Commissioning Strategy

8/20/2019 Commissioning Strategy

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Commissioning StrategyCommissioning Strategy

PETROTEC EPC Contracting Seminar ©


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The Commissioning ProcessThe Commissioning Process

Key StagesKey Stages

Preparation andplanning

Mechanical Completionand Integrity checking

Performance andAcceptance testing

Start Up & InitialOperation

Client Ownership

Commissioning &Operational Testing



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The Commissioning Process DetailThe Commissioning Process Detail -- 11





Pre-commissioning &Operational Testing

Appointment of Commissioning Manageror Lead Commissioning Engineer;

Appointment of Commissioning TeamMembers and Support Staff;

Training;

Compile Information;

Safety and Risk Assessment;

Commissioning Strategy Development;

Procedures and Checklist Development;

Detailed Plan and Budget Preparation;

Post Commissioning



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Commissioning StrategyCommissioning Strategy

Equipment Level Activities

SystemLevel Activities

Facility/Plant LevelActivities

CommissioningStrategy

Commissioning Master Plan

Individual itemcommissioning plans,

procedures and checklists



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Platform Commissioning IssuesPlatform Commissioning Issues Time construction phasing out and commissioning activitiesTime construction phasing out and commissioning activities

Time commissioning starts of the various parts of the systemsTime commissioning starts of the various parts of the systems

relative to each other;relative to each other;

Relationships and timings determining when various systemsRelationships and timings determining when various systemsneed to be available:need to be available:

Electrical, Diesel, Water, InstrumentationElectrical, Diesel, Water, Instrumentation

Sequencing of the overall process, shutdowns to ensure unsafeSequencing of the overall process, shutdowns to ensure unsafeconditions are resolved with ESD system;conditions are resolved with ESD system;

Initial commissioning and start up planning;Initial commissioning and start up planning;

Scheduling before performance testing;Scheduling before performance testing;

Performance testing;Performance testing;



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Developing Startup ProceduresDeveloping Startup Procedures

Engineering and construction companies generally follow aEngineering and construction companies generally follow a

systematic procedure where by their startup engineers reviewsystematic procedure where by their startup engineers reviewthe process design several times as it is developed;the process design several times as it is developed;

After the first review, a preliminary startAfter the first review, a preliminary start--up and operationsup and operationsprocedure is written;procedure is written;

Decide what must be added to the design to make the processDecide what must be added to the design to make the processcapable of being started up and operated;capable of being started up and operated;

By the time the final engineering flowBy the time the final engineering flow--sheets have beensheets have beenreleased a complete startup and operating instructions manualreleased a complete startup and operating instructions manualshould have been completed.should have been completed.



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Issues consideredIssues considered

Various part of the process, depend each other;Various part of the process, depend each other;

Is there enough surge capacity;Is there enough surge capacity;

Are there provisions to prevent abnormal pressures,Are there provisions to prevent abnormal pressures,temperatures and rates of reaction;temperatures and rates of reaction;

Where are additional valves and bypass lines needed;Where are additional valves and bypass lines needed;

Special lines to allow equipment to be started up and reSpecial lines to allow equipment to be started up and re--runrunproduct/raw materials.product/raw materials.



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System Level ActivitiesSystem Level Activities

Utilities systemsUtilities systems -- diesel, instrument air, process water, firediesel, instrument air, process water, fire

water, drainage, condensate return;water, drainage, condensate return;

Electrical systems;Electrical systems;

Instrumentation and control systems;Instrumentation and control systems;

Cleaning and flushing;Cleaning and flushing;

Purging;Purging;

Schedule Initial start up and shutdowns;Schedule Initial start up and shutdowns;

Performance testing;Performance testing;



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Equipment Level ActivitiesEquipment Level Activities

Pressure testing & mechanical integrity testing of vessel,Pressure testing & mechanical integrity testing of vessel,tanks, drums and pipe work;tanks, drums 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 installations;Control Systems and Instrumentation installations;

Operational testing;Operational testing;

Proof testing and acceptance.Proof testing and acceptance.



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What can be done during mechanical completionWhat can be done during mechanical completion

Utilities Piping install and tested

Lube and Seal-Oil Systems Cleaned

Instrumentation and Control Loops Proven

Piping, tanks and Vessels Cleaned

Boil-Out, Dry-Out and Acid Cleaning

Turbine, Motor and Pump Run-Ins

Nitrogen Purge and Tightness Testing



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ProceduresProcedures

Procedures are written description/instructions that describeProcedures are written description/instructions that describethe logical sequence of activities required to perform a workthe logical sequence of activities required to perform a workprocess and the specific actions required to perform eachprocess and the specific actions required to perform each

activity;activity;

If written procedures are not written, there is no basis forIf written procedures are not written, there is no basis formonitoring performance, focus for improvement or mechanismmonitoring performance, focus for improvement or mechanismby which to capture learning;by which to capture learning;

The establishment of procedures allow more time and mentalThe establishment of procedures allow more time and mentalenergy to deal with the unexpected, which always happenenergy to deal with the unexpected, which always happenduring commissioning.during commissioning.



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Commissioning/Startup LogicCommissioning/Startup Logic

A Critical Path Network (Plan) with written procedures withA Critical Path Network (Plan) with written procedures withrelated documents are required. These should define activities f related documents are required. These should define activities f oror

each unit system.each unit 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;

Estimate duration for starting up each system;Estimate duration for starting up each system;

Resources requiredResources required -- labor, materials, equipment, services;labor, materials, equipment, services;

Temperatures, pressures, fluid flows used.Temperatures, pressures, fluid flows used.



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Commissioning/Startup and Shutdown IssuesCommissioning/Startup and Shutdown Issues

System and equipment level, we want to avoid:System and equipment level, we want to avoid:

Creation/existence of explosive mixtures, usually because ofCreation/existence of explosive mixtures, usually because ofthe presence of air;the presence of air;

Water hammer and water based explosion effects, due toWater hammer and water based explosion effects, due tocontact between water and hot substances (steam, oil, etc.);contact between water and hot substances (steam, oil, etc.);

In particular, during commissioning hot fluids and gases will beIn particular, during commissioning hot fluids and gases will becoming into contact with cold surfaces in places that would becoming into contact with cold surfaces in places that would behot under normal operations.hot under normal operations.



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Mechanical Completion andMechanical Completion andIntegrity CheckingIntegrity Checking



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Mechanical Completion and Integrity InspectionMechanical Completion and Integrity Inspection





Pre-commissioning &Operational Testing

InspectionInspection Pressure testingPressure testing

Cleaning and FlushingCleaning and Flushing

Machinery checkoutMachinery checkout

Post Commissioning



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Categories of Process EquipmentCategories of Process Equipment

Compressors, Tanks, GeneratorsCompressors, Tanks, Generators

Gas TurbinesGas Turbines

Medium voltage motorsMedium voltage motors Pressure Vessels and PipePressure Vessels and Pipe--worksworks

FinFin--Fan CoolersFan Coolers

CondensersCondensers

Machinery/Rotating EquipmentMachinery/Rotating Equipment ValvesValves

Instrumentation and ControlsInstrumentation and Controls

Electrical EquipmentElectrical Equipment



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Machinery/ Rotating EquipmentMachinery/ Rotating Equipment

PumpsPumps

Diesel GeneratorsDiesel Generators

Gas TurbinesGas Turbines

CompressorsCompressors

Electric MotorsElectric Motors



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Check that installations are completed per specification. Refer:Check that installations are completed per specification. Refer:

Piping Plan Drawings;Piping Plan Drawings;

Layout and construction drawings;Layout and construction drawings;

P & IDP & ID’’ss

Electrical, Instrumentation and control systems are checkedElectrical, Instrumentation and control systems are checkedout and documentation sign:out and documentation sign:

Inspection is done by the commissioning engineers in theirInspection is done by the commissioning engineers in theirfield, such as piping, electrical, instrumentation, etc.;field, such as piping, electrical, instrumentation, etc.;



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Divide unit into manageable areas;Divide unit into manageable areas;

In a large platform, assign individuals or teams to specificIn a large platform, assign individuals or teams to specificareas;areas;

Establish a master set of piping plan drawings and P&IDEstablish a master set of piping plan drawings and P&ID’’s,s,

mark up areas:mark up areas:

Individual commissioning engineers or teams walk every lineIndividual commissioning engineers or teams walk every lineand mark up every item that can be confirmed as present onand mark up every item that can be confirmed as present onmaster set of drawings;master set of drawings;

Use different colorsUse different colors ““highlighterhighlighter”” pens to indicate differentpens to indicate differentprocess systems.process systems.



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Every line must be walked! Physically sight everything! Every line must be walked! Physically sight everything!



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ProcedureProcedure -- Hints/TipsHints/Tips

Ensure pipes, vessels, valves etc. are all in the right place;Ensure pipes, vessels, valves etc. are all in the right place;

Valves are correct typeValves are correct type -- globe, gate, control;globe, gate, control;

Vents, drains, check valves, etc.;Vents, drains, check valves, etc.;

Flanges, bolts, types of bolts, correctFlanges, bolts, types of bolts, correct gaskets,etcgaskets,etc;;

Blind flanges and swingable blinds in place, correct rating;Blind flanges and swingable blinds in place, correct rating;

Check all tag numbers;Check all tag numbers;

Punch list any nonPunch list any non--conformances installations.conformances installations.



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Pipe StressingPipe Stressing

Piping should provide adequately expansion and contraction duePiping should provide adequately expansion and contraction dueto temperature changes, without placing excessive stresses onto temperature changes, without placing excessive stresses onequipment;equipment;

Misalignment between matching flanges on pipeMisalignment between matching flanges on pipe--workwork -- particularparticularwhere there are changes in direction (elbows) can causewhere there are changes in direction (elbows) can causestressing;stressing;

Misalignments where pipeMisalignments where pipe--work connects to machinery, vesselswork connects to machinery, vesselsand other process equipment;and other process equipment;

Can often be seen visually, or checked with gauges using theCan often be seen visually, or checked with gauges using the

same procedures we use to align rotating equipment.same procedures we use to align rotating equipment.



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Piping and EquipmentPiping and EquipmentSupportsSupports



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Piping and equipment supportsPiping and equipment supports

Mobile supports permit and guide thermal growth of equipmentMobile supports permit and guide thermal growth of equipment

undergoing temperature change;undergoing temperature change;

If not design correctly, vessels, equipment, pipe work, nozzlesIf not design correctly, vessels, equipment, pipe work, nozzlesheat exchangers etc. may be damaged.heat exchangers etc. may be damaged.


Typical piping support methodsTypical piping support methods


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Piping and equipment supportsPiping and equipment supports

Inspection prior to start up:Inspection prior to start up:

Check that installations are according to specification, etc.;Check that installations are according to specification, etc.;

Inspection during warm up:Inspection during warm up:

Check thermal growth is occurring and supports are responding asCheck thermal growth is occurring and supports are responding as

per design;per design;

Check that there is no surface buckling or crimpingCheck that there is no surface buckling or crimping –– correct ifcorrect ifoccurring;occurring;

Check expansion joints;Check expansion joints;

Check long straight runs of piping for bowing or support shoes tCheck long straight runs of piping for bowing or support shoes thathatmay have slipped;may have slipped;

Rule of thumbRule of thumb -- bowing is excessive if you can see it.bowing is excessive if you can see it.



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Inspection of spring supportsInspection of spring supports

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 contract as required;check to establish piping can expand and contract as required;

establish that springs can absorb loads.establish that springs can absorb loads.



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Vessels and ColumnsVessels and Columns



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Inspection of Vessels and ColumnsInspection of Vessels and Columns

The inspection of vessels, columns, etc., should be scheduledThe inspection of vessels, columns, etc., should be scheduledand completed before construction close them up;and completed before construction close them up;

Other inspectionsOther inspections -- e.g. for completeness or piping, insulation,e.g. for completeness or piping, insulation,safety etc. can be scheduled later;safety etc. can be scheduled later;

If a vessel has been sealed up by construction, it is your dutyIf a vessel has been sealed up by construction, it is your duty toto

inspect it, even it construction resist.inspect it, even it construction resist.



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Inspection of Vessels and ColumnsInspection of Vessels and Columns

Check that distributors have been installed correctly;Check that distributors have been installed correctly;

DeDe--misters installed correctly and of correct materials, design, tymisters installed correctly and of correct materials, design, typepe

Vortex breakers in place;Vortex breakers in place;

TraysTrays -- packed orpacked or ““bubblebubble--capcap”” are correct:are correct:

Bubble caps not jammed or damaged, down comers clear,Bubble caps not jammed or damaged, down comers clear,supports all OK.supports all OK.



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Pressure TestingPressure Testing -- ObjectivesObjectives

The objective of pressure testing is to confirm the mechanicalThe objective of pressure testing is to confirm the mechanicalintegrity of the plant;integrity of the plant;

Verifying capability pressure is contain as per design and pressVerifying capability pressure is contain as per design and pressureurehold;hold;

Ensure there are no leaks and verify that the plant can be reliaEnsure there are no leaks and verify that the plant can be reliablybly

made leak free;made leak free;

Identify any vulnerabilities well before the plant is placed intIdentify any vulnerabilities well before the plant is placed intooservice;service;

Meet the client requirements and industry standards.Meet the client requirements and industry standards.



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Pressure TestingPressure Testing -- proceduresprocedures

When using water for testing and flushing, should contain aWhen using water for testing and flushing, should contain arust inhibitor. Using one low in chloride content for stainlessrust inhibitor. Using one low in chloride content for stainlesssteel lines;steel lines;

After testing, water should be drained completely from allAfter testing, water should be drained completely from alllines, specially those that do not normally carry water, steamlines, specially those that do not normally carry water, steamor steam condensate;or steam condensate;

All low points should be checked for presence of water;All low points should be checked for presence of water;

Lines should be dried by blowing hot air, dry inert gas orLines should be dried by blowing hot air, dry inert gas orinstrument air.instrument air.



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Pressure TestingPressure Testing -- Procedures 2Procedures 2

Isometric drawings of all systems to be tested should beIsometric drawings of all systems to be tested should bedisplayed on a board and marked up as each section is tested;displayed on a board and marked up as each section is tested;

Hydro testing of piping and equipment according to code. ThisHydro testing of piping and equipment according to code. Thistest requirements is to confirm mechanical strength suggestedtest requirements is to confirm mechanical strength suggestedby design pressure and function;by design pressure and function;

All water, steam, condensate, oil, gas and process steam pipingAll water, steam, condensate, oil, gas and process steam pipingshould beshould be hydrotestedhydrotested;;

Major equipment already tested as per code must be isolatedMajor equipment already tested as per code must be isolatedby sealing each end.by sealing each end.



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Before flushing is started, check the process thoroughly toBefore flushing is started, check the process thoroughly toensure:ensure:

Screens have been installed in front of pump suctions;Screens have been installed in front of pump suctions;

Blinds in front of equipment such as compressors andBlinds in front of equipment such as compressors and

turbines;turbines;

InstallInstall ““JumperJumper”” spool pieces to allow for continuity ofspool pieces to allow for continuity offlow.flow.



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FlushingFlushing

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),Pipes greater than 30 in diameter (0.75 m),

oror

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.



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FlushingFlushing

Regardless of whether pipes are cleaned with water, steam,Regardless of whether pipes are cleaned with water, steam,air or nitrogen, flow velocities should be high enough toair or nitrogen, flow velocities should be high enough toensure that pipes will be suitably scoured;ensure that pipes will be suitably scoured;

Need to ensure that the debris from one piece of equipmentNeed to ensure that the debris from one piece of equipmentwill not simply be flushed into another;will not simply be flushed into another;

Water velocities should be at least 12 ft/sec (approx. 3.75Water velocities should be at least 12 ft/sec (approx. 3.75m/sec);m/sec);

Air velocities a minimum of 200 ft/sec (approx. 65 m/sec);Air velocities a minimum of 200 ft/sec (approx. 65 m/sec);



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PrePre--commissioningcommissioningandand

Operational TestingOperational Testing



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The Commissioning Process DetailThe Commissioning Process Detail -- 33




Diesel and other utilities commissionedDiesel and other utilities commissionedand introduced;and introduced;

Dry running trials;Dry running trials; Hot running trials;Hot running trials;

SafeSafe--fluid dynamic testing;fluid dynamic testing;

Solvent dynamic testing;Solvent dynamic testing;

Process fluid tests.Process fluid tests.


Commissioning &

Operational Testing

Owner takes

ownership



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Commissioning UtilitiesCommissioning Utilities



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Commissioning UtilitiesCommissioning Utilities

Utilities commissioning usually represents the first phase ofUtilities commissioning usually represents the first phase ofcommissioning, as these usually need to operational first,commissioning, as these usually need to operational first,before the rest of the plant can be commissioned;before the rest of the plant can be commissioned;

The steps for commissioning each utility should be planned inThe steps for commissioning each utility should be planned indetail;detail;

Provides planning practice for planning the startup of the mainProvides planning practice for planning the startup of the mainplant.plant.



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Commissioning Utilities GuidelinesCommissioning Utilities Guidelines

Check supply pressures of all servicesCheck supply pressures of all services -- cooling water,cooling water,instrument air, nitrogen etc.instrument air, nitrogen etc.

At the most distant points, open drains, vent valves or pipeAt 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 correctCheck that instrument air is clean and dry, and at correctpressure;pressure;

Circulate water to waste water system until water lines clearCirculate water to waste water system until water lines clearand clean;and 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 it is clean.Drain condensate to waste water until it is clean.PETROTEC EPC Contracting Seminar ©


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Commissioning Electrical SystemsCommissioning 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 busCheck 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. MakeCheck grounding systems for continuity and resistance. Makesure all electrical equipment, vessels, structures are connectedsure all electrical equipment, vessels, structures are connected

to the grounding system in accordance with drawings andto the grounding system in accordance with drawings andspecifications;specifications;

Check that all sealed fittings are filled with proper sealants,Check that all sealed fittings are filled with proper sealants, allallexplosion proof, vaporexplosion proof, vapor--tight, dusttight, dust--tight and weather tighttight and weather tight

enclosures are properly closed and secured;enclosures are properly closed and secured;

Check motor control and power circuitry for correct hookup andCheck motor control and power circuitry for correct hookup androtation correct direction.rotation correct direction.



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Commissioning Electrical SystemsCommissioning Electrical Systems -- 22


Check all nameplates and panel directories to ensure that eachCheck all nameplates and panel directories to ensure that eachcircuit breaker is hooked to the proper circuit. Label and tag acircuit breaker is hooked to the proper circuit. Label and tag allll

breakers and Off On Automatic, even though their applicationbreakers and Off On Automatic, even though their applicationmay seem obvious;may seem obvious;

Operate main transformer primary disconnect switch andOperate main transformer primary disconnect switch andswitchswitch--gear main circuit breaker and makegear main circuit breaker and make ajustmentsajustments;;

Check voltmeter at switchCheck voltmeter at switch--gear for proper voltage;gear for proper voltage;

Close first switchClose first switch--gear circuit breaker, second, third etc.gear circuit breaker, second, third etc.

Close first motor control centre main circuit breaker, then eachClose first motor control centre main circuit breaker, then eachmotor starter circuit breaker. Repeat for each MCC.motor starter circuit breaker. Repeat for each MCC.

Check overload breakers, fuses and heaters to ensure that theCheck overload breakers, fuses and heaters to ensure that the

correct capacity units have been installed.correct capacity units have been installed.



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Commissioning Electrical SystemsCommissioning Electrical Systems -- 33


Check that all lighting and power circuits are functioningCheck that all lighting and power circuits are functioningcorrectly;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 ofUncouple each motor, replace fuses and check direction ofrotation 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 guardsReplace all couplings, check drive belts and make sure guardsare installed.are installed.



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Operational TestingOperational Testing



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Commissioning/Operational TestingCommissioning/Operational Testing

Progresses through several stages;Progresses through several stages;

Dry runs of individual items of equipmentDry runs of individual items of equipment

Hot testing of individual items of equipment and systems;Hot testing of individual items of equipment and 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.



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Dry runs and Hot TestsDry runs and Hot Tests

Check that motors are connected correctly and turn in the rightCheck that motors are connected correctly and turn in the rightdirection;direction;

Shafts and impellers move freely;Shafts and impellers move freely;

Equipment that is to be operated at temperature, raise toEquipment that is to be operated at temperature, raise to

temperature and check;temperature and check;

These tests should be performed by the manufacturerThese tests should be performed by the manufacturer’’ssrepresentative but witnessed by members of the clientrepresentative but witnessed by members of the client’’ssoperating/commissioning personnel.operating/commissioning personnel.



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Hot testing equipmentHot testing equipment

Applies to equipment whose leakApplies to equipment whose leak--tightness must be tested attightness must be tested atoperating temperatures and after temperature reversals;operating temperatures and after temperature reversals;

Any equipment having complicated seals through which leakageAny equipment having complicated seals through which leakagecould occur;could occur;

Rotating machinery which must be able to rotate freely atRotating machinery which must be able to rotate freely at

temperature eg. Gas turbines, etc.temperature eg. Gas turbines, etc.



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Hot testing proceduresHot testing procedures

The thermal shock tolerance of equipment must be determinedThe thermal shock tolerance of equipment must be determinedbeforehand;beforehand;

To avoid thermal shock, the temperature of the heatingTo avoid thermal shock, the temperature of the heatingmedium may have to be raised gradually;medium may have to be raised gradually;

Time required for a hot test must be established in advance;Time required for a hot test must be established in advance;

Establish a uniform temperature in all parts of equipment thatEstablish a uniform temperature in all parts of equipment thatare supposed to be uniformly hot during operation to avoidare supposed to be uniformly hot during operation to avoidsetting up stresses;setting up stresses;



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Dynamic TestingDynamic Testing



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S fS f Fl id D i T tiFl id D i T ti


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SafeSafe--Fluid Dynamic TestingFluid Dynamic Testing

Closed loop dynamic testing with safe fluids consists of operatiClosed loop dynamic testing with safe fluids consists of operatingngequipment systems with air, water, inert gases etc.equipment systems with air, water, inert gases 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 theEstablishes performance while there is still time to modify theplant;plant;

Familiarizes and train operators with the operation of theFamiliarizes and train operators with the operation of theequipment before hazardous materials are introduced;equipment before hazardous materials are introduced;


G l P i i l f T tiGeneral Principles for Testing


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General Principles for TestingGeneral Principles for Testing

For most plants, a period of 2For most plants, a period of 2--3 weeks is usually sufficient for3 weeks is usually sufficient foroperational testing, after the mechanical dry running ofoperational testing, after the mechanical dry running ofindividual 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 fluidAir and water tests should be set up in a closed loop with fluidsscontinuously recycled, with loops as large as possible;continuously recycled, with loops as large as possible;

The loop should ideally be the same loop that will be subject toThe loop should ideally be the same loop that will be subject tosolvent testing;solvent testing;

Tests should continue for several days in order to give all shif Tests should continue for several days in order to give all shif tstsa chance to conduct the same tests;a chance to conduct the same tests;

All shifts should be given the opportunity to start up andAll shifts should be given the opportunity to start up andshutdown each closed loop test.shutdown each closed loop test.


Gene al P inciples fo TestingGeneral Principles for Testing


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General Principles for TestingGeneral Principles for Testing

A rough flowA rough flow--sheet should be developed for air and watersheet should be developed for air and watertests, predicting all information that normally appears on atests, predicting all information that normally appears on aprocess flow sheetprocess flow sheet -- flow, temperature, pressure, heat transfer,flow, temperature, pressure, heat transfer,

power etc.power etc.

alerting commissioning team of risks from overalerting commissioning team of risks from over--pressuring,pressuring,overloading, temperatureoverloading, temperature--shocking and stressingshocking and stressingequipment, etc.;equipment, etc.;


Cautions during TestingCautions during Testing


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Cautions during TestingCautions 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 system;Excessive weight of liquid into parts of the system;

Care must be taken not to collapse or burst pressure vesselsCare must be taken not to collapse or burst pressure vesselsand tanks:and tanks:

ensure there is always adequate venting;ensure there is always adequate venting;

avoid pulling a vacuum.avoid pulling a vacuum.



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Dynamic TestingDynamic Testing -- Simulated OperationsSimulated Operations

At the end of the simulation, water should be drainedAt the end of the simulation, water should be drained --equipment dried and purged;equipment dried and purged;

Depending on the processDepending on the process -- drying may not be necessarydrying may not be necessary --purging will always be required;purging will always be required;



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Dynamic Testing with Process SolventDynamic Testing with Process Solvent Introduce the process solvent. (if there is more than one, introIntroduce the process solvent. (if there is more than one, introduceduce

only one at this stage);only one at this stage);

The dynamic testing procedure used for the safe fluid test isThe dynamic testing procedure used for the safe fluid test isrepeated for the process solvent dynamic testing;repeated for the process solvent dynamic testing;

After operations with the first solvent have been broughtAfter operations with the first solvent have been broughtcompletely under control, should the second solvent be introducecompletely under control, should the second solvent be introducedd

(if there is one).(if there is one).



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Stages of dynamic testing with aStages of dynamic testing with a ““solventsolvent”” Drain safe fluid and purge air used in the previous test fromDrain safe fluid and purge air used in the previous test from

the system;the system;

Dry out equipment where safe fluid was water. Check flowDry out equipment where safe fluid was water. Check flowsheets for where water is likely to accumulate.sheets for where water is likely to accumulate.

Fill systems with the solvent. Ensure provisions made forFill systems with the solvent. Ensure provisions made forventing and drains closed;venting and drains closed;

When adequate levels established, place pumps andWhen adequate levels established, place pumps andcompressors 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 byHeat up the systems to simulate operating conditions byplacing reflux,placing reflux, reboilerreboiler and condensation systems intoand condensation systems intooperationoperation


Stages of dynamic testing with a “solvent”


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Stages of dynamic testing with aStages of dynamic testing with a

““solventsolvent

””

Systematically check out instrumentation and control loops;Systematically check out instrumentation and control loops;

After instruments has been checked out, switchAfter instruments has been checked out, switchinstrumentation to automatic control;instrumentation to automatic control;

All shifts should go through starting and stopping equipment,All shifts should go through starting and stopping equipment,heating and cooling closed loop systems;heating and cooling closed loop systems;

DynamicDynamic ““solventsolvent”” testing offers the best opportunity fortesting offers the best opportunity foroperator training before theoperator training before the ““real thingreal 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 mustReliability of emergency shutdown systems and alarms mustbe proven;be proven;

Critical instruments must be calibrated as per data sheets.Critical instruments must be calibrated as per data sheets.



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Closed Loop Dynamic Testing with Process FluidClosed Loop Dynamic Testing with Process Fluid


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p y gp y g

Finally, introduce process fluid;Finally, introduce process fluid;

During this step, instruments should be calibrated to coverDuring this step, instruments should be calibrated to covertheir full range of flow, temperature and pressure or as pertheir full range of flow, temperature and pressure or as perdata sheets.;data sheets.;

Ensure that instruments, process analyzers and safety devicesEnsure that instruments, process analyzers and safety devices

are kept working properly during these processes;are kept working properly during these processes;

After operations with process fluid are brought completelyAfter operations with process fluid are brought completelyunder control, final stage of startunder control, final stage of start--up be attempted.up be attempted.


Preparing to introduce process fluidsPreparing to introduce process fluids


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Before introducing hazardous liquids into the plant, completeBefore introducing hazardous liquids into the plant, completeadditional pressure testing and purging;additional pressure testing and purging;

Check that the stresses and strains of dynamic testing has notCheck that the stresses and strains of dynamic testing has notcaused any leakscaused any leaks –– check and repair as needed.;check and repair as needed.;


Pressure testing and purgingPressure testing and purging


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Consists of pressuring and deConsists of pressuring and de--pressuring with nitrogen severalpressuring with nitrogen severaltimes, until at least


76/95


77/95

Start Up and InitialStart Up and InitialOperationOperation


Start Up and Initial OperationStart Up and Initial Operation


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Client takes ownership

Introduction of process fluidIntroduction of process fluid

StartStart--up and initial operationup and initial operation

TroubleTrouble--shooting and problemshooting and problem

correction.correction.

Plant taken to full operations.Plant taken to full operations.





Start Up LogicStart Up Logic


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It is common practice to buy in product and start up the lastIt is common practice to buy in product and start up the lastpast of the process first and work backwards to the front. E.g.past of the process first and work backwards to the front. E.g.

Start up units, get this working and in control;Start up units, get this working and in control;

Then possibly start up other systems as per startup plan;Then possibly start up other systems as per startup plan;

Finally, feed preparation.Finally, feed preparation.


Into the initial operationInto the initial operation


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Once raw materials are fed into the unitOnce raw materials are fed into the unit -- usually at reducedusually at reducedrate until operating pressures have been established;rate until operating pressures have been established;

As each section is started up, establish as quickly as possibleAs each section is started up, establish as quickly as possiblethat process conditions are as expected;that process conditions are as expected;

If potentially serious problems develop, there should be noIf potentially serious problems develop, there should be no

hesitation on going into an emergency shutdown.hesitation on going into an emergency shutdown.


Ramping up UnitRamping up Unit


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Unit is brought slowly to design flowUnit is brought slowly to design flow--rates and operatingrates and operatingconditions;conditions;

Usually done in steps with operating data evaluated andUsually done in steps with operating data evaluated andverified as OK at each step;verified as OK at each step;


Coordination and Supervision during start upCoordination and Supervision during start up


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Additional personnel, both supervisory andAdditional personnel, both supervisory and ““onon--thethe--groundground””are required at this stage;are required at this stage;

Cooperation between startup personnel and plant supervisoryCooperation between startup personnel and plant supervisorypersonnel is critical at this stage:personnel is critical at this stage:

Need a daily meeting.;Need a daily meeting.;

Brief each shift supervision on the day activities.Brief each shift supervision on the day activities.



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84/95

Performance and AcceptancePerformance and AcceptanceTrailsTrails


Performance and Acceptance TestingPerformance and Acceptance Testing


85/95




Performance trails;Performance trails; Formal Acceptance testFormal Acceptance test





The Performance TrailsThe Performance Trails


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Once the plant is fully operational, the finalOnce the plant is fully operational, the final ““proving trailproving trail”” ororperformance run is performed in order to prove the plant canperformance run is performed in order to prove the plant cando what it is supposed to do;do what it is supposed to do;

The values or range of values for each independent variableThe values or range of values for each independent variable --flow, temperature, pressure, level, concentrations, etc.flow, temperature, pressure, level, concentrations, etc.operating the plant must be as per operating design ;operating the plant must be as per operating design ;

The plant is brought up to those conditions and the preThe plant is brought up to those conditions and the pre--agreedagreedtrial period begins.trial period begins.


Before the trail or performance runBefore the trail or performance run

W d hW d h


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We need to ensure thatWe need to ensure that……

Control of plant operating conditions has been achieved. I.e.Control of plant operating conditions has been achieved. I.e.temperature, pressures, levels and analyses are reasonablytemperature, pressures, levels and analyses are reasonably

constant or in the case of a batch process, there isconstant or in the case of a batch process, there isrepeatability;repeatability;

Daily material and energy balanced can be performed and thatDaily material and energy balanced can be performed and thatthese agree withthese agree with ““officialofficial”” production figures;production figures;

Operation design and specifications are being achievedOperation design and specifications are being achievedconsistently.consistently.


Need to verifyNeed to verify ……..


88/95

Physical operation, capability and capacity of plant andPhysical operation, capability and capacity of plant andequipment;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.


AcceptanceAcceptance


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When the plant has met the Performance and Acceptance testWhen the plant has met the Performance and Acceptance testrequirements designed by the commissioning team there isrequirements designed by the commissioning team there isusually a formal acceptance process involving signing ofusually a formal acceptance process involving signing ofacceptance certificates;acceptance certificates;

Once the plant is accepted it is officially part of the normalOnce the plant is accepted it is officially part of the normaloperationsoperations -- the responsibility of operations and maintenance;the responsibility of operations and maintenance;

Commissioning is officially over;Commissioning is officially over;

The may still be outstanding punchlist itemsThe may still be outstanding punchlist items


Acceptance TestingAcceptance Testing


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It is common practice to prove performance repeatability andIt is common practice to prove performance repeatability andplant integrity as part of the performance test. That is:plant integrity as part of the performance test. That is:

Shutdown and Start Up the plant on several occasions andShutdown and Start Up the plant on several occasions andbring it up to test conditions to prove repeatability. Also rampbring it up to test conditions to prove repeatability. Also rampdown and ramp up while online;down and ramp up while online;

ReRe--inspection of critical process equipmentinspection of critical process equipment -- particularlyparticularly

columns to ensure they have not been damaged by thecolumns to ensure they have not been damaged by theperformance run.performance run.


Commercial Significant of AcceptanceCommercial Significant of Acceptance


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Formal Acceptance represents formal acknowledgment that theFormal Acceptance represents formal acknowledgment that the--

Contractor has fullContractor has full--filled their contractual obligations;filled their contractual obligations;

Commissioning team have fullCommissioning team have full--filled their obligations;filled their obligations;

Completion of the Capital Project and transfer to Operations;Completion of the Capital Project and transfer to Operations;

Expenses and costs from acceptance onwards are now operatingExpenses and costs from acceptance onwards are now operatingexpenses not capital project costs;expenses not capital project costs;

All subject to agreed punchAll subject to agreed punch--list items.list items.



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PostPost--CommissioningCommissioning


Client takes ownership of platformClient takes ownership of platform


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From plant onFrom plant on--stream to settled downstream to settled downand in regular production;and in regular production;

Adjustments, modifications and faultAdjustments, modifications and faultcorrection;correction;

Completion of outstanding punchlistCompletion of outstanding punchlistitemsitems


Client takes ownershipClient takes ownership


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Covers the period immediately after Acceptance;Covers the period immediately after Acceptance;

Outstanding punchOutstanding punch--list items are completed;list items are completed;

The first routine maintenance checks are performed, findingsThe first routine maintenance checks are performed, findingsevaluated and reported;evaluated and reported;

Process equipment and items covered by warranty areProcess equipment and items covered by warranty arescrutinized for signs of premature wearscrutinized for signs of premature wear--out or problems;out or problems;

Operating data is collected and evaluated to ensure consistentOperating data is collected and evaluated to ensure consistentplant operations are maintained and sustainable.plant operations are maintained and sustainable.



95/95

Back toBack to ““Business as UsualBusiness as Usual””


Commissioning Strategy

Documents

Transcript of Commissioning Strategy