Slide 2 The Commissioning Process Key Stages Preparation and planning Mechanical Completion and Integrity checking Pre-commissioning &Operational Testing Start Up & Initial Operation Performance and acceptance testing Post Commissioning Slide 3 1. Preparation and planning Appointment of Commissioning Manager or Lead Commissioning ngineer! Appointment of Commissioning Team Mem"ers and S#pport Staff! Training! Information Compilation! Safety and $isk Assessment! Commissioning Strategy Development; Procedures and Checklist Development; %etailed Plan and &#dget Preparation! Slide 4 Commissioning Strategyt L Facility Commissioning Issues Time phasing constr#ction and commissioning acti'ities Time phasing the commissioning of the 'ario#s parts of the plant relati'e to each other! $elationships and timings determining (hen 'ario#s systems need to "e a'aila"le) lectrical* Steam* +ater* Instr#mentation Se,#encing of the o'erall plant start#p and sh#tdo(n to ens#re (e do not create #nsafe conditions! Initial start #p! Process Control and Sh#tdo(n! Performance testing!Slide 6 Developing Startup Procedures ngineering and constr#ction companies generally follo( a systematic proced#re (here "y their start#p engineers re'ie( the process design se'eral times as it is de'eloped! After the first re'ie(* a preliminary start-#p and operations proced#re is (ritten! %ecide (hat m#st "e added to the design to make the process capa"le of "eing started #p and operated! &y the time the final engineering flo(-sheets ha'e "een released a complete start#p and operating instr#ctions man#al sho#ld ha'e "een completed- Slide 7 Issues considered Are 'ario#s part of the process too depend on one another! Is there eno#gh s#rge capacity! Are there pro'isions to pre'ent a"normal press#res* temperat#res and rates of reaction! +here are additional 'al'es and "ypass lines needed! Special lines to allo( e,#ipment to "e started #p and rer#n prod#ct.ra( materials- Slide 8 System Level ctivities Utilities systems - steam* instr#ment air* process (ater* fire (ater* drainage* condensate ret#rn! lectrical systems! Instr#mentation and instr#mentation systems! Cleaning and fl#shing! P#rging! Initial start #p and sh#tdo(ns! Performance testing! Slide 9 !"uipment Level ctivities Press#re testing & mechanical integrity testing of 'essel* col#mns and pipe (ork! /eat 0changers* condensers* coolers etc- Mechanical e,#ipment and machinery! Control Systems and Instr#mentation! Operational testing! Proof testing and acceptance- #hat can $e done $e%ore mechanical completiont Utilities commissioning L#"e and Seal-Oil Systems Cleaned Instr#mentation and Control Loops Pro'en Piping* To(ers and 1essels Cleaned &oil-O#t* %ry-O#t and Acid Cleaning T#r"ine* Motor and P#mp $#n-Ins 2itrogen P#rge and Tightness Testing Slide 12 Procedures Proced#res are (ritten ro#tines.instr#ctions that descri"e the logical se,#ence of acti'ities re,#ired to perform a (ork process and the specific actions re,#ired to perform each acti'ity! If there are no (ritten proced#res* there is no "asis for monitoring performance* foc#s for impro'ement or mechanism "y (hich to capt#re learning! The esta"lishment of proced#res and ro#tines allo( more time and mental energy to deal (ith the #ne0pected* (hich al(ays happen d#ring commissioning- Slide 13
Commissioning&Startup Logic A Critical Path 2et(ork 3Plan4 (ith (ritten proced#res (ith related doc#ments are re,#ired- These sho#ld define for the facility* each plant system) -----The order in (hich the systems (ill "e started #p! -----Indi'id#al acti'ities at each stage! -----Operation testing re,#irements! -----%#rations* (aiting times* cooling times! -----Total d#ration for starting #p each system! -----$eso#rces re,#ired - la"o#r* materials* e,#ipment* ser'ices! -----Temperat#res* press#res* fl#id flo(s #sed- Slide 14 Commissioning&Startup and Shutdo'n Issues At the facility* system and e,#ipment le'el* (e (ant to a'oid) -----Creation.e0istence of e0plosi'e mi0t#res* #s#ally "eca#se of the presence of air! +ater hammer and (ater "ased e0plosion effects* d#e to contact "et(een (ater and hot s#"stances 3steam* oil* etc-4! In partic#lar* d#ring commissioning hot fl#ids and gases (ill "e coming into contact (ith cold s#rfaces in places that (o#ld "e hot #nder normal operations- Slide 15 (. )echanical Completion and Integrity Chec*ing Inspection Press#re testing Cleaning and 5l#shing Machinery checko#t Slide 17 Categories o% Process !"uipment $e"oilers & Other Shell & T#"e /eat 0changers &oilers and 5ired /eaters Press#re 1essels and Pipe-(ork 5in-5an Coolers Condensers Machinery.$otating ,#ipment 1al'es Instr#mentation lectrical ,#ipment Slide 18 )achinery& +otating !"uipment P#mps Steam T#r"ines 6as T#r"ines Compressors 6as ngines lectric Motors Slide 19 )echanical Completion and Integrity Inspection In'ol'es checking that e'erything has "een "#ilt and it there as per specification- $efer) ----- Piping Plan %ra(ings! -----Layo#t and constr#ction dra(ings! -----P & I%7s lectrical systems* Instr#mentation and control systems checko#t do(n "y appropriately ,#alified personnel 3lectricians and Instr#mentation technicians4- 6eneral commissioning engineers generally do not get in'ol'ed in this in a hands-on manner-lide 20 )echanical Completion and Integrity Inspection Procedure %i'ide plant into managea"le areas! In a large plant* assign indi'id#als or teams to specific areas! sta"lish a master set of piping plan dra(ings and P&I%7s* mark #p areas) Indi'id#al commissioning engineers or teams (alk e'ery line and mark #p e'ery item that can "e confirmed as present on master set of dra(ings! Use different colo#red 8highlighter9pens to indicate different ser'ices-Slide 21 'ery line m#st "e (alked: Physically sight e'erything: Slide 22 )echanical Completion and Integrity Inspection Procedure , -ints&Tips ns#re pipes* 'essels* 'al'es etc- are all in the right place! 1al'es are correct type - glo"e* gate* control! 1ents* drains* steam traps etc- 5langes* "olts* types of "olts! &lind flanges and s(inga"le "linds in place* correct rating! Check all tag n#m"ers! P#nchlist any non-conformances-de 23 Pipe Stressing Piping sho#ld pro'ide ade,#ately for e0pansion and contraction d#e to temperat#re changes* (itho#t .placing e0cessi'e stresses on e,#ipment! Misalignment "et(een matching flanges on pipe(ork - partic#lar (here there are changes in direction 3el"o(s4 can ca#se stressing! Misalignments (here pipe-(ork connects to machinery* 'essels and other process e,#ipment! Can often "e seen 'is#ally* or checked (ith ga#ges #sing the same proced#res (e #se to align rotating e,#ipment- Slide 25 Piping and !"uipment Supports Slide 26 Mo"ile s#pports permit and g#ide the thermal gro(th of e,#ipment #ndergoing temperat#re change! If they do not f#nction correctly* 'essels* e,#ipment* pipe (ork* no;;les heat e0changers etc- may "e damaged- Slide 27 Slide 28 Piping and e"uipment supports Inspection prior to start #p) -----Check that installed according to specification and not <ammed! Inspection d#ring (arm #p) -----Check thermal gro(th is occ#rring and s#pports are responding as per design! Check that there is no s#rface "#ckling or crimping - this needs to "e corrected! -----Check e0pansion <oints! Check long straight r#ns of piping for "o(ing or s#pport shoes that may ha'e slipped! Rule of thumb - bowing is excessive if you can see it. Slide 29 Piping and e"uipment supports Inspection after cool-do(n) Check that sliding s#pports ha'e ret#rned to original positions! sta"lish that e,#ipment can e0pand and contract as re,#ired- Slide 30 Inspection o% spring supports &efore hydro-testing) -----Check that spring stops are installed- 3If not* the (eight of (ater in pipe (ill deform the spring4- After hydro-testing "#t "efore heating) Check that stops are remo'ed! Check that spring pointer is positioned to cold setting! Slide 31 Inspection o% spring supports %#ring and at end of heating) Check pointer has not e0ceeded hot setting! After cool do(n) check to esta"lish piping can e0pand and contract as re,#ired! esta"lish that springs can a"sor" loads-Slide 32 Slide 33 Inspection o% .essels and Tan*s The inspection of 'essels* col#mns and reactors sho#ld "e sched#led to "e completed "efore constr#ction has closed them #p! Other inspections - e-g- for completeness or piping* ins#lation* safety etc- can "e sched#led later! If a 'essel has "een sealed #p "y constr#ction* it is yo#r d#ty to inspect it* e'en it constr#ction resist- Slide 34 Inspection o% .essels and Tan*s Check that distri"#tors ha'e "een installed correctly! %e-misters installed correctly and of correct materials* design* type! 1orte0 "reakers in place! Trays - packed or 8"#""le-cap9are correct) &#""le caps not <ammed or damaged* do(n comers clear* s#pports all O=- Slide 35 Pressure TestingSlide 36 Press#re Testing - O"<ecti'es The o"<ecti'e of press#re testing is to confirm the mechanical integrity of the plant! 1erifying capa"ility of containing the press#res it has "een designed to hold! ns#re there are no leaks and 'erify that the plant can "e relia"ly made leak free! Identify any '#lnera"ilities (ell "efore the plant is placed into ser'ice! Meet the re,#irements of legislation* local* international and ind#stry standards- Slide 37 Pressure Testing , responsi$ilities Press#re tests of tanks* reactors and piping for mechanical strength and tightness of <oints is #s#ally done "y the constr#ction team! Commissioning team representati'es sho#ld (itness and certify the tests! 2eed to 'erify that all necessary safety preca#tions ha'e "een taken! Slide 38
Pressure Testing , procedures +ater for testing and fl#shing sho#ld contain a r#st inhi"itor - one lo( in chloride content for stainless steel lines! After testing* (ater sho#ld "e drained completely from all lines that do not normally carry (ater* steam or steam condensate! All lo( points sho#ld "e checked for presence of (ater! Lines sho#ld "e dried "y "lo(ing hot air* dry inert gas or instr#ment air- Slide 39 Pressure Testing , .acuum Systems 5inal checks of 'ac##m systems are "est performed "y p#lling a 'ac##m and o"ser'ing the rate of press#re rise in the "locked in system! 0cessi'e leaks can then "e located "y applying a mild positi'e press#re and testing each flange (ith "#""le sol#tion- Slide 40 Pressure Testing , Procedures ( Isometric dra(ings of all systems to "e tested sho#ld "e displayed on a "oard and marked #p as each section is tested! /ydrotesting of piping and e,#ipment according to code re,#irements to confirm mechanical strength sho#ld "e carried o#t on gro#ps of e,#ipment nat#rally s#ggested "y design press#re and f#nction! All (ater* steam* condensate* oil* gas and process steam piping sho#ld "e hydrotested! Ma<or e,#ipment that has already "een tested as part of man#fact#ring may "e isolated "y "lanks- Slide 41 Cleaning and FlushingSlide 42
2eed to ens#re no constr#ction de"ris is left in pipes of 'essels - (elding rods* "olts* glo'es* rags etc- Large de"ris 3l#m"er* ca"le* packaging4 sho#ld ha'e "een remo'ed d#ring mechanical integrity inspections! Small de"ris 3rags* n#ts* dirt4 m#st "e fl#shed o#t of all pipe and 'essels! +here oil coatings m#st "e remo'ed* chemical cleaning is necessary-Slide 43 &efore fl#shing is started* check the process thoro#ghly to ens#re) Screens ha'e "een installed in front of p#mp s#ctions! -----&linds in front of e,#ipment s#ch as compressors and t#r"ines! 8>#mper9spool pieces to allo( for contin#ity of flo(- Slide 44 Flushing Can "e handled "y geographic plant area! Sections too large for (ater fl#shing) -----Pipes greater than ?@ in diameter 3@-AB m4* or -----Pipes that sho#ld not "e to#ched (ith (ater! Sho#ld all "e "lo(n o#t (ith air or inert gas- Slide 45 Flushing $egardless of (hether pipes are cleaned (ith (ater* steam* air or nitrogen* flo( 'elocities sho#ld "e high eno#gh to ens#re that pipes (ill "e s#ita"ly sco#red! 2eed to ens#re that the de"ris from one piece of e,#ipment (ill not simply "e fl#shed into another! +ater 'elocities sho#ld "e at least CD ft.sec 3appro0- ?-AB m.sec4! Air 'elocities a minim#m of D@@ ft.sec 3appro0- EB m.sec4! Slide 46 /. Pre,commissioning and 0perational Testing 4. Slide 47 5. Steam and other #tilities commissioned and introd#ced! %ry r#nning trials! /ot r#nning trials! Safe-fl#id dynamic testing! Sol'ent dynamic testing! Process fl#id tests- Slide 48 Commissioning 1tilities Slide 49 Utilities commissioning #s#ally represents the first phase of commissioning* as these #s#ally need to operational first* "efore the rest of the plant can "e commissioned! The steps for commissioning each #tility sho#ld "e planned in detail! Pro'ides planning practice for planning the start#p of the main plant- Slide 50 Commissioning 1tilities , 2road 3uidelines Check s#pply press#res of all ser'ices - steam* cooling (ater* instr#ment air* nitrogen etc- At the most distant points* open drains* 'ent 'al'es or pipe flanges and p#rge #ntil fl#ids come o#t clean and r#st free! P#rge."lo( o#t lines to each piece of e,#ipment! Check that instr#ment air is clean and dry* and at correct press#re! Circ#late (ater to (aste (ater system #ntil (ater lines clear and clean! 5l#sh (aste (ater and drain systems to ens#re no "lockages! Check operation of steam traps! %rain condensate to (aste (ater #ntil is is clean- 51 Commissioning 1tilities Introducing Steam Steam #s#ally represents the first 8ha;ardo#s9fl#id introd#ced into the 8ne(9system! Admit steam slo(ly into the distri"#tion system (ith .atmospheric "leeds open) Cold pipes (ill condense steam in places (here it (o#ld not #nder normal operation! Can lead to 8(ater hammer9- can distort and r#pt#re lines! After system has "een (armed* slo(ly raise press#re and "lo( do(n the system (ith traps "ypassed* #ntil clean! Then place steam traps into ser'ice and check operation-S lide 52 -igh Pressure Steam Systems Specific Issues The cleanliness and p#rity of high press#re steam systems -partic#larly (here the steam is #sed to dri'e a steam t#r"ine sho#ld "e checked "y #se of a 8target9! 5or ne( "oilers* or ne( sections added to steam system -"lo( do(n at f#ll press#re! +hen steam appears clean* fit a target (ith a 8mirrored9 s#rface 3ie- Small steel plate (hich has "een polished* so that it is in the steam "lo( do(n stream! &lo( do(n the "oiler or system so that the target is impinged #pon for a fe( min#tes! Check target - ens#re there are no small 8pock marks9left on the target- If pock marked - repeat process- Slide 53 !lectrical SystemsSlide 54 Commissioning lectrical Systems The following checks are typical of what is required Open circ#it "reakers and s(itches! Check that all "#s-"ars are free of dirt and foreign matter! Check gro#nding systems for contin#ity and resistance- Make s#re all electrical e,#ipment* 'essels* str#ct#res are connected to the gro#nding system in accordance (ith dra(ings and specifications! Check that all sealed fittings are filled (ith proper sealants* all e0plosion proof* 'apo#r-tight* d#st-tight and (eather tight enclos#res are properly closed and sec#red! Check motor control and po(er circ#itry for correct hook#p-Sl ide 55 Commissioning lectrical Systems - D Check all nameplates and panel directories to ens#re that each circ#it "reaker and s(itch does control the proper circ#it- La"el all s(itches e'en tho#gh their application may seem o"'io#s! Close main transformer primary disconnect s(itch and s(itch-gear main circ#it "reaker! Check 'oltmeter at s(itch-gear for proper 'oltage! Close first s(itch-gear circ#it "reaker* second* third etc- Close first motor control centre main circ#it "reaker* then .each motor starter circ#it "reaker- $epeat for each MCC- Check o'erload "reakers and heaters to ens#re that the correct capacity #nits ha'e "een installed- Slide 56 Commissioning lectrical Systems - ? The following checks are typical of what is required Check that all lighting and po(er circ#its are f#nctioning correctly! Check motor "earings for proper l#"rication! $emo'e motor po(er f#ses and check main contractor* .interlock and se,#encing de'ices! Unco#ple each motor* replace f#ses and check direction of rotation "y momentarily pressing the start "#tton* then stop! Check man#al* then a#tomatic operation- $eplace all co#plings* check dri'e "elts and make s#re g#ards are installed- Slide 58 0perational TestingSlide 59 Progresses thro#gh se'eral stages! %ry r#ns of indi'id#al items of e,#ipment /ot testing of indi'id#al items of e,#ipment and systems! Se'eral stages of %ynamic Testing of) Indi'id#al items of e,#ipment! ------Indi'id#al Systems.processes in isolation! The (hole ne( process plant installation- Slide 60 Dry runs and -ot Tests Check that motors are connected correctly and t#rn in the right direction! Shafts and impellers mo'e freely! ,#ipment that is to "e operated at temperat#re* raise to temperat#re and check! These tests sho#ld "e performed "y the man#fact#rer7s representati'e "#t (itnessed "y mem"ers of the client7s operating.commissioning personnel- Slide 61 -ot testing e"uipment Applies to e,#ipment (hose leak-tightness m#st "e tested at operating temperat#res and after temperat#re re'ersals! 5i0ed-"ed catalytic reactors that in normal conditions are heated "y heat transfer fl#ids (here leakage (o#ld contaminate the catalyst! Critical e0changers (hose steam or cooling (ater is at a high press#re than the process fl#id! Any e,#ipment ha'ing complicated seals thro#gh (hich leakage co#ld occ#r! $otating machinery (hich m#st "e a"le to rotate freely at temperat#re eg- Steam t#r"ines* etc- Slide 62 -ot testing procedures The thermal shock tolerance of e,#ipment m#st "e determined "eforehand! To a'oid thermal shock* the temperat#re of the heating medi#m may ha'e to "e raised grad#ally! Time re,#ired for a hot test m#st "e esta"lished in ad'ance! sta"lish a #niform temperat#re in all parts of e,#ipment that are s#pposed to "e #niformly hot d#ring operation to a'oid setting #p stresses! Slide 63 Dynamic Testing Slide 64 In'ol'es operating the e,#ipment* "efore introd#cing 8li'e9process fl#id! %#ring dynamic testing* (e progress thro#gh) -----Safe-fl#id dynamic testing! %ynamic testing (ith sol'ent! -----Closed loop testing (ith process fl#id- Once process fl#id is introd#ced* normal plant safety proced#res m#st come into effect as if it (ere a li'e operating plant- Slide 65 Sa%e,Fluid Dynamic Testing Closed loop dynamic testing (ith safe fl#ids consists of operating e,#ipment systems (ith air* (ater* inert gases etc- This permits flo( testing of e,#ipment! 6i'es first indication of ho( control loops (ork! sta"lishes performance (hile there is still time to modify the plant! 5amiliarises operators (ith the operation of the e,#ipment "efore ha;ardo#s materials are introd#ced! 6ets rid of a lot of dirt (hich (o#ld "e more diffic#lt to clear once the process fl#id has "een introd#ced- Slide 66 3eneral Principles %or Testing 5or most plants* a period of D-? (eeks is #s#ally s#fficient for operational testing* after the mechanical dry r#nning of indi'id#al pieces of e,#ipment and hot testing complete! Air and (ater tests sho#ld "e set #p in a closed loop (ith fl#ids contin#o#sly recycled* (ith loops as large as possi"le! The loop sho#ld ideally "e the same loop that (ill "e s#"<ect to sol'ent testing! Tests sho#ld contin#e for se'eral days in order to gi'e all shifts a chance to cond#ct the same tests! All shifts sho#ld "e gi'en the opport#nity to start #p and sh#tdo(n each closed loop test A ro#gh flo(-sheet sho#ld "e de'eloped for air and (ater tests* predicting all information that normally appears on a process flo( sheet - flo(* temperat#re* press#re* heat transfer* po(er etc- -----(ill assist in alerting commissioning team to risks from o'er-press#ring* o'erloading* temperat#re-shocking and stressing e,#ipment!e 68 Cautions during Testing %ynamic testing may lead to)aead to) -----Un#s#al or #nforeseen differential e0pansions! -----Corrosion! -----0cessi'e (eight of li,#id into parts of the system! Care m#st "e taken not to collapse or "#rst press#re 'essels and tanks) ----ens#re there is al(ays ade,#ate 'enting! ----a'oid p#lling a 'ac##m Slide 69 Dynamic Testing , Simulated 0perations Safe luid Testing A#0iliary ser'ices m#st "e "ro#ght into operation first) (ater cooling* inert gas generators* "oiler feed(ater* fire(ater* steam prod#ction* etc- +ater is p#mped thro#gh the process 3e0cept (here special conditions do not permit it4 and "oiled #p in col#mns! Compressors and "lo(ers sho#ld "e operated on air or inert gas- Slide 70 The .alue o% Dynamic Testing -Simulated 0perations 1al#e of sim#lated operations (ill "e to allo( operator to "ecome familiar (ith the operation of the process* "efore ha;ardo#s fl#ids are introd#ced! ,#ipment deficiencies can "ecome apparent d#ring dynamic testing! 5ail#res and pro"lems more easily corrected (ith safe fl#ids present Leaks sho#ld "e fo#nd and tightened! Instr#ments can "e placed into ser'ice - altho#gh selection of set-points (ill ha'e to "e deferred! Inspect the plant for e'idence of design and constr#ction errors-Slide 71 At the end of the sim#lation* (ater sho#ld "e drained - e,#ipment dried and p#rged! %epending on the process - drying may not "e necessary - "#t p#rging (ill al(ays "e re,#ired! Slide 72 Dynamic testing 'ith a solvent After safe fl#id testing and s#"se,#ent repairs and modifications* (e are ready for dynamic closed loop testing (ith a sol'ent! The 8sol'ent9is a relati'ely safe fl#id (hose properties are close to that of the process fl#id* or the process fl#id itself! In order to allo( for contin#o#s re-circ#lation of the sol'ent and the #se of different sol'ents in different parts of the plant* temporary lines (ill need to "e installed- Slide 73
Dynamic Testing 'ith Process Solvent Introd#ce the process sol'ent- 3if there is more than one* introd#ce only one at this stage4! The dynamic testing proced#re #sed for the safe fl#id test is repeated for the process sol'ent dynamic testing! After operations (ith the first sol'ent ha'e "een "ro#ght completely #nder control* sho#ld the second sol'ent "e introd#ced 3if there is one4- Slide 74 Dynamic testing 'ith a solvent The p#rpose of dynamic testing (ith a sol'ent is to check o#t e,#ipment and instr#ment loops at* or near design conditions prior to the introd#ction of more ha;ardo#s process fl#id! 2o reactions sho#ld "e allo(ed to occ#r d#ring these tests* so as to ens#re that test fl#ids remain predicta"le in composition and properties! 6#idelines #sed for safe-testing apply! 2eed to plan ho( sol'ent (ill "e fed into the .system and later remo'ed- Slide 75 Stages o% dynamic testing 'ith a 4solvent5 %rain safe fl#id and p#rge air #sed in the pre'io#s test from the system! %ry o#t e,#ipment (here safe fl#id (as (ater- Check flo( sheets for (here (ater is likely to acc#m#late- 5ill systems (ith the sol'ent- ns#re pro'isions made for 'enting and drains closed! +hen ade,#ate le'els esta"lished* place p#mps and compressors online to complete filling! Start closed loop circ#lation! /eat #p the systems to sim#late operating conditions "y placing refl#0* re"oiler and condensation systems into .operationSlide 76 Systematically check o#t instr#mentation and control loops! After instr#ments ha'e checked o#t* place as many as possi"le on a#tomatic control! All shifts sho#ld go thro#gh starting and stopping e,#ipment* heating and cooling closed loop systems! %ynamic 8sol'ent9testing offers the "est opport#nity for operator training "efore the 8real thing9! Operate e,#ipment as near as possi"le to design capacities! $elia"ility of emergency sh#tdo(n systems and alarms m#st "e pro'en! Critical instr#ments m#st "e cali"rated o'er their f#ll range-Slide 77 %eli"erately operate e,#ipment near its limits) 5lood col#mns! ase compressors into mild s#rges and plot s#rge c#r'es! O'erload condensers! %o not fear "lo(ing a relief 'al'e or t(o: After tests ha'e "een completed* plant sho#ld "e ready for initial operation- Slide 78
Closed Loop Dynamic Testing 'ith Process Fluid 5inally* introd#ce process fl#id! %#ring this step* instr#ments sho#ld "e cali"rated to co'er their f#ll range of flo(* temperat#re and press#re! ns#re that instr#ments* process analysers and safety de'ices are kept (ork properly d#ring these processes! After operations (ith process fl#id are "ro#ght completely #nder control sho#ld the final stage of start-#p "e attempted- Slide 79 Preparing to introduce process %luids &efore introd#cing ha;ardo#s li,#ids into the plant* (e complete additional press#re testing and p#rging! 2eed to check that the stresses and strains of dynamic testing has not ca#sed any leaks - these m#st "e fo#nd and fi0ed! Slide 80
Pressure testing and purging Consists of press#ring and de-press#ring (ith nitrogen se'eral times* #ntil at least F?G o0ygen is reached! 1ac##m systems sho#ld "e e'ac#ated and then repress#red (ith nitrogen! Long r#ns of piping are s(ept (ith nitrogen! +hile #nder press#re* rate of press#re loss of the 8"locked in9system is monitored as a check for leaks and that no 'ents or drains ha'e "een left open- Slide 81 Dehydrating $y Circulation It is #s#ally not possi"le to (ater-free e,#ipment simply "y draining! Only positi'e method to (ater-free process e,#ipment is oil circ#lation follo(ed "y repeated draining of lo( points! ns#re s#fficient lo( point drains are pro'ided on piping* control 'al'e loops* 'essels and process machinery! Start#p lines - deli'er oil to #pper part 3trays4 of distillation to(ers 3si;e for D@G of net distillate prod#ct rate4! Slide 82 6. Start 1p and Initial 0peration Slide 83 Introd#ction of process fl#id Start-#p and initial operation Tro#"le-shooting and pro"lem correction- Plant taken to f#ll operations- Slide 84Slide 85 Start 1p Logic It is common practice to "#y in prod#ct and start #p the last past of the process first and (ork "ack(ards to the front- -g- ----Start #p refining* get this (orking and in control! Then possi"ly start #p reaction and reco'ery! ----5inally* feed preparation- Slide 86 Into the initial operation Once ra( materials are fed into the plant H #s#ally at red#ced rate #ntil reaction conditions ha'e "een esta"lished! As each section is started #p* esta"lish as ,#ickly as possi"le that process conditions are as e0pected! If potentially serio#s pro"lems de'elop* there sho#ld "e no hesitation on going into an emergency sh#tdo(n- Slide 87 +amping up the plant Plant is "ro#ght slo(ly to design feed-rates and operating conditions! Us#ally done in steps (ith operating data e'al#ated and 'erified as O= at each step! Plant and la"oratory data are no( "eing collected and sho#ld "e "eing e'al#ated promptly! Slide 88 Coordination and Supervision during start up Additional personnel* "oth s#per'isory and 8onthe-gro#nd9are re,#ired at this stage! Cooperation "et(een start#p personnel and plant s#per'isory personnel is critical at this stage) 2eed a daily meeting at least! Often* a "riefing each shift- Slide 89 Trou$le Shooting At this stage* many pro"lem (ith e,#ipment of the process itself may "ecome apparent! The commissioning process goes thro#gh (hat is often an intense 3and hopef#lly short4 period of pro"lem tro#"le shooting* pro"lem sol'ing* engineering correction and plant modification! Slide 90
7.Per%ormance and cceptance Trails Slide 91 Performance trails! 5ormal Acceptance test Slide 92 The Per%ormance Trails Once the plant is f#lly operational* the final 8pro'ing trail9or performance r#n is performed in order to pro'e the plant can do (hat it is s#pposed to do! The 'al#es or range of 'al#es for each independent 'aria"le - flo(* temperat#re* press#re* le'el* concentrations* etc- to (hich the plant m#st "e operated to are determined! The plant is "ro#ght #p to those conditions and the pre-agreed trial period "egins- Slide 93 2e%ore the trail or per%ormance run need to ensure thatI Control of plant operating conditions has "een achie'ed- I-e- temperat#re* press#res* le'els and analyses are reasona"ly constant or in the case of a "atch process* there is repeata"ility! %aily material and energy "alanced can "e performed and that these agree (ith 8official9 prod#ction fig#res! Prod#ct specifications are "eing achie'ed consistently- Slide 94 8eed to veri%y 9 . Physical operation* capa"ility and capacity of plant and e,#ipment! nergy and mass "alance! Process chemistry! fficiencies* yields and ,#ality! All to specification- Slide 95 cceptance +hen the plant has met the Performance and Acceptance test re,#irements designed "y the commissioning team there is #s#ally a formal acceptance process in'ol'ing signing of acceptance certificates! Once the plant is accepted it is officially part of the normal operations - the responsi"ility of operations and maintenance! Commissioning is officially o'er! The may still "e o#tstanding p#nchlist items Slide 96 cceptance Testing It is common practice to pro'e performance repeata"ility and plant integrity as part of the performance test- That is) -----Sh#tdo(n and Start Up the plant on se'eral occasions and "ring it #p to test conditions to pro'e repeata"ility- Also ramp do(n and ramp #p (hile online! -----$e-inspection of critical process e,#ipment -partic#larly col#mns to ens#re they ha'e not "een damaged "y the performance r#n- Slide 97
Commercial Signi%icant o% cceptance 5ormal Acceptance represents formal ackno(ledgment that the Contractor has f#ll-filled their contract#al o"ligations! Commissioning team ha'e f#ll-filled their o"ligations! Completion of the Capital Pro<ect and transfer to Operations! 0penses and costs from acceptance on(ards are no( operating e0penses not capital pro<ect costs! All s#"<ect to agreed p#nch-list items- Slide 98 7.Post,Commissioning Slide 99 5rom plant on-stream to settled do(n and in reg#lar prod#ction! Ad<#stments* modifications and fa#lt correction! Completion of o#tstanding p#nchlist itemsSlide 100 Co'ers the period immediately after Acceptance! O#tstanding p#nch-list items are completed! The first ro#tine maintenance checks are performed* findings e'al#ated and reported! Process e,#ipment and items co'ered "y (arranty are scr#tini;ed for signs of premat#re (ear- o#t or pro"lems! Operating data is collected and e'al#ated to ens#re consistent plant operations are maintained and s#staina"le- Typical chec* list Installation of gland packing and l#"rication of 'al'es and minor machinelJ* checking rotation of dri'ers and so on- Isolating e,#ipment* remo'ing e0pansion <oints* r#pt#re discs and relief 'al'es from pipe(ork and e,#ipment "efore line fl#shing* cleaning and testing- Cleaning of pipe(ork "y fl#shing* steaming* "lo(ing and so on- /ydra#lic and.or pne#matic press#re testing of e,#ipment and pipe(ork- Application of special treatment or other preparation of inside s#rfaces- Testing of relief 'al'es- $emo'ing loose material and dirt* installation of internals* inspection and closing #p of 'essels and so on- Installation of orifice plates after line cleaning* installation of temporaly strainers* remo'al of slip-plates and so on- Checking electrical installations- Checking alignment of ma<or machinery and dri'ersK cleaning and fl#shing l#"ricating oil installations and so on- II- Carrying o#t short r#nning-in tests on machinery as re,#ired- Checking action of instr#ments and control 'al'es* testing electrical controls and alarms and so on- Cali"ration of instr#ments- %rying o#t refractories- Ad<#stment of pipe s#pports for e0pansion- $emo'al* cleaning and replacement of temporary strainers- Checking orifice plates and permanent "lanks* relief systems* safety pro'isions and so on- Charging ra( materials* process chemicals* f#el and so on* as re,#ired- +arming-#p* starting-#p fl#id flo(s and so on* as re,#ired- Tightening of hot <oints- Starting-#p and operating the 'ario#s plant items- $o#tine maintenance* cleaning* plant ad<#stments and so on-