commissioning

1. Workshop on “Plant Commissioning and Start-Up Procedures” Dr. Himadri Banerji

MD EcoUrja Ex Reliance and Tata Organized By :

2. Standard Implementation Path is show here

3. The Commissioning Process Key State Preparation and planning Mechanical

Completion and Integrity checking Pre-commissioning & Operational Testing Start Up

& Initial Operation Performance and Acceptance testing Post Commissioning

4. The Commissioning Process Detail - 1 Preparation and • Appointment of

Commissioning planning Manager or Lead Commissioning Engineer Mechanical •

Appointment of Commissioning Team Completion Members and Support Staff and

Integrity checking • Training Pre-commissioning & • Information Compilation

Operational Testing • Safety and Risk Assessment Start Up & Initial • Commissioning

Strategy Operation Development; • Procedures and Checklist Performance and

Development Acceptance testing • Post Commissioning Post Commissioning •

Detailed Plan and Budget Preparation;

5. The Commissioning Process Details – 1Facility Commissioning Issues Time

phasing construction and commissioning activities Time phasing the commissioning of

the various parts of the plant relative to each other Relationships and timings

determining when various systems need to be available: Electrical, Steam, Water,

Instrumentation Sequencing of the overall plant startup and shutdown to ensure we do

not create unsafe conditions Initial start up Process Control and Shutdown

Performance testing

6. Developing Startup Procedures Engineering and construction companies generally

follow a systematic procedure where by their startup engineers review the process

design several times as it is developed After the first review, a preliminary start-up and

operations procedure is written Decide what must be added to the design to make the

process capable of being started up and operated; By the time the final engineering

flow-sheets have been released a complete startup and operating instructions manual

should have been completed.

7. Issues Considered Are various part of the process too depend on one another Is

there enough surge capacity Are there provisions to prevent abnormal pressures,

temperatures and rates of reaction Where are additional valves and bypass lines

needed Special lines to allow equipment to be started up and rerun product/raw

materials.

8. System Level Activities Utilities systems - steam, instrument air, process water, fire

water, drainage, condensate return Electrical systems Instrumentation and

instrumentation systems; Cleaning and flushing Purging Initial start up and shutdowns

Performance testing

9. Equipment Level Activities Pressure testing & mechanical integrity testing of vessel,

columns and pipe work. Heat Echanger, condensers, coolers etc. Mechanical

equipment and machinery. Control Systems and Instrumentation. Operational testing.

Proof testing and acceptance.

10. What can be done before mechanicalcompletion Utilities commissioning Lube and

Seal-Oil Systems Cleaned Instrumentation and Control Loops Proven Piping, Towers

and Vessels Cleaned Boil-Out, Dry-Out and Acid Cleaning Turbine, Motor and Pump

Run-Ins Nitrogen Purge and Tightness Testing

11. Building Organisational Learning Best Practice Benchmarking Improvement

Industry Processes Standards Corporate Procedures and Knowledge Base Check

sheets Legislation Experience Process Design Specific Machinery &Equipment

12. Procedures Procedures are written routines/instructions that describe the logical

sequence of activities required to perform a work process and the specific actions

required to perform each activity. If there are no written procedures, there is no basis

for monitoring performance, focus for improvement or mechanism by which to capture

learning. The establishment of procedures and routines allow more time and mental

energy to deal with the unexpected, which always happen during commissioning.

13. Commissioning / Startup Logic A Critical Path Network (Plan) with written

procedures with related documents are required. These should define for the facility,

each plant system: • The order in which the systems will be started up. • Individual

activities at each stage. • Operation testing requirements. • Durations, waiting times,

cooling times. • Total duration for starting up each system. • Resources required -

labour, materials, equipment services • Temperatures, pressures, fluid flows used.

14. BY DR.HIMADRI BANERJI MD ECOURJAEX. RELIANCE AND TATA Copyright

www.ecouja.com 15

15. Commissioning / Startup and Shutdown Issues At the facility, system and

equipment level, we want to avoid: • Creation/existence of explosive mixtures, usually

because of the presence of air. • Water hammer and water based explosion effects,

due to contact between water and hot substances (steam, oil, etc.) In particular, during

commissioning hot fluids and gases will be coming into contact with cold surfaces in

places that would be hot under normal operations.

16. Mechanical Completion and Integrity Checking

17. Mechanical Completion and Integrity Inspection Preparation and planning •

Inspection Mechanical Completion • Pressure testing and Integrity checking • Cleaning

and Flushing • Machinery checkout Pre-commissioning & Operational Testing Start Up

& Initial Operation Performance and Acceptance testing Post Commissioning

18. Categories of Process Equipment Distillation Towers / Fractionation Towers Re-

boilers & Other Shell & Tube Heat Exchangers Boilers and Fired Heaters Pressure

Vessels and Pipe-work Fin-Fan Coolers Condensers Machinery/Rotating Equipment

Valves Instrumentation Electrical Equipment

19. Machinery / Rotating Equipment Pumps Steam Turbines Gas Turbines

Compressors Gas Engines Electric Motors

20. Mechanical Completion and IntegrityInspection Involves checking that everything

has been built and it there as per specification. Refer: • Piping Plan Drawings • Layout

and construction drawings • P & ID’s Electrical systems, Instrumentation and control

systems checkout done by appropriately qualified personnel (Electricians and

Instrumentation technicians). General commissioning engineers generally do not get

involved in this in a hands-on manner.

21. Mechanical Completion and IntegrityInspection Procedure Divide plant into

manageable areas; In a large plant, assign individuals or teams to specific areas;

Establish a master set of piping plan drawings and P&ID’s, mark up areas: Individual

commissioning engineers or teams walk every line and mark up every item that can be

confirmed as present on master set of drawings. Use different colored “highlighter”

pens to indicate different services.

22. Mechanical Completion and Integrity InspectionEvery line must be walked!

Physically see every

23. Mechanical Completion and IntegrityInspection Procedure Hints / Tips Ensure

pipes, vessels, valves etc. are all in the right place. Valves are correct type - globe,

gate, control; Vents, drains, steam traps etc. Flanges, bolts, types of bolts. Blind

flanges and swing able blinds in place, correct rating. Check all tag numbers. Punch

list any non-conformances.

24. Pipe Stressing Piping should provide adequately for expansion and contraction

due to temperature changes, without placing excessive stresses on equipment;

Misalignment between matching flanges on pipe work particular where there are

changes indirection (elbows) can cause stressing; Misalignments where pipe-work

connects to machinery, vessels and other process equipment; Can often be seen

visually, or checked with gauges using the same procedures we use to align rotating

equipment.

25. Piping and Equipment Supports

26. Piping and equipment support Mobile supports permit and guide the thermal

growth of equipment undergoing temperature change; If they do not function correctly,

vessels, equipment, pipe work, nozzles heat exchangers etc. may be damaged.

27. Typical Piping Support Methods

28. Piping and Equipment Supports Inspection prior to start up: • Check that installed

according to specification and not jammed; Inspection during warm up: • Check

thermal growth is occurring and supports are responding as per design; • Check that

there is no surface buckling or crimping - this needs to be corrected; • Check

expansion joints; • Check long straight runs of piping for bowing or support shoe that

may have slipped; • Rule of thumb - bowing is excessive if you can see it.

29. Piping and Equipment Supports Inspection after cool-down: • Check that sliding

supports have returned to original positions; • Establish that equipment can expand

and contract as required.

30. Inspection of Spring Supports Before hydro-testing: • Check that spring stops are

installed. (If not, the weight of water in pipe will deform the spring). After hydro-testing

but before heating: • Check that stops are removed; • Check that spring pointer is

positioned to cold setting;

31. Inspection of Spring Supports During and at end of heating: • Check pointer has

not exceeded hot setting; After cool down: • check to establish piping can expand and

• establish that springs can absorb loads.

32. Vessels and Columns

33. Inspection of Vessels and Columns The inspection of vessels, columns and

reactors should be scheduled to be completed before construction has closed them

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

scheduled later; If a vessel has been sealed up by construction, it is your duty to

inspect it, even it construction resist.

34. Inspection of Vessels and Columns Check that distributors have been installed

correctly; De-misters installed correctly and of correct materials, design, type; Vortex

breakers in place; Trays - packed or “bubble-cap” are correct: • Bubble caps not

jammed or damaged, down comers clear, supports all OK.

35. Pressure Testing

36. Pressure Testing - Objectives The objective of pressure testing is to confirm the

mechanical integrity of the plant; Verifying capability of containing the pressures it has

been designed to hold; Ensure there are no leaks and verify that the plant can be

reliably made leak free; Identify any vulnerabilities well before the plant is placed into

service; Meet the requirements of legislation, local, international and industry

standards.

37. Pressure Testing – Responsibilities Pressure tests of tanks, reactors and piping for

mechanical strength and tightness of joints is usually done by the construction team;

Commissioning team representatives should witness and certify the tests; Need to

verify that all necessary safety precautions have been taken;

38. Pressure Testing - Procedures Water for testing and flushing should contain a rust

inhibitor - one low in chloride content for stainless steel lines; After testing, water

should be drained completely from all lines that do not normally carry water, steam or

steam condensate; All low points should be checked for presence of water; Lines

should be dried by blowing hot air, dry inert gas or instrument air.

39. Pressure Testing – Vacuum Systems Final checks of vacuum systems are best

performed by pulling a vacuum and observing the rate of pressure rise in the blocked

in system; Excessive leaks can then be located by applying a mild positive pressure

and testing each flange with bubble solution.

40. Pressure Testing – Procedures 2 Isometric drawings of all systems to be tested

should be displayed on a board and marked up as each section is tested; Hydro

testing of piping and equipment according to code requirements to confirm mechanical

strength should be carried out on groups of equipment naturally suggested by design

pressure and function; All water, steam, condensate, oil, gas and process steam

piping should be hydro tested; Major equipment that has already been tested as part

of manufacturing may be isolated by blanks.

41. Cleaning and Flushing

42. Cleaning and Flushing Need to ensure no construction debris is left in pipes of

vessels - welding rods, bolts, gloves, rags etc. Large debris (lumber, cable, packaging)

should have been removed during mechanical integrity inspections; Small debris

(rags, nuts, dirt) must be flushed out of all pipe and vessels; Where oil coatings must

be removed, chemical cleaning is necessary.

43. Cleaning and Flushing Before flushing is started, check the process thoroughly to

ensure: • Screens have been installed in front of pump suctions. • Blinds in front of

equipment such as compressors and turbines; • “Jumper” spool pieces to allow for

continuity of flow.

44. Flushing Can be handled by geographic plant area; Sections too large for water

flushing: • Pipes greater than 30 in diameter (0.75 m), or • Pipes that should not be

touched with water; Should all be blown out with air or inert gas.

45. Flushing Regardless of whether pipes are cleaned with water, steam, air or

nitrogen, flow velocities should be high enough to ensure that pipes will be suitably

scoured; Need to ensure that the debris from one piece of equipment will not simply be

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

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

46. Pre-Commissioning and Operational Testing

47. The Commissioning Process Detail - 3 Preparation and planning Mechanical •

Steam and other utilities Completion commissioned and introduced; and Integrity

checking • Dry running trials; • Hot running trials; Pre-commissioning & • Safe-fluid

dynamic testing; Operational Testing • Solvent dynamic testing; • Process fluid tests.

Start Up & Initial Operation Performance and Acceptance testing Post Commissioning

48. Commissioning Utilities

49. Commissioning Utilities Utilities commissioning usually represents the first phase

of commissioning, as these usually need to operational first, before the rest of the

plant can be commissioned; The steps for commissioning each utility should be

planned in detail; Provides planning practice for planning the startup of the main plant.

50. Commissioning Utilities – Broad Guidelines Check supply pressures of all services

- steam, cooling water, instrument air, nitrogen etc. At the most distant points, open

drains, vent valves or pipe flanges and purge until fluids come out clean and rust free;

Purge/blow out lines to each piece of equipment; Check that instrument air is clean

and dry, and at correct pressure; Circulate water to waste water system until water

lines clear and clean; Flush waste water and drain systems to ensure no blockages;

Check operation of steam traps; Drain condensate to waste water until is clean.

51. Commissioning UtilitiesIntroducing Steam Steam usually represents the

first “hazardous” fluid introduced into the “new” system; Admit steam slowly

into the distribution system with atmospheric bleeds open: • Cold pipes will

condense steam in places where it would not under normal operation; • Can

lead to “water hammer”- can distort and rupture lines; After system has been

warmed, slowly raise pressure and blow down the system with traps

bypassed, until clean; Then place steam traps into service and check

operation.

52. High Pressure Steam SystemsSpecific Issues The cleanliness and purity

of high pressure steam systems - particularly where the steam is used to

drive a steam turbine should be checked by use of a “target”; For new boilers,

or new sections added to steam system - blow down at full pressure; When

steam appears clean, fit a target with a “mirrored” surface (ie. Small steel

plate which has been polished, so that it is in the steam blow down stream;

Blow down the boiler or system so that the target is impinged upon for a few

minutes; Check target - ensure there are no small “pock marks” left on the

target. If pock marked - repeat process.

53. Electrical Systems

54. Machinery and System Check-Out Check-out A crew of specialized

individuals need to be mobilized to do the check-out and pre-commissioning

in a plant: • All control loops, settings of PID loops, stroking of valves,

transmitter calibration, etc… • P&ID conformity; is the plant built according the

P&ID, is all instrumentation correctly installed, are they connected, are all

valves correctly installed, etc… • Mechanical installation of all (major)

equipment; levelling correct, alignments done, oil flushing satisfactory, etc… •

Analyzer calibration, checking of tubing, problem assessment and

identification. • Control systems functional check, communications check,

integrity check, safety features checking, emergency stops check, critical

operating parameters checking, etc… • Electrical check-out; check-out of

MCC’s, switchgears, selectivity studies, protection systems, functional

checks, etc…

55. Commissioning Electrical SystemsThe following checks are typical of

what is required Open circuit breakers and switches; Check that all bus-bars

are free of dirt and foreign matter; Check grounding systems for continuity

and resistance. Make sure all electrical equipment, vessels, structures are

connected to the grounding system in accordance with drawings and

specifications; Check that all sealed fittings are filled with proper sealants, all

explosion proof, vapour-tight, dust-tight and weather tight enclosures are

properly closed and secured; Check motor control and power circuitry for

correct hookup.

56. Commissioning Electrical Systems – 2The Following checks are typical of

what is required Check all nameplates and panel directories to ensure that

each circuit breaker and switch does control the proper circuit. Label all

switches even though their application may seem obvious; Close main

transformer primary disconnect switch and switch-gear main circuit breaker;

Check voltmeter at switch-gear for proper voltage; Close first switch-gear

circuit breaker, second, third etc. Close first motor control centre main circuit

breaker, then each motor starter circuit breaker. Repeat for each MCC.

Check overload breakers and heaters to ensure that the correct capacity

units have been installed.

57. Commissioning Electrical Systems – 3The following checks are typical of

what is required Check that all lighting and power circuits are functioning

correctly; Check motor bearings for proper lubrication; Remove motor power

fuses and check main contractor, interlock and sequencing devices;

Uncouple each motor, replace fuses and check direction of rotation by

momentarily pressing the start button, then stop; Check manual, then

automatic operation. Replace all couplings, check drive belts and make sure

guards are installed.

58. Electric Motor Driven Pumps

59. Operational Testing

60. Operational Testing Progresses through several stages; Dry runs of

individual items of equipment Hot testing of individual items of equipment and

systems; Several stages of Dynamic Testing of: • Individual items of

equipment; • Individual Systems/processes in isolation; • The whole new

process plant installation.

61. Dry Runs and Hot Tests Check that motors are connected correctly and

turn in the right direction; Shafts and impellers move freely; Equipment that is

to be operated at temperature, raise to temperature and check; These tests

should be performed by the manufacturer’s representative but witnessed by

members of the client’s operating/commissioning personnel.

62. Hot Testing Equipment Applies to equipment whose leak-tightness must

be tested at operating temperatures and after temperature reversals; Fixed-

bed catalytic reactors that in normal conditions are heated by heat transfer

fluids where leakage would contaminate the catalyst; Critical exchangers

whose steam or cooling water is at a high pressure than the process fluid;

Any equipment having complicated seals through which leakage could occur;

Rotating machinery which must be able to rotate freely at temperature eg.

Steam turbines, etc.

63. Hot Testing Procedures The thermal shock tolerance of equipment must

be determined beforehand; To avoid thermal shock, the temperature of the

heating medium may have to be raised gradually; Time required for a hot test

must be established in advance; Establish a uniform temperature in all parts

of equipment that are supposed to be uniformly hot during operation to avoid

setting up stresses;

64. Dynamic Testing

65. Dynamic Testing Involves operating the equipment, before introducing

“live” process fluid; During dynamic testing, we progress through: • Safe-fluid

dynamic testing; • Dynamic testing with solvent; • Closed loop testing with

process fluid. Once process fluid is introduced, normal plant safety

procedures must come into effect as if it were a live operating plant.

66. Safe-Fluid Dynamic Testing Closed loop dynamic testing with safe fluids

consists of operating equipment systems with air, water, inert gases etc. This

permits flow testing of equipment; Gives first indication of how control loops

work; Establishes performance while there is still time to modify the plant;

Familiarizes operators with the operation of the equipment before hazardous

materials are introduced; Gets rid of a lot of dirt which would be more difficult

to Clear once the process fluid has been introduced.

67. General Principles for Testing For most plants, a period of 2-3 weeks is

usually sufficient for operational testing, after the mechanical dry running of

individual pieces of equipment and hot testing complete; Air and water tests

should be set up in a closed loop with fluids continuously recycled, with loops

as large as possible; The loop should ideally be the same loop that will be

subject to solvent testing; Tests should continue for several days in order to

give all shifts a chance to conduct the same tests; All shifts should be given

the opportunity to start up and shutdown each closed loop test.

68. General Principles for Testing A rough flow-sheet should be developed

for air and water tests, predicting all information that normally appears on a

process flow sheet - flow, temperature, pressure, heat transfer, power etc. will

assist in alerting commissioning team for risks from over- pressuring, over

loading temperature-shocking and stressing equipment;

69. Cautions During Testing Dynamic testing may lead to: • Unusual or

unforeseen differential expansions; • Corrosion • Excessive weight of liquid

into parts of the system; Care must be taken not to collapse or burst pressure

vessels and tanks: • ensure there is always adequate venting; • avoid pulling

a vacuum.

70. Dynamic Testing – Simulated OperationsSafe Fluid Testing Auxiliary

services must be brought into operation first: • water cooling, inert gas

generators, boiler feed water, firewater, steam production, etc. Water is

pumped through the process (except where special conditions do not permit

it) and boiled up in columns; Compressors and blowers should be operated

on air or inert gas.

71. The Value of Dynamic Testing –Simulated Operations Value of simulated

operations will be to allow operator to become familiar with the operation of

the process, before hazardous fluids are introduced; Equipment deficiencies

can become apparent during dynamic testing; Failures and problems more

easily corrected with safe fluids present Leaks should be found and

tightened; Instruments can be placed into service - although selection of set-

points will have to be deferred; Inspect the plant for evidence of design and

construction errors.

72. Dynamic Testing – Simulated Operations

73. Dynamic Testing with a Solvent After safe fluid testing and subsequent

repairs and modifications, we are ready for dynamic closed loop testing with a

solvent; The “solvent” is a relatively safe fluid whose properties are close to

that of the process fluid, or the process fluid itself; In order to allow for

continuous re-circulation of the solvent and the use of different solvents in

different parts of the plant, temporary lines will need to be installed.

74. Dynamic Testing with Process Solvent Introduce the process solvent. (if

there is more than one, introduce only one at this stage); The dynamic testing

procedure used for the safe fluid test is repeated for the process solvent

dynamic testing; After operations with the first solvent have been brought

completely under control, should the second solvent be introduced (if there is

one).

75. Dynamic Testing with a Solvent The purpose of dynamic testing with a

solvent is to check out equipment and instrument loops at, or near design

conditions prior to the introduction of more hazardous process fluid; No

reactions should be allowed to occur during these tests, so as to ensure that

test fluids remain predictable in composition and properties; Guidelines used

for safe-testing apply; Need to plan how solvent will be fed into the system

and later removed.

76. Stages of Dynamic Testing with a “Solvent” Drain safe fluid and purge air

used in the previous test from the system; Dry out equipment where safe fluid

was water. Check flow sheets for where water is likely to accumulate. Fill

systems with the solvent. Ensure provisions made for venting and drains

closed; When adequate levels established, place pumps and compressors

online to complete filling; Start closed loop circulation; Heat up the systems to

simulate operating conditions by placing reflux, re-boiler and condensation

systems into operation

77. Stages of Dynamic Testing with a “Solvent” Systematically check out

instrumentation and control loops; After instruments have checked out, place

as many as possible on automatic control; All shifts should go through

starting and stopping equipment, heating and cooling closed loop systems;

Dynamic “solvent "testing offers the best opportunity for operator training

before the “real thing”; Operate equipment as near as possible to design

capacities; Reliability of emergency shutdown systems and alarms must be

proven; Critical instruments must be calibrated over their full range.

78. Stages of Dynamic Testing with a “Solvent” Deliberately operate

equipment near its limits: Flood columns; Ease compressors into mild surges

and plot surge curves; Overload condensers; Do not fear blowing a relief

valve or two! After tests have been completed, plant should be ready for initial

operation.

79. Closed Loop Dynamic Testing with Process Fluid Finally, introduce

process fluid; During this step, instruments should be calibrated to cover their

full range of flow, temperature and pressure; Ensure that instruments,

process analysers and safety devices are kept work properly during these

processes; After operations with process fluid are brought completely under

control should the final stage of start-up be attempted.

80. Preparing to Introduce Process Fluid Before introducing hazardous liquids

into the plant, we complete additional pressure testing and purging; Need to

check that the stresses and strains of dynamic testing has not caused any

leaks – these must be found and fixed;

81. Pressure Testing and Purging Consists of pressuring and de-pressuring

with nitrogen several times, until at least <3% oxygen is reached; Vacuum

systems should be evacuated and then re-pressured with nitrogen; Long runs

of piping are swept with nitrogen; While under pressure, rate of pressure loss

of the “blocked in "system is monitored as a check for leaks and that no vents

or drains have been left open.

82. Dehydrating by Circulation It is usually not possible to water-free

equipment simply by draining; Only positive method to water-free process

equipment is oil circulation followed by repeated draining of low points;

Ensure sufficient low point drains are provided on piping, control valve loops,

vessels and process machinery; Startup lines - deliver oil to upper part (trays)

of distillation towers (size for 20% of net distillate product rate);

83. Start Up and Initial Operation

84. Preparation and planningMechanical Completionand Integrity checking

Pre-commissioning & Operational Testing • Introduction of process fluid •

Start-up and initial operation • Trouble-shooting and Start Up & Initial

Operation problem correction. • Plant taken to full operations. Performance

and Acceptance testingPost Commissioning

85. Most plants in petrochemical/chemical industry have the following

“general ”form. Feed Reaction Recovery Product Preparation refiningStart Up

from the End of the Process and Work back

86. Start Up Logic It is common practice to buy in product and start up the

last past of the process first and work backwards to the front. E.g. • Start up

refining, get this working and in control; • Then possibly start up reaction and

recovery; • Finally, feed preparation.

87. Into the Initial Operation Once raw materials are fed into the plant –

usually at reduced rate until reaction conditions have been established; As

each section is started up, establish as quickly as possible that process

conditions are as expected; If potentially serious problems develop, there

should be no hesitation on going into an emergency shutdown.

88. Ramping up the Plant Plant is brought slowly to design feed-rates and

operating conditions; Usually done in steps with operating data evaluated and

verified as OK at each step; Plant and laboratory data are now being

collected and should be being evaluated promptly;

89. Coordination and SupervisionDuring Start Up Additional personnel, both

supervisory and “on the- ground” are required at this stage; Cooperation

between startup personnel and plant supervisory personnel is critical at this

stage: • Need a daily meeting at least; • Often, a briefing each shift.

90. Trouble Shooting At this stage, many problem with equipment of the

process itself may become apparent; The commissioning process goes

through what is often an intense (and hopefully short) period of problem

trouble shooting, problem solving, engineering correction and plant

modification;

91. Performance and Acceptance Trails

92. Preparation and planning Mechanical Completionand Integrity

checkingPre-commissioning & Operational Testing Start Up & Initial

Operation Performance and • Performance trails; Acceptance testing • Formal

Acceptance testPost Commissioning

93. The Performance Trials Once the plant is fully operational, the final

“proving trial” or performance run is performed in order to prove the plant can

do what it is supposed to do; The values or range of values for each

independent variable - flow, temperature, pressure, level, concentrations, etc.

to which the plant must be operated to are determined; The plant is brought

up to those conditions and the pre- agreed trial period begins.

94. Before the Trails of Performance RunNeed to Ensure that… Control of

plant operating conditions has been achieved. I.e. temperature, pressures,

levels and analyses are reasonably constant or in the case of a batch

process, there is repeatability; Daily material and energy balanced can be

performed and that these agree with “official” production figures; Product

specifications are being achieved consistently.

95. Need to Verify … Physical operation, capability and capacity of plant and

equipment; Energy and mass balance; Process chemistry; Efficiencies, yields

and quality; All to specification.

96. Acceptance When the plant has met the Performance and Acceptance

test requirements designed by the commissioning team there is usually a

formal acceptance process involving signing of acceptance certificates; Once

the plant is accepted it is officially part of the normal operations - the

responsibility of operations and maintenance; Commissioning is officially

over; The may still be outstanding punchlist items

97. Acceptance Testing It is common practice to prove performance

repeatability and plant integrity as part of the performance test. That is: •

Shutdown and Start Up the plant on several occasions and bring it up to test

conditions to prove repeatability. Also ramp down and ramp up while online; •

Re-inspection of critical process equipment - particularly columns to ensure

they have not been damaged by the performance run.

98. Commercial Significant of Acceptance Formal Acceptance represents

formal acknowledgment that the: • Contractor has full-filled their contractual

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

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

costs from acceptance onwards are now operating expenses not capital

project costs; All subject to agreed punch-list items.

99. Post-Commissioning

100. Preparation and planning Mechanical Completionand Integrity

checkingPre-commissioning & Operational Testing Start Up & Initial • From

plant on-stream to settled down Operation and in regular production;

Performance and • Adjustments, modifications and fault Acceptance testing

correction; • Completion of outstanding punch listPost Commissioning items

101. Post Commissioning Covers the period immediately after Acceptance;

Outstanding punch-list items are completed; The first routine maintenance

checks are performed, findings evaluated and reported; Process equipment

and items covered by warranty are scrutinized for signs of premature wear-

out or problems; Operating data is collected and evaluated to ensure

consistent plant operations are maintained and sustainable.

102. BY DR.HIMADRI BANERJI MD ECOURJAEX. RELIANCE AND TATA

Copyright www.ecouja.com 103

103. WORKSHOP ON PLANT START UP AND

COMMISSIONINGSEQUENTIAL START UPAUTOMATION IN PLANT

START UP AND COMISSIONINGBY DR. HIMADRI BANERJI(EX RELIANCE

AND TATA)www.ecourja.com BY DR.HIMADRI BANERJI MD ECOURJA EX.

RELIANCE AND TATA Copyright www.ecouja.com 104

104. Automation for Controlled Start Up To advocate the usage of process

integration in industrial practice, it is important to be able to guarantee not

only robust control during near steady state operation, but also to provide

procedures for generating fast and reliable start-up sequences. BY

DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright

www.ecouja.com 105

105. Sequential Start Up and Shutdown UsingAutomation in Plant…Burner

Management System1. Burner Management System in Power Plants General

The Burner Management System must be designed to ensure a safe, orderly

operating sequence in the start-up and shutdown of fuel firing equipment and

to reduce possible errors by following the operating procedure. The system is

intended to protect against malfunction of fuel firing equipment and

associated systems. The safety features of the system shall be designed to

provide protection in most common emergency situations, however, the

system cannot replace an intelligent operators reasonable judgment in all

situations. In some phases of operation, the BMS shall provide permissive

interlocks only to insure safe start-up of equipment. Once the equipment is in

service, the operator must follow acceptable safe operating practices. BY


www.ecouja.com 106

106. Sequential Start Up…BMS FunctionsThe BMS shall be designed to

perform the following functions:1.Prevent firing unless a satisfactory furnace

purge has first been completed.2. Prohibit start-up of the equipment unless

certain permissive interlocks have first been completed.3. Monitor and control

the correct component sequencing during start-up and shutdown of the

equipment.4. Conditionally allow the continued operation of the equipment

only while certain safety interlocks remaining satisfied.5. Provide component

condition feedback to the operator and, if so equipped, to the plant control

systems and/or data loggers.6. Provide automatic supervision when the

equipment is in service and provide means to make a Master Fuel Trip (MFT)

should certain unacceptable firing conditions occur.7. Execute a MFT upon

certain adverse unit operating conditions. BY DR.HIMADRI BANERJI MD

ECOURJA EX. RELIANCE AND TATA Copyright www.ecouja.com 107

107. Furnace Explosions A common cause of furnace explosions is “Fuel

leakage into an idle furnace and the ignition of the accumulation by a spark or

other source of ignition”. Proper attention to the design of the interlocks and

trip system to provide a safe light up of the boiler furnace is required. BY


www.ecouja.com 108

108. Furnace Purge…Permissives Before any fuel firing is permitted, either

initially or after a boiler trip, a satisfactory furnace purge cycle must be

completed. Prior to starting a furnace purge cycle, the operator must ensure

that the following purge requirements are satisfied[i]: 1. Drum level within

operating range (not high, not low) 2. Instrument air header pressure within

operating range 3. Fan is in service 4. Purge airflow capable of a minimum of

70% of the full load airflow established through the unit[ii]. BY DR.HIMADRI

BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright

www.ecouja.com 109

109. Furnace Purge…Permissives 5. All flame scanners reading "No Flame“

6. Natural gas block valves are proven closed 7. Fuel oil block valves are

proven closed 8. Air dampers are in the fully open position 9. Natural gas, or

fuel oil, header pressure upstream of block valve is satisfactory 10. Pilot gas

header pressure is satisfactory 11. Burner Control System is energized 12. A

"No Master Fuel Trip condition" condition is established BY DR.HIMADRI


www.ecouja.com 110

110. Pre Purge Permissives Pre purge permissive condition checks and

furnace purge are to be initiated by the operator from the local BMS panel

(you may see detailed guidelines on cold starting using fuel oil, cold starting

using natural gas from operating manuals). Purge air flow: The total furnace

airflow shall not be reduced below the purge rate airflow (70% of the

maximum continuous airflow capacity). Reducing airflow below these limits

will lead to a MFT, and a new furnace purge will be required. Suggested color

design: Purge Permissives indicating lights: white Purge Available indicating

light: green Purge in progress indicating light: amber Purge complete

indicating light: white MFT reset indicating light: red BY DR.HIMADRI


www.ecouja.com 111

111. Main Flame Start-Up Sequence The main flame start-up sequence, from

the lighting the of the pilot flame through main flame light-off, is an automated

sequence. Once the start-up sequence has begun, only the “BOILER STOP”

switch and the “EMERGENCY STOP” will interrupt the start-up sequence.

Any interruption of the start-up sequence requires a post-fire purge prior to

attempting to start the boiler again. To initiate the start-up sequence, the

operator activates the “START BOILER” switch. BY DR.HIMADRI BANERJI

MD ECOURJA EX. RELIANCE AND TATA Copyright www.ecouja.com 112

112. Pilot Flame Light-Off Before the burner can be started, satisfactory light-

off conditions for the pilot and main burners must be met. This is

accomplished when the following conditions are satisfied: For the pilot igniter:

1. MFT relay reset 2. Pilot gas header pressure normal For natural gas: 1. All

of the above mentioned for the pilot igniter 2. Natural gas pressure normal 3.

Natural gas control valve is in light-off position BY DR.HIMADRI BANERJI

MD ECOURJA EX. RELIANCE AND TATA Copyright www.ecouja.com 113

113. Pilot Flame Light-Off For fuel oil: 1. All of the above mentioned for the

pilot igniter 2. Oil gun is in place in the burner 3. Oil pressure is normal 4.

Fuel oil atomizing interlocks are satisfied 5. Fuel oil atomizing medium is

provided to the burner 6. Oil control valve is in light-off position Other

Conditions: 1. No MFT condition after purge 2. All flame scanners report no

flame 3. All natural gas, or all fuel oil, block valves shown closed 4. All air

dampers are in light-off position BY DR.HIMADRI BANERJI MD ECOURJA

EX. RELIANCE AND TATA Copyright www.ecouja.com 114

114. Pilot Flame Light-Off Failure to meet any of these conditions shall

prevent the burner light-off operation. To light the pilot flame, the pilot header

vent valve, and, for natural gas fuel, the natural gas vent valve shall be

closed by the boiler control system. Then, sequentially, the igniter transformer

is energized, the pilot gas block valves are open and a 10 second pilot

ignition timer starts counting down. When ignition timer cycle is completed,

the igniter transformer is de-energized and the pilot flame scanner is checked

by the control system. If the pilot flame is present, the main flame light-off

sequence continues. BY DR.HIMADRI BANERJI MD ECOURJA EX.


115. Pilot Flame Light-Off If the pilot flame fails, the boiler control system

initiates a pilot flame failure shutdown. Additional attempts of pilot light-off are

permissible provided a successful pilot light-off is made within 10 minutes

after the furnace purge. Note that if the pilot flame continues to fail after

several attempts, the boiler should be inspected to determine the fault and

the condition corrected. BY DR.HIMADRI BANERJI MD ECOURJA EX.


116. Main Flame Light-Off Once the pilot flame is made, the boiler control

system opens the header block valves for the selected fuel. A main flame

light-off timer begins a 15 second countdown for natural gas, or 20 seconds

for fuel oil, to establish and stabilize the main flame. At 5 seconds before time

out, the boiler control system closes the pilot block valves and opens the pilot

vent valve. The remaining 5 seconds are used to detect the main flame. For

the typical dual flame scanner design, a main flame failure shutdown is

initiated if both flame scanners return a “no flame” signal to the burner control

system. This will generate a boiler trip, and another furnace purge will be

required. Once the burner is lit, the system is in the NORMAL RUN

CONDITION and combustion controls should be released to modulation

control BY DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND

TATA Copyright www.ecouja.com 117

117. Shutdown Shutdown Per NFPA 8501, section 6-2.4.5, “The normal

shutdown cycle for the boiler shall accomplish the following in the order listed:

(a) Shut off fuel supply to the main burner. (b) Interrupt spark and shut off fuel

supply to igniters, if in operation. (c) For oil: 1. Where used, open the

recirculating valve. 2. Shut off atomizing medium, if desired. (d) For gas, vent

piping between safety shutoff valves to atmosphere. (e) Perform a post purge

of the boiler furnace enclosure. (f) Shut down fan, if desired.” For a safety

shutdown, a manual reset is also required. Normal Boiler Shutdown A normal

shutdown is initiated by operating BOILER SHUTDOWN switch. This will

initiate the shut down sequence listed above. BY DR.HIMADRI BANERJI MD

ECOURJA EX. RELIANCE AND TATA Copyright www.ecouja.com 118

118. Boiler Master Fuel Trip Any of the following conditions shall cause a

boiler trip to occur. This results in the shutdown of all fuel and requires

another furnace purge cycle before any attempt at re-lighting. For fuel oil: 1.

Excessive steam pressure. 2. Low water level. 3. Low fuel pressure. 4. Low

oil temperature. 5. Loss of combustion air supply. 6. Loss of flame. 7. Loss of

control system power. 8. Loss of atomizing medium, if used. BY DR.HIMADRI


www.ecouja.com 119

119. Boiler Master Fuel Trip For natural gas: 1. Excessive steam pressure or

water temperature. 2. Low water level. 3. High or low gas pressure. 4. Loss of

combustion air supply. 5. Loss of flame. 6. Loss of control system power. BY


www.ecouja.com 120

120. Boiler Master Fuel Trip In the event of an MFT, the control system shall

initiate the following: 1. Execute a shut down as listed above. 2. Illuminate the

appropriate indicator lights and alarms. 3. Return the system to the pre-purge

state Boiler restart will be inhibited until all pre-purge requirements are

satisfied. BY DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND

TATA Copyright www.ecouja.com 121

121. Alarms The following is a list of recommended alarm conditions: 1. Any

boiler or burner trip signal 2. High or low water level 3. High furnace pressure

4. Partial Loss of flame (For the typical two scanner system, one indicates “no

flame”) 5. Main fuel shutoff valves closed 6. Loss of control system power 7.

Unsuccessful burner shutdown BY DR.HIMADRI BANERJI MD ECOURJA

EX. RELIANCE AND TATA Copyright www.ecouja.com 122

122. Interface with the CombustionControl System (CCS) The following list, at

a minimum, of signals should be sent to the Combustion Control System: 1.

Controls to purge position 2. Controls to light-off position 3. Normal run

condition: release controls to modulation 4. Main natural gas block valve

open: permissive to place gas control valve in automatic. 5. Master fuel trip:

run boiler load to zero and place combustion controls in manual. 6. Oil

recirculation signal Under the provisions of NFPA 8501, section 6-5.2.3, for a

single burner boiler, the BMS and CCS may reside in the same processor.

This option can reduce the integration complexity and increase the BMS to

CCS interface reliability. BY DR.HIMADRI BANERJI MD ECOURJA EX.


123. Operator Interface The above describes a traditional operator interface

using discrete switches and indicator lights. The control designer is

encouraged to incorporate a graphical user interface or similar options in

order to enhance the ease of use and readability of the boiler control system

operator interface Workshop on Start Up and Commissioning Dr. Himadri

Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com

124. SEQUENTIAL START UP AUTOMATION DESIGN PRINCIPLES OF

BURNER MANAGEMENT SYSTEM Workshop on Start Up and

Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata

www.ecourja.com

125. Design Principles of Sequential Start-Up…Case Study in Burner

Management System Design Introduction Burner Management System

Objectives BMS Design Standards and Definitions BMS Logic BMS

Strategies and Hardware ◦ Types of Burner Management Systems BMS

Interface to SCADA Systems Summary Workshop on Start Up and


www.ecourja.com

126. IntroductionBurnerManagementSystems....a starting point. Workshop on

Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance

and Tata www.ecourja.com

127. Introduction What is a BMS? A Burner Management System is defined

as the following: ◦ A Control System that is dedicated to boiler safety,

operator assistance in the sequential safe starting and stopping of fuel

preparation and burning equipment, and the prevention of mis-operation of

and damage to fuel preparation and fuel burning equipment. 1 1. From NFPA

8501 “Standard for Single Burner Boiler Operation” Workshop on Start Up

and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata

www.ecourja.com

128. Burner Management Objective Sequence burner through safe start-up

Insure a complete pre-purge of boiler Supervise safety limits during operation

Supervise the flame presence during operation Sequence a safe shutdown at

end of cycle Integrate with combustion control system for proper fuel and air

flows Workshop on Start Up and Commissioning Dr. Himadri Banerji MD

EcoUrja, Ex Reliance and Tata www.ecourja.com

129. BMS Design Standards Each Burner Management System should be

designed in accordance with the below listed guidelines to control and

monitor all sequences of the start-up and shutdown of the burner ◦ National

Fire Protection Association (NFPA 8501 /8502 or others) ◦ Industrial Risk

Insurers (IRI) ◦ Factory Mutual loss prevention guidelines o Each burner

management system should be designed to accomplish a safety shutdown in

the event of an unsafe condition. (FAIL SAFE) Workshop on Start Up and


www.ecourja.com

130. BMS Design Standards U.S. National Fire Protection Association

(NFPA) ◦ Governs safety system design on virtually all boilers (regardless of

the process to be used to combust the fuel) ◦ Requires the separation of the

Burner Management System from any other control system ◦ Requires the

use of a hardwired backup tripping scheme for microprocessor based

systems ◦ Requires that a single failure NOT prevent an appropriate

shutdown ◦ Factory Mutual loss prevention guidelines. Workshop on Start Up


www.ecourja.com

131. NFPA 8501 NFPA 8501 Standard for Single Burner Boiler Operation ◦

Single Burner Boilers with fuel input greater than 12.5 mBTU/Hr (Approx. 250

BHP) ◦ Single Fuel or Combination of Fuels (Common being Natural Gas /

No.2 Oil / No. 6 Oil) ◦ Simultaneous Firing Workshop on Start Up and


www.ecourja.com

132. NFPA 8502 NFPA 8502 Standard for Prevention of Furnace

Explosions / Implosions in Multiple Burner Boilers ◦ Multiple Burner Boilers

with fuel input greater than 12.5 mBTU/Hr ◦ Single Fuel or Combination of

Fuels including Pulverized Coal ◦ Emphasis on implosion protection (larger

boilers with induced draft systems) Workshop on Start Up and


www.ecourja.com

133. BMS Definitions Furnace Explosions ◦ “Ignition of accumulated

combustible mixture within the confined space of a furnace or associated

boiler passes, ducts, and fans that convey gases of combustion to the stack”1

◦ Magnitude and intensity of explosion depends on relative quantity of

combustibles and the proportion of air at the time of ignition 1. From NFPA

8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner

Boilers” Workshop on Start Up and Commissioning Dr. Himadri Banerji MD


134. BMS Definitions Furnace Explosions can occur with any or a

combination of the following:1 ◦ Momentary loss of flame followed by delayed

re-ignition ◦ Fuel leakage into an idle furnace ignited by source of ignition

(such as a welding spark) ◦ Repeated Light-off attempts without proper

purging ◦ Loss of Flame on one Burner while others are in operation ◦

Complete Furnace Flame-out followed by an attempt to light a burner 1. From

NFPA 8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner

Boilers” Workshop on Start Up and Commissioning Dr. Himadri Banerji MD


135. BMS Definitions Furnace Implosions ◦ More common in large Utility

Boilers ◦ Caused by any of the following: Malfunction of equipment regulating

boiler gas flow resulting in furnace exposure to excessive induced draft fan

head capability Rapid decay for furnace gas temperature and pressure due to

furnace trip 1. From NFPA 8502 “Prevention of Furnace Explosions /

Implosions in Multiple Burner Boilers” Workshop on Start Up and


www.ecourja.com

136. BMS Basic Definitions Common Terminology ◦ Supervised Manual

Manual Burner Light-off with Interlocks ◦ Automatic Recycling (Single Burner

Only) Automatic Burner Start and Stop based on preset operating range (ie..

Drum pressure) ◦ Automatic Non Recycling (Single Burner Only) Automatic

Burner Start and Stop based on Manual command to start. Workshop on



137. Types of Flame Scanners Infrared (IR) Detectors ◦ Single Burner

Applications ◦ More Suitable with Oil Burning Flames Ultra-Violet (UV)

Detectors ◦ Multiple Burner Applications ◦ More Suitable for Gas Burners and

Combination Gas / Oil Burners Self Check Scanners ◦ Flame Signal is

interrupted at set intervals to verify proper operation of scanner Workshop on



138. Single Burner BMS Inputs Low Low Drum Level (D) High Steam

Pressure (D) (D) Purge Purge Air Flow Minimum Air Flow (D) (D) Limits Made

Flame / No Flame Hold to Purge SCRL RESET MO DE BURNER FUEL

SELECT FD FAN OFF ON GAS OIL HAND OFF AUTO (D) Fuel Oil Temp

Low Fuel Oil Temp High (D) (D) Fuel Oil Press Low Fuel Oil Flow (A) (D)

Atomizing Medium Flow > Min Atomizing AE TE (D) Medium Common Alarm

Output Press Low (D) Remote Annunciator (By Others) FEEDWATER PSH

PSL STEAM PT PSH FT IGNITER Safety Shut Off GAS LSLL & Vent Valves

LSLL Fuel Fuel Gas Gas FT PSL TSH TSL FS Press Press Low High (D) (D)

PSL PSL OIL Safety Shut Off Control Valves Valve ATOMIZING Control

Valve & MEDIUM Shut Off Valve (D) - Descrete Signal Used By Flame

Safeguard System FT PSL PSH GAS Safety Shut Off & Control Vent Valves

Valve Workshop on Start Up and Commissioning Dr. Himadri Banerji MD


139. BMS Logic Burner Management Systems can be broken down into

“Interlock Groups” Typical BMS Interlock Groups: ◦ Boiler Purge ◦ Igniter

Header Valve Management ◦ Main Fuel Header Valve Management ◦ MFT

(Master Fuel Trip) Logic Workshop on Start Up and Commissioning Dr.

Himadri Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com

140. Purge Interlocks BOILER TRIPPED AND PURGE / RESET PB START-

UP TIMER START FD FAN PERMISSIVES SATISFIED: - MAIN FUEL

VALVES CLOSED - NO FLAME PRESENT - FD FAN RUNNING AND -

MINIMUM AIR FLOW SWITCH MADE - WATER LEVEL SATISFACTORY -

ATOMIZING MEDIUM ON - FUEL SUPPLY PRESSURE NOT LOW

ENERGIZE FUEL RELAY NOT AND PURGE SIGNAL TO CCS PURGE AIR

FD DAMPER IN FLOW SWITCH AND FULL OPEN MADE POSITION

PURGE TIMER SET PURGE COMPLETE NO YES REMOVE PURGE TO

CCS SYSTEM TRIP Workshop on Start Up and Commissioning Dr. Himadri

Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com

141. Igniter Interlocks PURGE COMPLETE AIR DAMPER IN LOW FIRE

FUEL VALVE IN LOW FIRE AND POSITION POSITION ENERGIZE

IGNITER AND IGNITER HEADER VALVES 10 SECOND DELAY 10 SEC

PILOT TRIAL FOR IGNITION TIMER COMPLETE FLAME PROVEN NOT

AND SYSTEM TRIP PERMIT FOR MAIN FLAME Workshop on Start Up and


www.ecourja.com

142. Main Flame Interlocks IGNITER TIMER COMPLETE FLAME AND

PROVEN ENERGIZE MAIN FUEL VALVES 10 SEC MAIN FLAME TRIAL

TIMER COMPLETE NOT AND DE-ENERGIZE IGNITION COMPONENTS

RELEASE TO MODULATE TO CCS SYSTEM TRIP Workshop on Start Up


www.ecourja.com

143. Single Burner Main Fuel Trip FOR OIL: FOR GAS: - LOWFUEL

PRESSURE - LOWFUEL GAS PRESSURE - LOWTEM PERATURE

(HEATED OILS) - HIGH GAS PRESSURE - LOSS OF COM BUSTION AIR -

LOSS OF COM BUSTION AIR - LOSS OF FLAM OR FAIL TO ESTABLISH E

- LOSS OF FLAM OR FAIL TO ESTABLISH E - LOSS OF CONTROL

SYSTEMENERGY - LOSS OF CONTROL SYSTEMENERGY - POWER

FAILURE - POWER FAILURE - LOWWATER LEVEL (AUXLEVEL

CONTACT) - LOWWATER LEVEL (AUXLEVEL CONTACT) - LOSS OF

ATOM IZING MEDIUM - EXCESSIVE STEAMDRUMPRESSURE -

EXCESSIVE STEAMDRUMPRESSURE - HIGH OIL TEMPERATURE

(HEATED OILS) OR OR TRIP BOILER TRIP IGNITER, TRIP MAIN FUEL

FUEL CONTROL IGNITER VALVES, VALVES, OPEN VALVE TO TRIP MFT

RELAY OPEN IGNITER VENT VALVE CLOSED VENT (GAS ONLY)

POSITION Workshop on Start Up and Commissioning Dr. Himadri Banerji

MD EcoUrja, Ex Reliance and Tata www.ecourja.com

144. BMS System Types Early Burner Management Systems ◦ Hardwired

Systems ◦ Solid State Systems Microprocessor Based Systems ◦ Honeywell

7800 series with fixed Logic. PLC Based Systems ◦ Programmable Logic

Controller (PLC) Based ◦ Powerful, versatile, expandable, more reliable.

Workshop on Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja,

Ex Reliance and Tata www.ecourja.com

145. Early Burner Management Systems Hardwired Systems ◦ Relay and

Timer Driven. Found on older installations ◦ Typical of Late 50’s, 60’s Solid

State Systems ◦ Solid State Processors and Relays ◦ Found on Systems

provided in the 70’s and 80’s ◦ Proprietary Hardware (ie.. Forney and

Peabody) ◦ Spare Parts are extremely hard to find. Workshop on Start Up


www.ecourja.com

146. MicroProcessor Based Systems Microprocessor Based System

providing: ◦ Burner Sequencing ◦ Ignition ◦ Flame Monitoring Fixed Program

with Limited Configuration Changes Components Selected Based on

Requirements ◦ Programmers, Flame Amplifiers, Message Displays



147. Typical BMS Layout AMPLIFIER EP PROGRAMMER AUTOMATIC

PRIMARY SAFETY CONTROL FIELD WIRING FIELD WIRING FLAME

SCANNER Workshop on Start Up and Commissioning Dr. Himadri Banerji


148. Micro Processor Capabilities Simple, Cost Effective Features ◦

Selectable Flame Amplifiers / Scanners ◦ Remote Display ◦ Remote Data

Communications via Modbus Port ◦ Modernization kits are available to

integrate with older systems ◦ Spare Parts Normally Readily Available



149. When These Systems are Used “Simple” Boiler Installations ◦ Packaged

Fire tube / Water tube Boilers (Steam / Hot Water) ◦ Single Burner ◦ One Fuel

at a Time ◦ No Flue Gas Re-Circulation ◦ Upgrades from Previous

MicroProcessor Based Systems Workshop on Start Up and Commissioning

Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com

150. PLC Based Burner Management Systems PLC Based Features ◦ NFPA

8501, 8502 ◦ Watchdog timer ◦ UL 508 Certification Redundant Scanners

Logic+ Message Center ◦ Shows program status ◦ Displays alarms ◦ Prompts

operator Workshop on Start Up and Commissioning Dr. Himadri Banerji MD


151. PLC System Basic Design Features Each PLC based burner

management system should incorporate a number of design techniques

which help detect and act upon unsafe failure modes which can occur in any

microprocessor based system. These design features include the following: ◦

Critical Input Checking ◦ Critical output channel monitoring ◦ Electro-

mechanical Master Fuel Trip (MFT) Relay ◦ Redundant Watchdog Timers ◦

Low Water Cut-out Monitoring During Blow Down Workshop on Start Up and


www.ecourja.com

152. PLC Based System Capabilities Provision for Multiple Fuel Firing ◦

Capped gas input during curtailment ◦ Changeover from gas to oil at any load

◦ Simultaneous firing of waste and fossil fuels Redundant Scanners, change

scanner with fuel Single or Multiple Burner Applications Integration of BMS

with SCADA Workshop on Start Up and Commissioning Dr. Himadri Banerji


153. PLC Based Operator Interfaces Features ◦ Clear Written Messages to

indicate status, required operator interaction, trip/alarm indication ◦ High

Visibility through two lines of display ◦ Messages reduce time consuming

troubleshooting ◦ Prioritizes Messages First Out Alarms Warning / Alarm

Messages Status Messages / Prompts Operator Workshop on Start Up and


www.ecourja.com

154. PLC System Layout Door Mounted Lights / Pushbuttons Logic+

Message SWITCH SILENCE LIGHT Display PLC CPU I/O I/O I/O I/O

COMBUSTION CONTROL SYSTEM FLAME AMPLIFIER (SINGLE /

REDUNDANT) I/O EXPANSION I/O FIELD DEVICES Workshop on Start Up


www.ecourja.com

155. Benefits of PLC Based Systems Flexibility / Reliability ◦ Programming

Software allows changes to system Choice of PLCs ◦ GE / Modicon / Allen

Bradley / Koyo Choice of Flame Scanners ◦ PPC / Fireye / Honeywell / Iris /

Coen Application Specific Quantity of Burners / Fuels is not restricted



156. When to Use PLC Based Systems “Complex” Boiler Installations ◦

Larger Packaged Units / Field Erected Units ◦ Multiple Burners ◦ Multiple

Fuels, On-line Fuel Changeovers ◦ Flue Gas Re-Circulation ◦ Replace

Existing Relay Logic Systems ◦ Requirement to maintain consistent control

platform (spare parts, etc..) Workshop on Start Up and Commissioning Dr.


157. BMS SCADA Interface BMS Systems can be integrated into a SCADA

System ◦ Allows Remote Monitoring of Flame Status ◦ Allows Remote Control

of BMS ◦ Events (ie.. Burner trip) can be routed to Historical Portion of

SCADA for fault evaluation ◦ Burner Operation can be trended over time



158. BMS SCADA Interface Interface Methods: SCADA PC MODBUS

COMMUNICATION PROTOCOL MODBUS COMMUNICATION

Communication PROTOCOL Interface (If Necessary) PLC CPU I/O I/O I/O

I/O BMS LOGIC+ SYSTEM FIREYE E110 SYSTEM Workshop on Start Up


www.ecourja.com

159. BMS SCADA Interface Workshop on Start Up and Commissioning Dr.


160. SummaryBenefits Associated with Sequential Start Up Automationand

Burner Management Systems ◦ Help Improve plant safety ◦ Help qualify for

reduced insurance cost ◦ Reduce Startup and Down Time with

comprehensive alarming and diagnostics Workshop on Start Up and


www.ecourja.com

161. Summary Review of Topics Discussed ◦ Sequential Start Up

Automation, ◦ Objectives of Burner Management Systems ◦ BMS Design

Considerations ◦ Basic BMS Logic ◦ Types of Burner Management Systems ◦

How BMS Systems can be integrated with Plant Wide SCADA Systems



162. SAFETY ISSUES THE WORK PERMIT SYSTEM (Reference Document

: <<AIGA 011/04 >>)Presented by Dr Himadri Banerji EcoUrja

www.ecourja.com

163. Summary Acknowledgement This document is adopted from the

European Industrial Gases Association document TP 10/04 – The Work

Permit System, and acknowledgement and thanks are hereby given to EIGA

for permission granted for the use of their documentPresented by Dr Himadri

Banerji EcoUrja www/ecourja.com

164. The Work Permit System. What is it? A work permit system consists

primarily of a standard procedure designed to ensure that potentially

hazardous routine and non routine work on industrial installations can be

carried out safely. The procedure should define the need for the following

essential steps: Details of the necessary preparatory work Clear definition of

responsibilities Appropriate training of the work force Provision of adequate

safety equipment A formal work permit with or without attached specific

checklists. This work permit: specifies the work to be accomplished and

authorizes it to be started under the strict observance of consigned work and

safety procedures After information and agreement of all other concerned

parties (process, safety, customers, suppliers,…)

165. The Work Permit System :When? For all non-routine works, For

hazardous routine works not covered by procedures, When work is

performed: by your employees and/or third parties

166. The Work Permit System (1/2):For what kind of work? A work permit is

required in case of: Potential oxygen deficiency or enrichment Potential

flammable/explosive atmosphere Potential high temperature/pressure

Potential hazardous chemicals, e.g.: toxic substances Confined space entry,

e.g.: tanks, cold box, pit, normally closed vessels Bypassing or

removing/altering safety devices or equipment Elevated works Introduction of

ignited sources where not permanently allowed (fire permit), e.g.: open flame,

welding, grinding, Electrical troubleshooting or repair on live circuits

Maintenance or repairs in areas or to equipment or lines, containing or

supposed to contain hazardous materials or conditions,

167. The Work Permit System (2/2):For what kind of work? Or also in case of:

Manual or powered excavations Use of mobile cranes Insulation or catalysts

handling Use of adapters Product conversion of stationary or mobile or

portable vessels and containers Temporary or permanent changes,

alterations, modification of equipment or processes, Exposure to traffic,

Exposure to moving/rotating machinery In proximity of vents, liquid of gas On

process lines with gas release Etc..

168. The Work Permit System : Why?1. Because: In charge of the work, you

don’t know everything about the site and the process around about the work

Safety measures have to be prepared You cannot start the work without the

OK of the production personnel or the customer or the supplier The

production needs your OK in order to re-start the plant after your work is

achieved2. To obtain a safe as well as a quick and cost effective work

169. The Work Permit System : Why? In order to define the scope of work for

everyone concerned/involved by and during the work, the Work Permit must

be prepared with: The person responsible for the work The person(s) in

charge of the production, the customer or supplier, who will release the

process before the work starts The other work bodies The person in charge

of HSE measures

170. The Work Permit System : How? Before issuing the Work Permit, you

must: Describe the work to be done List all the specifications and drawings

which are required Issue detailed planning with all involved entities Determine

the logging and tagging procedures Fill-in together the work permit and sign,

The start of the work must be authorized by production and/or user, The re-

start of the process must take place after the work is finished.

171. The Work Permit System :Review of Flowsheets, Drawings

andSpecification Purpose of the review is to ensure all key persons involved

in jobplanning have a thorough understanding of the job. It shouldinclude:

Process fluids and materials involved, Degree of isolation, Effect of other

processes, Power supply isolation, Specialist advice, Location of

underground services and pipes, Location of elevated power cables, Location

of elevated pipelines and walkways, Purging and lock-out requirements,

Pressure, Temperature, Valve identification, Equipment specification,

Operating and maintenance instructions, Materials of construction and

compatibilities

172. The Work Permit System :Work site inspection Anyone involved and

signing the Safe Work Permit must visit the work place in order: •To inspect

the work area Neighbouring activities, site rules, overhead, underground,

access, natural hazards (flood, rain, snow…), etc,.. •To identify potential

hazards Flammable, oxygen, toxic substances, confined spaces, electricity,

pressure, temperature, moving objects, traffic, falls/trips/slips, etc,..

173. The Work Permit System :Development of Work ProceduresPreparation

of a detailed work procedure is essential to ensure the work willproceed

safely in a planned and logical manner: Following requirements to be

considered: Reference drawings, Timing of various operations, Details of any

special equipment, Needs to inform local authorities, safety precautions and

equipment, Emergency procedures, etc,.. The procedure should include:

Logging and tagging procedures: Electricity, process fluids Instrumentation,

utilities (water, air, oil,…) Depressurising, Draining, Venting, Purging,

Flushing, Isolating, Atmosphere checking, Disassembly of equipment,

Method of repair, Reassembly and installation, Quality control, Pressure and

leak testing, Reinstatement of equipment, Hand-back procedure, etc..

174. The Work Permit System : Example form Appendix 1 EIGA/IGC WORK

PERMIT n° …….. Any attached document or log sheet ? YES NO HOW

MANY ……….. List of attached documents ……………….

……………………….…………..……………...

……………………………………………….. 1. WORK ACTIVITY Plant / Unit :

………………...……………….

…………………………………………………………………………………………

………………..………...… Description of work to be done………………....

……..….………….…………….

……………………………………………………………………….......… Permit

valid from :………………………………………………………… Hours/date To :

……………………………………………………………………. Hours/date Have

all relevant departments/personnel been consulted ? YES NOT APPLICABLE

2. POTENTIAL HAZARDS & HAZARDOUS JOBS YES NO YES NO . Jobs

performed by contractors or temporary workers . Maintenance or repairs in

areas, or to equipment or lines, . Potential oxygen deficiency or enrichment

containing or supposed to contain hazardous materials or conditions .

Potential flammable / explosive atmosphere . Manual or powered excavations

. Potential high temperature / pressure . Use of mobile cranes . Potential

exposure to hazardous chemicals (toxic, reactive, . Insulation or catalyst

handling acid, caustic….) . Use of adapters . Confined space entry . Product

conversion of stationary or mobile or portable vessels . Bypassing or

removing/altering safety devices and equipment and containers . Elevated

work . Temporary or permanent changes, alterations, modifications of .

Introduction of ignition sources where not permanently equipment or

processes allowed (fire permit) . Exposure to traffic (road, mail) . Electrical

troubleshooting or repair on live circuits . Exposure to moving / rotating

machinery Others (state) ……………………..……...

………………………………………………………………………… 3. SAFETY

PRECAUTIONS YES NO YES NO YES NO . Draining . Remove hazardous

materials . Standby man . Depressurising . Fresh air ventilation . Elevated

work . Physical Isolation . Atmosphere analysis : . Contractors trained .

Electrical Isolation . Oxygen . Eliminate ignition sources

175. The Work Permit System :Work Planning WORK SCOPE REVIEW

DRAWINGS / FLOWSHEETS INSPECT WORKSITE IDENTIFY SAFETY

PRECAUTIONS COMPLIANCE WITH REGULATIONS DEVELOP WORK

PROCEDURE ASSIGN RESPONSIBILITIES COMMUNICATION

PROCEDURES WORK EXECUTION

176. The Work Permit System :Work Execution PREPARATORY WORK

ISSUE WORK PERMITS SUPERVISION MONITORING WORK

COMPLETED TESTING RE-INSTATE EQUIPMENT RETURN WORK

PERMIT HANDBACK PLANT / EQUIPMENT

177. The Work Permit System :Permit Issuer’s Responsibilities INSPECTING

WORK AREA IDENTIFYING HAZARDS DEFINING SAFETY

PRECAUTIONS OBSERVING PRINCIPLES OF SAFE WORKING

PRACTICES CREATING WORK PERMIT CONDITIONS REVIEWING

WORK WITH PERMIT ACCEPTOR ISSUING WORK PERMIT

IMPLEMENTING HANDBACK PROCEDURE

178. The Work Permit System :Permit Acceptor’s Responsibilities

UNDERSTANDING OF WORK PROCEDURES UNDERSTANDING

POTENTIAL HAZARDS AND SAFETY PRECAUTIONS ACCEPTING THE

SAFE WORK PERMIT OBSERVING PERMIT CONDITIONS COMPLYING

WITH HANDBACK PROCEDURE

179. The Work Permit System :In Brief Many accidents have occurred due to

lack of Work Permit or non observance of its consigned safety measures. The

Safe Work Permit is useful for: The safety of persons in charge of the work

The safety of persons in charge of the process The risk management of the

process and equipment It is not one more administrative paper! Fill in and

follow correctly the work permit, because…. It could save your life!

commissioning

Documents

plant commissioning

commissioning process

commissioning activities

tightness testing

proof testing

shutdown performance

process water

process control