plant commissioning and startup

8/12/2019 Plant Commissioning and Startup

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Plant Commissioning

& Start-Up


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Aims of Pre-Commissioning

The initial start-up of any plant, irrespective of size, type or industry, is aunique occurrence.

Therefore, start-up poses some special problems. Lack of experience in dealing with these problems has frequently resulted in

prolonged and costly start-ups.

This presentation will provide guidelines for all those involved in the

execution of a project on how to achieve a successful plant commissioning &

start-up.

The requirements for start-up oriented thinking at all stages of the project,

from engineering to commissioning, will be demonstrated.

Emphasis is on effective planning and use of available resources, both

material and manpower. Troubleshooting performed during the actual start-up can be very expensive

and must be done as effectively as possible.

Effective trouble shooting can minimize the time and cost of going from the

initial start-up to full production.


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Aims of Pre-Commissioning

Ensure the Plant is constructed as designed. Ensure the Plant is clean.

Ensure all the instrumentation, safety systems and

machinery are fully functional.

Ensure all vessel internals is installed correctly.

Ensure the Plant is leak tight.


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Key to Effective Pre-Commissioning

Planning and Preparation-milestone & progress report Work closely with the Construction Group

Divide the Plant into small sections and pre-commission

each one as it becomes available.

Hold regular pre-commissioning meetings to check progress

and to keep all parties informed.


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Typical List of Systems

Electricity Portable/Cooling water

Nitrogen

Fuel gas/liquid

Plant/Instrument air

Hot oil/Steam system

Other utility systems (AHU)

Tankage Area

Security system


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Planning & Preparation

Master drawings for cleaning. Master drawings for instrument checks.

Identify needs for vendor representatives and outside

contractors.

Ensure sufficient manpower available.

Ensure sufficient materials are available.


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Planning & Preparation

Prepare systems breakdown and mark-up on a master P&ID. Agree systems with construction.

Agree timing for hand over of each system (installation-

commissioning-training).

Prepare pre-commissioning plan for each system.


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Pre-commissioning Plan

Marked-up P&ID showing cleaning points, instruments to beremoved, etc.

Description of system plan.

Schedule for activities.

List of consumables required.

Requirement for vendor representative.

Special safety activities.


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Plant Inspection

Inspect the plant by system: Main output is a punch list of items to be put right

Punch list items should be categorized

-AMust fix

-BCan be delayed

Perform regular updates of the punch list

A weekly punch list review meeting should be held to

monitor progress


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Plant Inspection

Drawing check Piping check

Equipment check

Electrical check

Laboratory check


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Plant InspectionDrawing Check

Plant check against P&ID: Positioning of instruments, equipment, valves, pipe

branches.

Materials of construction-comply to specification.

Pipe dimensions

Equipment check


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Plant InspectionPiping Check

Check runs are provided with expansion loops, springsupports and anchor points as required.

As heat applied to plant, ensure:

-Spring supports correctly set

-Heat exchangers have sufficient expansion allowance.

When plant at normal temperature, check there are no

piping irregularities.


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Plant InspectionEquipment Check

Vessels: --Erected as Engineering Datasheet

-Gaskets, clips, bolts, and nuts are correct material and

fitted correctly

-Demisters fitted correctly and no gaps between wall and

pad

-All flanged connections secure and gaskets of correct

material

-Nozzles clear

-Vessel clean


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Vessels (cont)-Trays and distributors

-Tracing and insulation

-Earth bonding must be checked

-Take photographs of the internals for future reference


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Plant InspectionSafe Vessel Entry

Safest option is to have NO N2 on site during pre-comm. Remove the max. amounts of toxic vapors or gas

Before allowing entry to a vessel:

-Vessel must be isolated from the rest of the plant and

open to the atmosphere

-Vessel must be completely free of combustibles and toxic

gases

-Combustible and oxygen gas tests must be taken

throughout the vessel

-Maximum ventilation must be provided

-Entry permit must be issued valid for the day of entry


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Plant InspectionSafe Vessel Entry

If at any time there is a doubt over excessive gas, then the

work should be stopped.

Station someone outside the vessel if the workers safety

could be jeopardized

Purpose is to firstly call for assistance NOT to enter Keep vessels that contain self-igniting deposits wet until

rendered safe

Safe structure outside the vessel to ensure easy

access/egress Vessel should be closed after inspection to prevent

unauthorized entry


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Heat Exchangers:

-Sliding supports check to ensure free operation

-Shipping stops and supports removed from expansions

bellows

-Check heads of large exchangers are clean-Inspect tube sheet and tubes if possible


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Pumps:-

-Aligned correctly and rotational direction correct

-Seal and lubrication systems installed, clean and working

-Pump suctions flushed clean prior to initial operation

-Switch pumps regularly during initial operation and cleanthe suction filter


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Compressors:-Seal and lubricant systems checked against P&IDs, installed

and working correctly

-Oil flushing is completed to compressor vendor satisfaction

-Follow vendor instrument for operation, start-up, pre-comm., commissioning and maintenance


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Plant InspectionElectrical Check

Electrical Pre-comm. ChecksMostly in Switch Room

-Main switches labeled

-Overload cut-outs set to protect motors from overheating

Electrical Checks During Construction:

-Testing cable continuity-Current leak testing

-Direction of motor rotation

-Electrical earthing of machinery, piping, etc.


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Plant InspectionElectrical Check

All such checks are the responsibility of theConstruction/Plant Electrical Engineer

Commissioning/Operating personnel required to be familiar

with layout and function of electrical equipment.

Suitable training to be organized on site.


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Plant InspectionLaboratory Check

Lab equipment fully in place and operational Lab staff suitably trained and familiar with equipment

operation

Pre-comm. checks will be carried out by the commissioning

chemist Exercise tests on all analytical procedures errors free

results

Plant sample point location check installation and

identification


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Thank YouPrepared by:- Aditya Gupta

plant commissioning and startup

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