Slide 1
Plant commissioning & start up procedure Slide 2
The Commissioning Process Key Stages • • • • • •
Preparation and planning Mechanical Completion and Integrity checking Pre-commissioning &Operational Testing Testing Start Up & Initial Operation Performance and acceptance testing Post Commissioning
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1. Preparatio Preparation n and planning planning • • • • • • • •
Appointment of Commissioning Manager or Lead Commissioning ngineer! Appointment of Commissioning Team Team Mem"ers and S#pport Staff! Training! Information Compilation! Safety and $isk Assessment! Commissioning Commissioning Strategy Development; Procedures and Checklist Checklist Development; %etailed Plan and #dget Preparation!
Slide 4
Commissioning Strategyt Strategyt L Facility Commissioning Issues • • • • •
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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* +a +ater* ter* 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 •
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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!
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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 completion • • • • • • •
t
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 $#n-Ins 2itrogen P#rge and Tightness Testing
Slide 12
Procedures •
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Proced#res are (ritten ro#tines.instr#ctions that descri"e the logical se,#ence of acti'ities re,#ired to perform a (ork process and the specific actions re,#ired to perform each acti'ity! If there are no (ritten proced#res* there is no "asis for monitoring performance* foc#s for impro'ement or mechanism "y (hich to capt#re learning!
The esta"lishment of proced#res and ro#tines allo( more time and mental energy to deal (ith the #ne0pected* (hich al(ays happen d#ring commissioning
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Slide 13
CommissioningStartup Logic •
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A Critical Path 2et(ork 3Plan4 (ith (ritten proced#res (ith related doc#ments are re,#ired These sho#ld define for the facility* each plant system) -----The order in (hich the systems (ill "e started #p! -----Indi'id#al acti'ities at each stage! -----Operation testing re,#irements! -----%#rations* (aiting times* cooling times! -----Total d#ration for starting #p each system! -----$eso#rces re,#ired - la"o#r* materials* e,#ipment* ser'ices! -----Temperat#res* press#res* fl#id flo(s #sed
Slide 14
CommissioningStartup 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* etc4! 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 • • • •
Slide 17 • • • • • • • •
Inspection Press#re testing Cleaning and 5l#shing Machinery checko#t
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 •
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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 mannerlide 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 , -intsTips • • • • •
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!
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Check all tag n#m"ers!
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P#nchlist any non-conformances de
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23
Pipe Stressing •
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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 •
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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
Slide 29
Piping and e"uipment supports •
Inspection after cool-do(n) Check that sliding s#pports ha'e ret#rned to original positions!
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sta"lish that e,#ipment can e0pand and contract as re,#ired
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Slide 30
Inspection o% spring supports •
efore hydro-testing)
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-----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! •
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----esta"lish that springs can a"sor" loads Slide 32
Slide 33
Inspection o% essels and Tan*s •
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•
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 - eg 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
Slide 35
Pressure Testing Slide 36 • • • • •
Press#re Testing - O"
Slide 37
Pressure Testing , responsi$ilities
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Press#re tests of tanks* reactors and piping for mechanical strength and tightness of
Slide 38
Pressure Testing , procedures •
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+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 •
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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 ( •
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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
Slide 41
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! • •
Cleaning and FlushingSlide 42
------8>#mper9spool pieces to allo( for contin#ity of flo( Slide 44 Flushing •
• •
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Can "e handled "y geographic plant area! Sections too large for (ater fl#shing) -----Pipes greater than ?@ in diameter 3@B 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 •
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$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!
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+ater 'elocities sho#ld "e at least D ft.sec 3appro0 ?B m.sec4!
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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 tilities 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 tilities , 2road 3uidelines •
Check s#pply press#res of all ser'ices - steam* cooling (ater* instr#ment air* nitrogen etc
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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!
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%rain condensate to (aste (ater #ntil is is clean 51
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• • • •
Commissioning tilities Introducing Steam • • • • •
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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 •
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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
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! •
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!lectrical SystemsSlide 54 Commissioning lectrical Systems The following checks are typical of what is required
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Check motor control and po(er circ#itry for correct hook#p Sl
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ide 55
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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
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• •
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 ar e 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
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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 •
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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
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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#"
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!
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• • •
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 •
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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 • •
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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 •
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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 • •
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%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!
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/eat #p the systems to sim#late operating conditions "y placing refl#0* re"oiler and condensation systems into .operation Slide 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 • •
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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 ar e 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 •
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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!
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+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 • •
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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 p 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 p 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 •
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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 TrailsSlide 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 that •
•
•
Control of plant operating conditions has "een achie'ed Ie 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
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 items Slide 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 (earo#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 •
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• • • • •
•
• •
•
• • • • • • • • • •
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
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
