid
introduced into the introduced into the new new system; system;
Admit steam slowly into the distribution system with Admit steam slowly into the distribution system with
atmospheric bleeds open: atmospheric bleeds open:
Cold pipes will condense steam in places where it Cold pipes will condense steam in places where it
would not under normal operation; would not under normal operation;
Can lead to Can lead to water hammer water hammer - - can distort and rupture can distort and rupture
lines; lines;
After system has been warmed, slowly raise pressure and After system has been warmed, slowly raise pressure and
blow down the system with traps bypassed, until clean; blow down the system with traps bypassed, until clean;
Then place steam traps into service and check operation. Then place steam traps into service and check operation.
Slide 52
High Pressure Steam Systems
High Pressure Steam Systems
Specific Issues Specific Issues
The cleanliness and purity of high pressure steam systems The cleanliness and purity of high pressure steam systems - -
particularly where the steam is used to drive a steam turbine particularly where the steam is used to drive a steam turbine
should be checked by use of a should be checked by use of a target target ; ;
For new boilers, or new sections added to steam system For new boilers, or new sections added to steam system - -
blow down at full pressure; blow down at full pressure;
When steam appears clean, fit a target with a When steam appears clean, fit a target with a mirrored mirrored
surface ( surface (ie ie. Small steel plate which has been polished, so that . Small steel plate which has been polished, so that
it is in the steam blow down stream; it is in the steam blow down stream;
Blow down the boiler or system so that the target is impinged Blow down the boiler or system so that the target is impinged
upon for a few minutes; upon for a few minutes;
Check target Check target - - ensure there are no small ensure there are no small pock marks pock marks left on left on
the target. If pock marked the target. If pock marked - - repeat process. repeat process.
Slide 53
Electrical Systems
Electrical Systems
Slide 54
Commissioning Electrical Systems
The following checks are typical of what is required The following checks are typical of what is required
Open circuit breakers and switches; Open circuit breakers and switches;
Check that all bus Check that all bus- -bars are free of dirt and foreign matter; bars are free of dirt and foreign matter;
Check grounding systems for continuity and resistance. Check grounding systems for continuity and resistance.
Make sure all electrical equipment, vessels, structures are Make sure all electrical equipment, vessels, structures are
connected to the grounding system in accordance with connected to the grounding system in accordance with
drawings and specifications; drawings and specifications;
Check that all sealed fittings are filled with proper sealants, Check that all sealed fittings are filled with proper sealants,
all explosion proof, all explosion proof, vapour vapour- -tight, dust tight, dust- -tight and weather tight and weather
tight enclosures are properly closed and secured; tight enclosures are properly closed and secured;
Check motor control and power circuitry for correct Check motor control and power circuitry for correct
hookup. hookup.
Slide 55
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2
2
Check all nameplates and panel directories to ensure that Check all nameplates and panel directories to ensure that
each circuit breaker and switch does control the proper each circuit breaker and switch does control the proper
circuit. Label all switches even though their application circuit. Label all switches even though their application
may seem obvious; may seem obvious;
Close main transformer primary disconnect switch and Close main transformer primary disconnect switch and
switch switch- -gear main circuit breaker; gear main circuit breaker;
Check voltmeter at switch Check voltmeter at switch- -gear for proper voltage; gear for proper voltage;
Close first switch Close first switch- -gear circuit breaker, second, third etc. gear circuit breaker, second, third etc.
Close first motor control centre main circuit breaker, then Close first motor control centre main circuit breaker, then
each motor starter circuit breaker. Repeat for each MCC. each motor starter circuit breaker. Repeat for each MCC.
Check overload breakers and heaters to ensure that the Check overload breakers and heaters to ensure that the
correct capacity units have been installed. correct capacity units have been installed.
Slide 56
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-
3
3
Check that all lighting and power circuits are functioning Check that all lighting and power circuits are functioning
correctly; correctly;
Check motor bearings for proper lubrication; Check motor bearings for proper lubrication;
Remove motor power fuses and check main contractor, Remove motor power fuses and check main contractor,
interlock and sequencing devices; interlock and sequencing devices;
Uncouple each motor, replace fuses and check direction of Uncouple each motor, replace fuses and check direction of
rotation by momentarily pressing the start button, then stop; rotation by momentarily pressing the start button, then stop;
Check manual, then automatic operation. Check manual, then automatic operation.
Replace all couplings, check drive belts and make sure Replace all couplings, check drive belts and make sure
guards are installed. guards are installed.
Slide 57
Electric motor driven pumps
Electric motor driven pumps
Slide 58
Operational Testing
Operational Testing
Slide 59
Operational Testing
Operational Testing
Progresses through several stages; Progresses through several stages;
Dry runs of individual items of equipment Dry runs of individual items of equipment
Hot testing of individual items of equipment and Hot testing of individual items of equipment and
systems; systems;
Several stages of Dynamic Testing of: Several stages of Dynamic Testing of:
Individual items of equipment; Individual items of equipment;
Individual Systems/processes in isolation; Individual Systems/processes in isolation;
The whole new process plant installation. The whole new process plant installation.
Slide 60
Dry runs and Hot Tests
Dry runs and Hot Tests
Check that motors are connected correctly and turn Check that motors are connected correctly and turn
in the right direction; in the right direction;
Shafts and impellers move freely; Shafts and impellers move freely;
Equipment that is to be operated at temperature, Equipment that is to be operated at temperature,
raise to temperature and check; raise to temperature and check;
These tests should be performed by the These tests should be performed by the
manufacturer manufacturer s representative but witnessed by s representative but witnessed by
members of the client members of the client s operating/commissioning s operating/commissioning
personnel. personnel.
Slide 61
Hot testing equipment
Hot testing equipment
Applies to equipment whose leak Applies to equipment whose leak- -tightness must be tested at tightness must be tested at
operating temperatures and after temperature reversals; operating temperatures and after temperature reversals;
Fixed Fixed- -bed catalytic reactors that in normal conditions are bed catalytic reactors that in normal conditions are
heated by heat transfer fluids where leakage would heated by heat transfer fluids where leakage would
contaminate the catalyst; contaminate the catalyst;
Critical exchangers whose steam or cooling water is at a Critical exchangers whose steam or cooling water is at a
high pressure than the process fluid; high pressure than the process fluid;
Any equipment having complicated seals through which Any equipment having complicated seals through which
leakage could occur; leakage could occur;
Rotating machinery which must be able to rotate freely at Rotating machinery which must be able to rotate freely at
temperature temperature eg eg. Steam turbines, etc. . Steam turbines, etc.
Slide 62
Hot testing procedures
Hot testing procedures
The thermal shock tolerance of equipment must be The thermal shock tolerance of equipment must be
determined beforehand; determined beforehand;
To avoid thermal shock, the temperature of the To avoid thermal shock, the temperature of the
heating medium may have to be raised gradually; heating medium may have to be raised gradually;
Time required for a hot test must be established in Time required for a hot test must be established in
advance; advance;
Establish a uniform temperature in all parts of Establish a uniform temperature in all parts of
equipment that are supposed to be uniformly hot equipment that are supposed to be uniformly hot
during operation to avoid setting up stresses; during operation to avoid setting up stresses;
Slide 63
Dynamic Testing
Dynamic Testing
Slide 64
Dynamic Testing
Dynamic Testing
Involves operating the equipment, before introducing Involves operating the equipment, before introducing
live live process fluid; process fluid;
During dynamic testing, we progress through: During dynamic testing, we progress through:
Safe Safe- -fluid dynamic testing; fluid dynamic testing;
Dynamic testing with solvent; Dynamic testing with solvent;
Closed loop testing with process fluid. Closed loop testing with process fluid.
Once process fluid is introduced, normal plant safety Once process fluid is introduced, normal plant safety
procedures must come into effect as if it were a live procedures must come into effect as if it were a live
operating plant. operating plant.
Slide 65
Safe
Safe
-
-
Fluid Dynamic Testing
Fluid Dynamic Testing
Closed loop dynamic testing with safe fluids consists of Closed loop dynamic testing with safe fluids consists of
operating equipment systems with air, water, inert gases operating equipment systems with air, water, inert gases
etc. etc.
This permits flow testing of equipment; This permits flow testing of equipment;
Gives first indication of how control loops work; Gives first indication of how control loops work;
Establishes performance while there is still time to modify Establishes performance while there is still time to modify
the plant; the plant;
Familiarises Familiarises operators with the operation of the equipment operators with the operation of the equipment
before hazardous materials are introduced; before hazardous materials are introduced;
Gets rid of a lot of dirt which would be more difficult to Gets rid of a lot of dirt which would be more difficult to
clear once the process fluid has been introduced. clear once the process fluid has been introduced.
Slide 66
General Principles for Testing
For most plants, a period of 2 For most plants, a period of 2- -3 weeks is usually sufficient 3 weeks is usually sufficient
for operational testing, after the mechanical dry running of for operational testing, after the mechanical dry running of
individual pieces of equipment and hot testing complete; individual pieces of equipment and hot testing complete;
Air and water tests should be set up in a closed loop with Air and water tests should be set up in a closed loop with
fluids continuously recycled, with loops as large as fluids continuously recycled, with loops as large as
possible; possible;
The loop should ideally be the same loop that will be The loop should ideally be the same loop that will be
subject to solvent testing; subject to solvent testing;
Tests should continue for several days in order to give all Tests should continue for several days in order to give all
shifts a chance to conduct the same tests; shifts a chance to conduct the same tests;
All shifts should be given the opportunity to start up and All shifts should be given the opportunity to start up and
shutdown each closed loop test. shutdown each closed loop test.
Slide 67
A rough flow A rough flow- -sheet should be developed for air sheet should be developed for air
and water tests, predicting all information that and water tests, predicting all information that
normally appears on a process flow sheet normally appears on a process flow sheet - - flow, flow,
temperature, pressure, heat transfer, power etc. temperature, pressure, heat transfer, power etc.
will assist in alerting commissioning team to will assist in alerting commissioning team to
risks from over risks from over- -pressuring, overloading, pressuring, overloading,
temperature temperature- -shocking and stressing equipment; shocking and stressing equipment;
Slide 68
Cautions during Testing
Cautions during Testing
Dynamic testing may lead to:
Unusual or unforeseen differential expansions; Unusual or unforeseen differential expansions;
Corrosion; Corrosion;
Excessive weight of liquid into parts of the Excessive weight of liquid into parts of the
system; system;
Care must be taken not to collapse or burst Care must be taken not to collapse or burst
pressure vessels and tanks: pressure vessels and tanks:
ensure there is always adequate venting; ensure there is always adequate venting;
avoid pulling a vacuum. avoid pulling a vacuum.
Slide 69
Dynamic Testing
Dynamic Testing
-
-
Simulated Operations
Safe Fluid Testing Safe Fluid Testing
Auxiliary services must be brought into operation Auxiliary services must be brought into operation
first: first:
water cooling, inert gas generators, boiler water cooling, inert gas generators, boiler
feedwater feedwater, firewater, steam production, etc. , firewater, steam production, etc.
Water is pumped through the process (except Water is pumped through the process (except
where special conditions do not permit it) and where special conditions do not permit it) and
boiled up in columns; boiled up in columns;
Compressors and blowers should be operated on Compressors and blowers should be operated on
air or inert gas. air or inert gas.
Slide 70
The Value of Dynamic Testing
The Value of Dynamic Testing
-
-
Value of simulated operations will be to allow operator to Value of simulated operations will be to allow operator to
become familiar with the operation of the process, before become familiar with the operation of the process, before
hazardous fluids are introduced; hazardous fluids are introduced;
Equipment deficiencies can become apparent during Equipment deficiencies can become apparent during
dynamic testing; dynamic testing;
Failures and problems more easily corrected with safe Failures and problems more easily corrected with safe
fluids present fluids present
Leaks should be found and tightened; Leaks should be found and tightened;
Instruments can be placed into service Instruments can be placed into service - - although selection although selection
of set of set- -points will have to be deferred; points will have to be deferred;
Inspect the plant for evidence of design and construction Inspect the plant for evidence of design and construction
errors. errors.
Slide 71
Dynamic Testing
Dynamic Testing
-
-
At the end of the simulation, water should be At the end of the simulation, water should be
drained drained - - equipment dried and purged; equipment dried and purged;
Depending on the process Depending on the process - - drying may not be drying may not be
necessary necessary - - but purging will always be required; but purging will always be required;
Slide 72
Dynamic testing with a solvent
After safe fluid testing and subsequent repairs and After safe fluid testing and subsequent repairs and
modifications, we are ready for dynamic closed modifications, we are ready for dynamic closed
loop testing with a solvent; loop testing with a solvent;
The The solvent solvent is a relatively safe fluid whose is a relatively safe fluid whose
properties are close to that of the process fluid, or properties are close to that of the process fluid, or
the process fluid itself; the process fluid itself;
In order to allow for continuous re In order to allow for continuous re- -circulation of circulation of
the solvent and the use of different solvents in the solvent and the use of different solvents in
different parts of the plant, temporary lines will different parts of the plant, temporary lines will
need to be installed. need to be installed.
Slide 73
Dynamic Testing with Process Solvent
Dynamic Testing with Process Solvent
Introduce the process solvent. (if there is more than Introduce the process solvent. (if there is more than
one, introduce only one at this stage); one, introduce only one at this stage);
The dynamic testing procedure used for the safe The dynamic testing procedure used for the safe
fluid test is repeated for the process solvent dynamic fluid test is repeated for the process solvent dynamic
testing; testing;
After operations with the first solvent have been After operations with the first solvent have been
brought completely under control, should the second brought completely under control, should the second
solvent be introduced (if there is one). solvent be introduced (if there is one).
Slide 74
The purpose of dynamic testing with a solvent is to The purpose of dynamic testing with a solvent is to
check out equipment and instrument loops at, or check out equipment and instrument loops at, or
near design conditions prior to the introduction of near design conditions prior to the introduction of
more hazardous process fluid; more hazardous process fluid;
No reactions should be allowed to occur during No reactions should be allowed to occur during
these tests, so as to ensure that test fluids remain these tests, so as to ensure that test fluids remain
predictable in composition and properties; predictable in composition and properties;
Guidelines used for safe Guidelines used for safe- -testing apply; testing apply;
Need to plan how solvent will be fed into the Need to plan how solvent will be fed into the
system and later removed. system and later removed.
Slide 75
Stages of dynamic testing with a Stages of dynamic testing with a solvent solvent
Drain safe fluid and purge air used in the previous test from Drain safe fluid and purge air used in the previous test from
the system; the system;
Dry out equipment where safe fluid was water. Check flow Dry out equipment where safe fluid was water. Check flow
sheets for where water is likely to accumulate. sheets for where water is likely to accumulate.
Fill systems with the solvent. Ensure provisions made for Fill systems with the solvent. Ensure provisions made for
venting and drains closed; venting and drains closed;
When adequate levels established, place pumps and When adequate levels established, place pumps and
compressors online to complete filling; compressors online to complete filling;
Start closed loop circulation; Start closed loop circulation;
Heat up the systems to simulate operating conditions by Heat up the systems to simulate operating conditions by
placing reflux, placing reflux, reboiler reboiler and condensation systems into and condensation systems into
operation operation
Slide 76
Systematically check out instrumentation and control loops; Systematically check out instrumentation and control loops;
After instruments have checked out, place as many as After instruments have checked out, place as many as
possible on automatic control; possible on automatic control;
All shifts should go through starting and stopping All shifts should go through starting and stopping
equipment, heating and cooling closed loop systems; equipment, heating and cooling closed loop systems;
Dynamic Dynamic solvent solvent testing offers the best opportunity for testing offers the best opportunity for
operator training before the operator training before the real thing real thing ; ;
Operate equipment as near as possible to design capacities; Operate equipment as near as possible to design capacities;
Reliability of emergency shutdown systems and alarms Reliability of emergency shutdown systems and alarms
must be proven; must be proven;
Critical instruments must be calibrated over their full range. Critical instruments must be calibrated over their full range.
Slide 77
Deliberately operate equipment near its limits: Deliberately operate equipment near its limits:
Flood columns; Flood columns;
Ease compressors into mild surges and plot surge curves; Ease compressors into mild surges and plot surge curves;
Overload condensers; Overload condensers;
Do not fear blowing a relief valve or two! Do not fear blowing a relief valve or two!
After tests have been completed, plant should be ready for After tests have been completed, plant should be ready for
initial operation. initial operation.
Slide 78
Closed Loop Dynamic Testing with
Closed Loop Dynamic Testing with
Process Fluid
Process Fluid
Finally, introduce process fluid; Finally, introduce process fluid;
During this step, instruments should be calibrated During this step, instruments should be calibrated
to cover their full range of flow, temperature and to cover their full range of flow, temperature and
pressure; pressure;
Ensure that instruments, process Ensure that instruments, process analysers analysers and and
safety devices are kept work properly during these safety devices are kept work properly during these
processes; processes;
After operations with process fluid are brought After operations with process fluid are brought
completely under control should the final stage of completely under control should the final stage of
start start- -up be attempted. up be attempted.
Slide 79
Preparing to introduce process fluids
Preparing to introduce process fluids
Before introducing hazardous liquids into the Before introducing hazardous liquids into the
plant, we complete additional pressure testing and plant, we complete additional pressure testing and
purging; purging;
Need to check that the stresses and strains of Need to check that the stresses and strains of
dynamic testing has not caused any leaks dynamic testing has not caused any leaks - - these these
must be found and fixed; must be found and fixed;
Slide 80
Pressure testing and purging
Pressure testing and purging
Consists of pressuring and de Consists of pressuring and de- -pressuring with pressuring with
nitrogen several times, until at least <3% oxygen is nitrogen several times, until at least <3% oxygen is
reached; reached;
Vacuum systems should be evacuated and then re Vacuum systems should be evacuated and then re- -
pressured with nitrogen; pressured with nitrogen;
Long runs of piping are swept with nitrogen; Long runs of piping are swept with nitrogen;
While under pressure, rate of pressure loss of the While under pressure, rate of pressure loss of the
blocked in blocked in system is monitored as a check for system is monitored as a check for
leaks and that no vents or drains have been left leaks and that no vents or drains have been left
open. open.
Slide 81
Dehydrating by Circulation
Dehydrating by Circulation
It is usually not possible to water It is usually not possible to water- -free equipment free equipment
simply by draining; simply by draining;
Only positive method to water Only positive method to water- -free process free process
equipment is oil circulation followed by repeated equipment is oil circulation followed by repeated
draining of low points; draining of low points;
Ensure sufficient low point drains are provided on Ensure sufficient low point drains are provided on
piping, control valve loops, vessels and process piping, control valve loops, vessels and process
machinery; machinery;
Startup lines Startup lines - - deliver oil to upper part (trays) of deliver oil to upper part (trays) of
distillation towers (size for 20% of net distillate distillation towers (size for 20% of net distillate
product rate); product rate);
Slide 82
Start Up and Initial Operation
Slide 83
Performance and
Acceptance testing
Post Commissioning
Introduction of process fluid Introduction of process fluid
Start Start- -up and initial operation up and initial operation
Trouble Trouble- -shooting and shooting and
problem correction. problem correction.
Plant taken to full operations. Plant taken to full operations.
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Slide 84
Starting Up the Plant
Starting Up the Plant
Product
refining
Recovery Reaction
Feed
Preparation
Most plants in petrochemical/chemical industry Most plants in petrochemical/chemical industry
have the following have the following general general form. form.
Start Up from the Start Up from the
End of the Process End of the Process
and Work back and Work back
Slide 85
Start Up Logic
Start Up Logic
It is common practice to buy in product and start It is common practice to buy in product and start
up the last past of the process first and work up the last past of the process first and work
backwards to the front. E.g. backwards to the front. E.g.
Start up refining, get this working and in Start up refining, get this working and in
control; control;
Then possibly start up reaction and recovery; Then possibly start up reaction and recovery;
Finally, feed preparation. Finally, feed preparation.
Slide 86
Into the initial operation
Into the initial operation
Once raw materials are fed into the plant Once raw materials are fed into the plant - - usually usually
at reduced rate until reaction conditions have been at reduced rate until reaction conditions have been
established; established;
As each section is started up, establish as quickly As each section is started up, establish as quickly
as possible that process conditions are as expected; as possible that process conditions are as expected;
If potentially serious problems develop, there If potentially serious problems develop, there
should be no hesitation on going into an should be no hesitation on going into an
emergency shutdown. emergency shutdown.
Slide 87
Ramping up the plant
Ramping up the plant
Plant is brought slowly to design feed Plant is brought slowly to design feed- -rates and rates and
operating conditions; operating conditions;
Usually done in steps with operating data Usually done in steps with operating data
evaluated and verified as OK at each step; evaluated and verified as OK at each step;
Plant and laboratory data are now being collected Plant and laboratory data are now being collected
and should be being evaluated promptly; and should be being evaluated promptly;
Slide 88
Coordination and Supervision during
Coordination and Supervision during
start up
start up
Additional personnel, both supervisory and Additional personnel, both supervisory and on on- -
the the- -ground ground are required at this stage; are required at this stage;
Cooperation between startup personnel and plant Cooperation between startup personnel and plant
supervisory personnel is critical at this stage: supervisory personnel is critical at this stage:
Need a daily meeting at least; Need a daily meeting at least;
Often, a briefing each shift. Often, a briefing each shift.
Slide 89
Trouble Shooting
Trouble Shooting
At this stage, many problem with equipment of the At this stage, many problem with equipment of the
process itself may become apparent; process itself may become apparent;
The commissioning process goes through what is The commissioning process goes through what is
often an intense (and hopefully short) period of often an intense (and hopefully short) period of
problem trouble shooting, problem solving, problem trouble shooting, problem solving,
engineering correction and plant modification; engineering correction and plant modification;
Slide 90
Performance and Acceptance Trails
Performance and Acceptance Trails
Slide 91
Performance and Acceptance Testing
Performance and Acceptance Testing
Performance and
Acceptance testing
Post Commissioning
Performance trails; Performance trails;
Formal Acceptance test Formal Acceptance test
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Slide 92
The Performance Trails
The Performance Trails
Once the plant is fully operational, the final Once the plant is fully operational, the final
proving trail proving trail or performance run is performed in or performance run is performed in
order to prove the plant can do what it is supposed order to prove the plant can do what it is supposed
to do; to do;
The values or range of values for each independent The values or range of values for each independent
variable variable - - flow, temperature, pressure, level, flow, temperature, pressure, level,
concentrations, etc. to which the plant must be concentrations, etc. to which the plant must be
operated to are determined; operated to are determined;
The plant is brought up to those conditions and the The plant is brought up to those conditions and the
pre pre- -agreed trial period begins. agreed trial period begins.
Slide 93
Before the trail or performance run need
Before the trail or performance run need
to ensure that
to ensure that
Control of plant operating conditions has been Control of plant operating conditions has been
achieved. I.e. temperature, pressures, levels and achieved. I.e. temperature, pressures, levels and
analyses are reasonably constant or in the case of a analyses are reasonably constant or in the case of a
batch process, there is repeatability; batch process, there is repeatability;
Daily material and energy balanced can be Daily material and energy balanced can be
performed and that these agree with performed and that these agree with official official
production figures; production figures;
Product specifications are being achieved Product specifications are being achieved
consistently. consistently.
Slide 94
Need to verify
Need to verify
.
.
Physical operation, capability and capacity of plant Physical operation, capability and capacity of plant
and equipment; and equipment;
Energy and mass balance; Energy and mass balance;
Process chemistry; Process chemistry;
Efficiencies, yields and quality; Efficiencies, yields and quality;
All to specification. All to specification.
Slide 95
Acceptance
Acceptance
When the plant has met the Performance and When the plant has met the Performance and
Acceptance test requirements designed by the Acceptance test requirements designed by the
commissioning team there is usually a formal commissioning team there is usually a formal
acceptance process involving signing of acceptance acceptance process involving signing of acceptance
certificates; certificates;
Once the plant is accepted it is officially part of the Once the plant is accepted it is officially part of the
normal operations normal operations - - the responsibility of operations the responsibility of operations
and maintenance; and maintenance;
Commissioning is officially over; Commissioning is officially over;
The may still be outstanding The may still be outstanding punchlist punchlist items items
Slide 96
Acceptance Testing
Acceptance Testing
It is common practice to prove performance It is common practice to prove performance
repeatability and plant integrity as part of the repeatability and plant integrity as part of the
performance test. That is: performance test. That is:
Shutdown and Start Up the plant on several Shutdown and Start Up the plant on several
occasions and bring it up to test conditions to occasions and bring it up to test conditions to
prove repeatability. Also ramp down and ramp up prove repeatability. Also ramp down and ramp up
while online; while online;
Re Re- -inspection of critical process equipment inspection of critical process equipment - -
particularly columns to ensure they have not been particularly columns to ensure they have not been
damaged by the performance run. damaged by the performance run.
Slide 97
Commercial Significant of Acceptance
Commercial Significant of Acceptance
Formal Acceptance represents formal acknowledgment Formal Acceptance represents formal acknowledgment
that the that the
Contractor has full Contractor has full- -filled their contractual filled their contractual
obligations; obligations;
Commissioning team have full Commissioning team have full- -filled their filled their
obligations; obligations;
Completion of the Capital Project and transfer to Completion of the Capital Project and transfer to
Operations; Operations;
Expenses and costs from acceptance onwards are now Expenses and costs from acceptance onwards are now
operating expenses not capital project costs; operating expenses not capital project costs;
All subject to agreed punch All subject to agreed punch- -list items. list items.
Slide 98
Post
Post
-
-
Commissioning
Commissioning
Slide 99
Post Commissioning
Post Commissioning
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
From plant on From plant on- -stream to settled stream to settled
down and in regular production; down and in regular production;
Adjustments, modifications and Adjustments, modifications and
fault correction; fault correction;
Completion of outstanding Completion of outstanding
punchlist punchlist items items
Slide 100
Post Commissioning
Post Commissioning
Covers the period immediately after Acceptance; Covers the period immediately after Acceptance;
Outstanding punch Outstanding punch- -list items are completed; list items are completed;
The first routine maintenance checks are performed, The first routine maintenance checks are performed,
findings evaluated and reported; findings evaluated and reported;
Process equipment and items covered by warranty Process equipment and items covered by warranty
are scrutinized for signs of premature wear are scrutinized for signs of premature wear- -out or out or
problems; problems;
Operating data is collected and evaluated to ensure Operating data is collected and evaluated to ensure
consistent plant operations are maintained and consistent plant operations are maintained and
sustainable. sustainable.

Plant Commissioning Start Up Procedure

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Plant commissioning & start up

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