Close-up look on plants Commissioning and Start up

By:Hassan Fallatah

Introduction

Hassan B. Fallatah

How Simple or Complex it is?

Plants Commissioning and Start up is a VERY complex process that requires:

• Talent & Competent Leadership.• Hard & effective Teamwork.• Proper Planning and execution.• Timely Communications and protocols. • Detailed Training.

Pyramid of Success

Project Parties Objectives

• EPC & PMT Teams:1.To finish plant construction.2.Leave project site as soon as possible.

Project Parties Objectives

• Commissioning and Start up Teams:1.To Learn the plant and the process.2.Check and Test the installed equipment.3.Confirm the plant will work as designed.4.Safely Commission the plant.5.Have a safe and successful Start up.6.Maintain steady & safe operation.

Achieving remarkable Commissioning and safe Start up

• Effectively estimate budget to avoid costly start up.• Factor organization goals into plans for a sustainable

operation. • Map the strategy in building an ideal start-up &

commissioning teams.• Consistently conduct a weekly joint walkthrough for all

project related parties.• Implement systematic monitoring and verification activities

throughout the project execution process.• Report all documentation data related to the project hand

over.• Meetings : (Daily – Weekly – Monthly)

OBSTACLES

• WHAT?• WHEN?• WHY?• HOW?

OBSTACLES EXAMPLES

• Mobilization for construction manpower. (Pro Welders) (NDT Technicians)

• Slow progress in concrete pre-casting.• Poor pipe spool fabrication progress.• Late delivery of steel structures.• Slow rate of mobilization for construction

manpower and labors strikes.• Interface progress.

OBSTACLES EXAMPLES

• Slow progress on pre-cast column/beam erection and cast-in-situ beams.

• Shortage of Argon gas.• Delivery of Piping Material (Pipe Fittings and

Flanges)• Low progress of hydro-testing due to low

production quantity of piping work.• Lack of operation manpower.

OBSTACLES EXAMPLES

• Schedules and milestones.• Ineffective procedures.• Risk of parallel activities (Hydro testing and

system punching).• Construction progress and systems handover.• Coordination between Commissioning and

construction groups.• Spare parts availabilities.

OBSTACLES ROOT CAUSES• Planning.• Design.• Installation.• Leadership.• Resources.• Work Quality.• Training.• Deliberate act of Sabotage.

KEYS FOR SUCCESS• ASSET OWNER ORGANIZATION:1. Overall planning.2. Supportive / Dynamic organization.3. Detailed operating and emergency procedures.4. Established standards and working practices.5. Competent personnel.6. Operator Training Simulator.7. Trained personnel.8. Resource planning.

KEYS FOR SUCCESS

• PLANT AND EQUIPMENT:1.Mechanical completion inspection.2.Commissioning procedures.3.Maintenance support.4.Prepared Q/C.5.Spare parts availability.

KEYS FOR SUCCESS

• PSSR.• Risk management & Risk assessment.• Licensors and Vendors support.• LERP & MERP & safety drills.• Updated Road Map plan.• EMP.• Identify Project Critical Paths.• Start- up Readiness review.

KEYS FOR SUCCESS• WATER OPERATION: 1.Confirm integrity and operational testing of

the equipment and Instruments.2.Provide operator training and familiarization

of the plant operation.3.Flush and clean all piping and vessels in order

to secure clean start up.4.Where applicable (SSC, Beds, dried systems).

OUTSTANDING EXAMLPE • PetroRabigh JV, Rabigh, Saudi Arabia.• 28 process units.• Mega project layout.• Independent power and steam supplier.• Massive petrochemical and refining complex.

High Olefins Fluid Catalytic Cracker (HOFCC)

HOFCC ALUMINUM PLATES

9” in

5” in

0.2 cm

HP STEAM TO MAIN AIR BLOWER