plant commissioning start up procedure

5/26/2018 Plant Commissioning Start Up Procedure

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Slide 1

Plant commissioning & start upPlant commissioning & start up

procedureprocedure


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Slide 2

The Commissioning ProcessThe Commissioning Process

Key StagesKey StagesPreparation and planning

Mechanical Completion

and Integrity checking

Performance and

Acceptance testing

Start Up & Initial

Operation

Post Commissioning

Pre-commissioning &

Operational Testing


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Slide 3

The Commissioning Process DetailThe Commissioning Process Detail -- 11Preparation and planning



Performance and

Acceptance testing

Start Up & Initial

Operation

Pre-commissioning &

Operational Testing

Appointment of CommissioningAppointment of Commissioning

Manager or Lead CommissioningManager or Lead Commissioning

Engineer;Engineer;

Appointment of Commissioning TeamAppointment of Commissioning Team

Members and Support Staff;Members and Support Staff;

Training;Training;

Information Compilation;Information Compilation;

Safety and Risk Assessment;Safety and Risk Assessment;

Commi ssioning StrategyCommi ssioning StrategyDevelopment;Development;

Procedures and Checkl i stProcedures and Checkl i st

Development;Development;

Detailed Plan and Budget Preparation;Detailed Plan and Budget Preparation;Post Commissioning


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Slide 4

Commissioning StrategyCommissioning Strategy

Equipment LevelActivities

System

Level Activities

Facility/Plant

Level Activities

Commissioning

StrategyCommissioning Master Plan

Individual item commissioning

plans, procedures and checklists


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Slide 5

Facility Commissioning IssuesFacility Commissioning Issues

Time phasing construction and commissioning activitiesTime phasing construction and commissioning activities

Time phasing the commissioning of the various parts of theTime phasing the commissioning of the various parts of the

plant relative to each other;plant relative to each other;

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

Electrical, Steam, Water, InstrumentationElectrical, Steam, Water, Instrumentation

Sequencing of the overall plant startup and shutdown toSequencing of the overall plant startup and shutdown to

ensure we do not create unsafe conditions;ensure we do not create unsafe conditions;

Initial start up;Initial start up;

Process Control and Shutdown;Process Control and Shutdown;

Performance testing;Performance testing;


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Slide 6

Developing Startup ProceduresDeveloping Startup Procedures

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

systematic procedure where by their startup engineerssystematic procedure where by their startup engineers

review the process design several times as it is developed;review the process design several times as it is developed;

After the first review, a preliminary startAfter the first review, a preliminary start--up and operationsup and operations

procedure is written;procedure is written;

Decide what must be added to the design to make theDecide what must be added to the design to make the

process capable of being started up and operated;process capable of being started up and operated;

By the time the final engineering flowBy the time the final engineering flow--sheets have beensheets have beenreleased a complete startup and operating instructionsreleased a complete startup and operating instructions

manual should have been completed.manual should have been completed.


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Slide 7

Issues consideredIssues considered Are various part of the process too depend on oneAre various part of the process too depend on one

another;another;

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

Are there provisions to prevent abnormalAre there provisions to prevent abnormal

pressures, temperatures and rates of reaction;pressures, temperatures and rates of reaction;

Where are additional valves and bypass linesWhere are additional valves and bypass lines

needed;needed; Special lines to allow equipment to be started upSpecial lines to allow equipment to be started up

and rerun product/raw materials.and rerun product/raw materials.


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Slide 8

System Level ActivitiesSystem Level Activities

Utilities systemsUtilities systems -- steam, instrument air, processsteam, instrument air, process

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

Electrical systems;Electrical systems;

Instrumentation and instrumentation systems;Instrumentation and instrumentation systems;

Cleaning and flushing;Cleaning and flushing;

Purging;Purging; Initial start up and shutdowns;Initial start up and shutdowns;

Performance testing;Performance testing;


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Slide 9

Equipment Level ActivitiesEquipment Level Activities

Pressure testing & mechanical integrity testing ofPressure testing & mechanical integrity testing of

vessel, columns and pipe work;vessel, columns and pipe work;

Heat Exchangers, condensers, coolers etc.Heat Exchangers, condensers, coolers etc. Mechanical equipment and machinery;Mechanical equipment and machinery;

Control Systems and Instrumentation;Control Systems and Instrumentation;

Operational testing;Operational testing;

Proof testing and acceptance.Proof testing and acceptance.


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Slide 10

What can be done before mechanicalWhat can be done before mechanical

completioncompletion

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


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Slide 11

BuildingBuilding OrganisationalOrganisational LearningLearning

Corporate

Knowledge Base

Best Practice

Benchmarking

IndustryStandards

Legislation

Process Design

Specific

Machinery &

Equipment

Procedures and

Check sheets

Improvement

Processes

Experience

Incidents and

Near Misses


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Slide 12

ProceduresProcedures Procedures are written routines/instructions thatProcedures are written routines/instructions that

describe the logical sequence of activities required todescribe the logical sequence of activities required to

perform a work process and the specific actionsperform a work process and the specific actions

required to perform each activity;required to perform each activity; If there are no written procedures, there is no basis forIf there are no written procedures, there is no basis for

monitoring performance, focus for improvement ormonitoring performance, focus for improvement or

mechanism by which to capture learning;mechanism by which to capture learning;

The establishment of procedures and routines allowThe establishment of procedures and routines allow

more time and mental energy to deal with themore time and mental energy to deal with the

unexpected, which always happen duringunexpected, which always happen during

commissioning.commissioning.


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Slide 13

Commissioning/Startup LogicCommissioning/Startup Logic A Critical Path Network (Plan) with written procedures withA Critical Path Network (Plan) with written procedures with

related documents are required. These should define for therelated documents are required. These should define for the

facility, each plant system:facility, each plant system:

The order in which the systems will be started up;The order in which the systems will be started up; Individual activities at each stage;Individual activities at each stage;

Operation testing requirements;Operation testing requirements;

Durations, waiting times, cooling times;Durations, waiting times, cooling times;

Total duration for starting up each system;Total duration for starting up each system; Resources requiredResources required -- labourlabour, materials, equipment,, materials, equipment,

services;services;

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


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Slide 14

Commissioning/Startup and Shutdown IssuesCommissioning/Startup and Shutdown Issues

At the facility, system and equipment level, weAt the facility, system and equipment level, we

want to avoid:want to avoid:

Creation/existence of explosive mixtures, usuallyCreation/existence of explosive mixtures, usually

because of the presence of air;because of the presence of air;

Water hammer and water based explosionWater hammer and water based explosion

effects, due to contact between water and hoteffects, due to contact between water and hot

substances (steam, oil, etc.);substances (steam, oil, etc.);

In particular, during commissioning hot fluids andIn particular, during commissioning hot fluids andgases will be coming into contact with coldgases will be coming into contact with cold

surfaces in places that would be hot under normalsurfaces in places that would be hot under normal

operations.operations.


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Slide 15

Mechanical Completion and IntegrityMechanical Completion and Integrity

CheckingChecking


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Slide 16


InspectionInspectionPreparation and planning



Performance and

Acceptance testing

Start Up & Initial

Operation

Pre-commissioning &

Operational Testing

InspectionInspection

Pressure testingPressure testing

Cleaning and FlushingCleaning and Flushing

Machinery checkoutMachinery checkout

Post Commissioning


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Slide 17

Categories of Process EquipmentCategories of Process Equipment Distillation Towers/Fractionation TowersDistillation Towers/Fractionation Towers

ReboilersReboilers & Other Shell & Tube Heat Exchangers& Other Shell & Tube Heat Exchangers

Boilers and Fired HeatersBoilers and Fired Heaters

Pressure Vessels and PipePressure Vessels and Pipe--workwork

FinFin--Fan CoolersFan Coolers

CondensersCondensers

Machinery/Rotating EquipmentMachinery/Rotating Equipment

ValvesValves

InstrumentationInstrumentation

Electrical EquipmentElectrical Equipment


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Slide 18

Machinery/ Rotating EquipmentMachinery/ Rotating Equipment

PumpsPumps

Steam TurbinesSteam Turbines

Gas TurbinesGas Turbines CompressorsCompressors

Gas EnginesGas Engines

Electric MotorsElectric Motors


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Slide 19


InspectionInspection

Involves checking that everything has been built and itInvolves checking that everything has been built and it

there as per specification. Refer:there as per specification. Refer:

Piping Plan Drawings;Piping Plan Drawings;

Layout and construction drawings;Layout and construction drawings;

P & IDP & IDss

Electrical systems, Instrumentation and control systemsElectrical systems, Instrumentation and control systems

checkout down by appropriately qualified personnelcheckout down by appropriately qualified personnel

(Electricians and Instrumentation technicians).(Electricians and Instrumentation technicians). General commissioning engineers generally do not getGeneral commissioning engineers generally do not get

involved in this in a handsinvolved in this in a hands--on manner.on manner.


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Slide 20


Inspection ProcedureInspection Procedure

Divide plant into manageable areas;Divide plant into manageable areas;

In a large plant, assign individuals or teams toIn a large plant, assign individuals or teams to

specific areas;specific areas; Establish a master set of piping plan drawings andEstablish a master set of piping plan drawings and

P&IDP&IDs, mark up areas:s, mark up areas:

Individual commissioning engineers or teams walkIndividual commissioning engineers or teams walk

every line and mark up every item that can beevery line and mark up every item that can beconfirmed as present on master set of drawings;confirmed as present on master set of drawings;

Use differentUse different colouredcoloured highlighterhighlighterpens topens to

indicate different services.indicate different services.


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Slide 21

Mechanical Completion and Integrity InspectionMechanical Completion and Integrity Inspection

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


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Slide 22


Inspection ProcedureInspection Procedure -- Hints/TipsHints/Tips

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

place;place;

Valves are correct typeValves are correct type -- globe, gate, control;globe, gate, control; Vents, drains, steam traps etc.Vents, drains, steam traps etc.

Flanges, bolts, types of bolts;Flanges, bolts, types of bolts;

Blind flanges andBlind flanges and swingableswingableblinds in place,blinds in place,

correct rating;correct rating;

Check all tag numbers;Check all tag numbers;

PunchlistPunchlist any nonany non--conformances.conformances.


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Slide 23

New PlantPiping Tie-ins!


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Slide 24

Pipe StressingPipe Stressing

Piping should provide adequately for expansion andPiping should provide adequately for expansion and

contraction due to temperature changes, withoutcontraction due to temperature changes, without

placing excessive stresses on equipment;placing excessive stresses on equipment;

Misalignment between matching flanges on pipeMisalignment between matching flanges on pipe--workwork --particular where there are changes inparticular where there are changes in

direction (elbows) can cause stressing;direction (elbows) can cause stressing;

Misalignments where pipeMisalignments where pipe--work connects towork connects to

machinery, vessels and other process equipment;machinery, vessels and other process equipment;

Can often be seen visually, or checked with gaugesCan often be seen visually, or checked with gauges

using the same procedures we use to align rotatingusing the same procedures we use to align rotating

equipment.equipment.


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Slide 25

Piping and Equipment SupportsPiping and Equipment Supports


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Slide 26

Piping and equipment supportsPiping and equipment supports

Mobile supports permit and guide the thermalMobile supports permit and guide the thermal

growth of equipment undergoing temperaturegrowth of equipment undergoing temperature

change;change; If they do not function correctly, vessels,If they do not function correctly, vessels,

equipment, pipe work, nozzles heat exchangersequipment, pipe work, nozzles heat exchangers

etc. may be damaged.etc. may be damaged.


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Slide 27

Typical piping support methodsTypical piping support methods


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Slide 28


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

Check that installed according to specification and not jammed;Check that installed according to specification and not jammed;

Inspection during warm up:Inspection during warm up:

Check thermal growth is occurring and supports are respondingCheck thermal growth is occurring and supports are respondingas per design;as per design;

Check that there is no surface buckling or crimpingCheck that there is no surface buckling or crimping -- this needsthis needs

to be corrected;to be corrected;

Check expansion joints;Check expansion joints; Check long straight runs of piping for bowing or support shoesCheck long straight runs of piping for bowing or support shoes

that may have slipped;that may have slipped;

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


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Slide 29


Inspection after coolInspection after cool--down:down:

Check that sliding supports have returned toCheck that sliding supports have returned to

original positions;original positions;

Establish that equipment can expand andEstablish that equipment can expand and

contract as required.contract as required.


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Slide 30

Inspection of spring supportsInspection of spring supports

Before hydroBefore hydro--testing:testing:

Check that spring stops are installed. (If not, theCheck that spring stops are installed. (If not, the

weight of water in pipe will deform the spring).weight of water in pipe will deform the spring). After hydroAfter hydro--testing but before heating:testing but before heating:

Check that stops are removed;Check that stops are removed;

Check that spring pointer is positioned to coldCheck that spring pointer is positioned to coldsetting;setting;


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Slide 31

Inspection of spring supportsInspection of spring supports

During and at end of heating:During and at end of heating:

Check pointer has not exceeded hot setting;Check pointer has not exceeded hot setting;

After cool down:After cool down:

check to establish piping can expand andcheck to establish piping can expand and

contract as required;contract as required;

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


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Slide 32

Vessels and ColumnsVessels and Columns


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Slide 33

Inspection of Vessels and ColumnsInspection of Vessels and Columns

The inspection of vessels, columns and reactorsThe inspection of vessels, columns and reactors

should be scheduled to be completed beforeshould be scheduled to be completed before

construction has closed them up;construction has closed them up;

Other inspectionsOther inspections -- e.g. for completeness or piping,e.g. for completeness or piping,

insulation, safety etc. can be scheduled later;insulation, safety etc. can be scheduled later;

If a vessel has been sealed up by construction, it isIf a vessel has been sealed up by construction, it is

your duty to inspect it, even it construction resist.your duty to inspect it, even it construction resist.


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Slide 34

Inspection of Vessels and ColumnsInspection of Vessels and Columns

Check that distributors have been installedCheck that distributors have been installed

correctly;correctly;

DeDe--misters installed correctly and of correctmisters installed correctly and of correctmaterials, design, type;materials, design, type;

Vortex breakers in place;Vortex breakers in place;

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

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


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Slide 35

Pressure TestingPressure Testing


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Slide 36

Pressure TestingPressure Testing -- ObjectivesObjectives

The objective of pressure testing is to confirm theThe objective of pressure testing is to confirm the

mechanical integrity of the plant;mechanical integrity of the plant;

Verifying capability of containing the pressures it hasVerifying capability of containing the pressures it has

been designed to hold;been designed to hold;

Ensure there are no leaks and verify that the plant canEnsure there are no leaks and verify that the plant can

be reliably made leak free;be reliably made leak free;

Identify any vulnerabilities well before the plant isIdentify any vulnerabilities well before the plant isplaced into service;placed into service;

Meet the requirements of legislation, local,Meet the requirements of legislation, local,

international and industry standards.international and industry standards.


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Slide 37

Pressure TestingPressure Testing -- responsibilitiesresponsibilities

Pressure tests of tanks, reactors and piping forPressure tests of tanks, reactors and piping for

mechanical strength and tightness of joints ismechanical strength and tightness of joints is

usually done by the construction team;usually done by the construction team; Commissioning team representatives shouldCommissioning team representatives should

witness and certify the tests;witness and certify the tests;

Need to verify that all necessary safety precautionsNeed to verify that all necessary safety precautions

have been taken;have been taken;


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Slide 38

Pressure TestingPressure Testing --proceduresprocedures

Water for testing and flushing should contain a rustWater for testing and flushing should contain a rust

inhibitorinhibitor -- one low in chloride content for stainlessone low in chloride content for stainless

steel lines;steel lines;

After testing, water should be drained completelyAfter testing, water should be drained completelyfrom all lines that do not normally carry water,from all lines that do not normally carry water,

steam or steam condensate;steam or steam condensate;

All low points should be checked for presence ofAll low points should be checked for presence of

water;water; Lines should be dried by blowing hot air, dry inertLines should be dried by blowing hot air, dry inert

gas or instrument air.gas or instrument air.


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Slide 39

Pressure TestingPressure Testing -- Vacuum SystemsVacuum Systems

Final checks of vacuum systems are bestFinal checks of vacuum systems are best

performed by pulling a vacuum and observing theperformed by pulling a vacuum and observing the

rate of pressure rise in the blocked in system;rate of pressure rise in the blocked in system;

Excessive leaks can then be located by applying aExcessive leaks can then be located by applying amild positive pressure and testing each flange withmild positive pressure and testing each flange with

bubble solution.bubble solution.


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Slide 40

Pressure TestingPressure Testing -- Procedures 2Procedures 2

Isometric drawings of all systems to be tested should beIsometric drawings of all systems to be tested should be

displayed on a board and marked up as each section isdisplayed on a board and marked up as each section is

tested;tested;

HydrotestingHydrotesting of piping and equipment according to codeof piping and equipment according to code

requirements to confirm mechanical strength should berequirements to confirm mechanical strength should be

carried out on groups of equipment naturally suggested bycarried out on groups of equipment naturally suggested by

design pressure and function;design pressure and function;

All water, steam, condensate, oil, gas and process steamAll water, steam, condensate, oil, gas and process steam

piping should be hydrotested;piping should be hydrotested; Major equipment that has already been tested as part ofMajor equipment that has already been tested as part of

manufacturing may be isolated by blanks.manufacturing may be isolated by blanks.


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Slide 41



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Slide 42


Need to ensure no construction debris is left inNeed to ensure no construction debris is left in

pipes of vesselspipes of vessels -- welding rods, bolts, gloves, ragswelding rods, bolts, gloves, rags

etc.etc.

Large debris (lumber, cable, packaging) shouldLarge debris (lumber, cable, packaging) should

have been removed during mechanical integrityhave been removed during mechanical integrity

inspections;inspections;

Small debris (rags, nuts, dirt) must be flushed outSmall debris (rags, nuts, dirt) must be flushed out

of all pipe and vessels;of all pipe and vessels;

Where oil coatings must be removed, chemicalWhere oil coatings must be removed, chemical

cleaning is necessary.cleaning is necessary.


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Slide 43


Before flushing is started, check the processBefore flushing is started, check the process

thoroughly to ensure:thoroughly to ensure:

Screens have been installed in front of pumpScreens have been installed in front of pumpsuctions;suctions;

Blinds in front of equipment such asBlinds in front of equipment such as

compressors and turbines;compressors and turbines;

JumperJumper spool pieces to allow for continuity ofspool pieces to allow for continuity offlow.flow.


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Slide 44

FlushingFlushing

Can be handled by geographic plant area;Can be handled by geographic plant area;

Sections too large for water flushing:Sections too large for water flushing:

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

Pipes that should not be touched with water;Pipes that should not be touched with water;

Should all be blown out with air or inert gas.Should all be blown out with air or inert gas.


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Slide 45

FlushingFlushing

Regardless of whether pipes are cleaned withRegardless of whether pipes are cleaned with

water, steam, air or nitrogen, flow velocitieswater, steam, air or nitrogen, flow velocities

should be high enough to ensure that pipes willshould be high enough to ensure that pipes will

be suitably scoured;be suitably scoured; Need to ensure that the debris from one piece ofNeed to ensure that the debris from one piece of

equipment will not simply be flushed intoequipment will not simply be flushed into

another;another;

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

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

65 m/sec);65 m/sec);


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Slide 46

PrePre--commissioning and Operationalcommissioning and Operational

TestingTesting


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Slide 47

The Commissioning Process DetailThe Commissioning Process Detail -- 33

Preparation and planning

Performance and

Acceptance testing

Start Up & Initial

Operation

Steam and other utilitiesSteam and other utilitiescommissioned and introduced;commissioned and introduced;

Dry running trials;Dry running trials;

Hot running trials;Hot running trials;

SafeSafe--fluid dynamic testing;fluid dynamic testing;

Solvent dynamic testing;Solvent dynamic testing;

Process fluid tests.Process fluid tests.



Pre-commissioning &

Operational Testing

Post Commissioning


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Slide 48

Commissioning UtilitiesCommissioning Utilities


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Slide 49


Utilities commissioning usually represents the firstUtilities commissioning usually represents the first

phase of commissioning, as these usually need tophase of commissioning, as these usually need to

operational first, before the rest of the plant can beoperational first, before the rest of the plant can be

commissioned;commissioned;

The steps for commissioning each utility should beThe steps for commissioning each utility should be

planned in detail;planned in detail;

Provides planning practice for planning the startupProvides planning practice for planning the startupof the main plant.of the main plant.


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Slide 50

Commissioning UtilitiesCommissioning Utilities -- Broad GuidelinesBroad Guidelines

Check supply pressures of all servicesCheck supply pressures of all services -- steam, cooling water,steam, cooling water,

instrument air, nitrogen etc.instrument air, nitrogen etc.

At the most distant points, open drains, vent valves or pipeAt the most distant points, open drains, vent valves or pipe

flanges and purge until fluids come out clean and rust free;flanges and purge until fluids come out clean and rust free;

Purge/blow out lines to each piece of equipment;Purge/blow out lines to each piece of equipment;

Check that instrument air is clean and dry, and at correctCheck that instrument air is clean and dry, and at correct

pressure;pressure;

Circulate water to waste water system until water lines clear anCirculate water to waste water system until water lines clear andd

clean;clean;

Flush waste water and drain systems to ensure no blockages;Flush waste water and drain systems to ensure no blockages;

Check operation of steam traps;Check operation of steam traps;

Drain condensate to waste water until is is clean.Drain condensate to waste water until is is clean.


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Slide 51


Introducing SteamIntroducing Steam Steam usually represents the firstSteam usually represents the first hazardoushazardous fluidfluid

introduced into theintroduced into the newnew system;system;

Admit steam slowly into the distribution system withAdmit steam slowly into the distribution system with

atmospheric bleeds open:atmospheric bleeds open: Cold pipes will condense steam in places where itCold pipes will condense steam in places where it

would not under normal operation;would not under normal operation;

Can lead toCan lead to water hammerwater hammer -- can distort and rupturecan distort and rupture

lines;lines;

After system has been warmed, slowly raise pressure andAfter system has been warmed, slowly raise pressure and

blow down the system with traps bypassed, until clean;blow down the system with traps bypassed, until clean;

Then place steam traps into service and check operation.Then place steam traps into service and check operation.


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Slide 52

High Pressure Steam SystemsHigh Pressure Steam Systems

Specific IssuesSpecific Issues The cleanliness and purity of high pressure steam systemsThe cleanliness and purity of high pressure steam systems --

particularly where the steam is used to drive a steam turbineparticularly where the steam is used to drive a steam turbine

should be checked by use of ashould be checked by use of a targettarget;;

For new boilers, or new sections added to steam systemFor new boilers, or new sections added to steam system --blow down at full pressure;blow down at full pressure;

When steam appears clean, fit a target with aWhen steam appears clean, fit a target with a mirroredmirrored

surface (surface (ieie. Small steel plate which has been polished, so that. Small steel plate which has been polished, so that

it is in the steam blow down stream;it is in the steam blow down stream;

Blow down the boiler or system so that the target is impingedBlow down the boiler or system so that the target is impingedupon for a few minutes;upon for a few minutes;

Check targetCheck target -- ensure there are no smallensure there are no small pock markspock marks left onleft on

the target. If pock markedthe target. If pock marked -- repeat process.repeat process.


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Slide 53

Electrical SystemsElectrical Systems


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Slide 54

Commissioning Electrical SystemsCommissioning Electrical Systems

The following checks are typical of what is requiredThe following checks are typical of what is required Open circuit breakers and switches;Open circuit breakers and switches;

Check that all busCheck that all bus--bars are free of dirt and foreign matter;bars are free of dirt and foreign matter;

Check grounding systems for continuity and resistance.Check grounding systems for continuity and resistance.

Make sure all electrical equipment, vessels, structures areMake sure all electrical equipment, vessels, structures areconnected to the grounding system in accordance withconnected to the grounding system in accordance with

drawings and specifications;drawings and specifications;

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

all explosion proof,all explosion proof, vapourvapour--tight, dusttight, dust--tight and weathertight and weather

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

Check motor control and power circuitry for correctCheck motor control and power circuitry for correct

hookup.hookup.


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Slide 55

Commissioning Electrical SystemsCommissioning Electrical Systems -- 22

The following checks are typical of what is requiredThe following checks are typical of what is required Check all nameplates and panel directories to ensure thatCheck all nameplates and panel directories to ensure that

each circuit breaker and switch does control the propereach circuit breaker and switch does control the proper

circuit. Label all switches even though their applicationcircuit. Label all switches even though their application

may seem obvious;may seem obvious;

Close main transformer primary disconnect switch andClose main transformer primary disconnect switch and

switchswitch--gear main circuit breaker;gear main circuit breaker;

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

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

Close first motor control centre main circuit breaker, thenClose first motor control centre main circuit breaker, then

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

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

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


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Slide 56

Commissioning Electrical SystemsCommissioning Electrical Systems -- 33

The following checks are typical of what is requiredThe following checks are typical of what is required Check that all lighting and power circuits are functioningCheck that all lighting and power circuits are functioning

correctly;correctly;

Check motor bearings for proper lubrication;Check motor bearings for proper lubrication;

Remove motor power fuses and check main contractor,Remove motor power fuses and check main contractor,interlock and sequencing devices;interlock and sequencing devices;

Uncouple each motor, replace fuses and check direction ofUncouple each motor, replace fuses and check direction of

rotation by momentarily pressing the start button, then stop;rotation by momentarily pressing the start button, then stop;

Check manual, then automatic operation.Check manual, then automatic operation.

Replace all couplings, check drive belts and make sureReplace all couplings, check drive belts and make sure

guards are installed.guards are installed.


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Slide 57

Electric motor driven pumpsElectric motor driven pumps


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Slide 58

Operational TestingOperational Testing


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Slide 59

Operational TestingOperational Testing

Progresses through several stages;Progresses through several stages;

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

Hot testing of individual items of equipment andHot testing of individual items of equipment andsystems;systems;

Several stages of Dynamic Testing of:Several stages of Dynamic Testing of:

Individual items of equipment;Individual items of equipment;

Individual Systems/processes in isolation;Individual Systems/processes in isolation;

The whole new process plant installation.The whole new process plant installation.


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Slide 60

Dry runs and Hot TestsDry runs and Hot Tests

Check that motors are connected correctly and turnCheck that motors are connected correctly and turn

in the right direction;in the right direction;

Shafts and impellers move freely;Shafts and impellers move freely; Equipment that is to be operated at temperature,Equipment that is to be operated at temperature,

raise to temperature and check;raise to temperature and check;

These tests should be performed by theThese tests should be performed by the

manufacturermanufacturers representative but witnessed bys representative but witnessed bymembers of the clientmembers of the clients operating/commissionings operating/commissioning

personnel.personnel.


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Slide 61

Hot testing equipmentHot testing equipment

Applies to equipment whose leakApplies to equipment whose leak--tightness must be tested attightness must be tested at

operating temperatures and after temperature reversals;operating temperatures and after temperature reversals;

FixedFixed--bed catalytic reactors that in normal conditions arebed catalytic reactors that in normal conditions are

heated by heat transfer fluids where leakage wouldheated by heat transfer fluids where leakage wouldcontaminate the catalyst;contaminate the catalyst;

Critical exchangers whose steam or cooling water is at aCritical exchangers whose steam or cooling water is at a

high pressure than the process fluid;high pressure than the process fluid;

Any equipment having complicated seals through whichAny equipment having complicated seals through which

leakage could occur;leakage could occur;

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

temperaturetemperature egeg. Steam turbines, etc.. Steam turbines, etc.


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Slide 62

Hot testing proceduresHot testing procedures

The thermal shock tolerance of equipment must beThe thermal shock tolerance of equipment must be

determined beforehand;determined beforehand;

To avoid thermal shock, the temperature of theTo avoid thermal shock, the temperature of the

heating medium may have to be raised gradually;heating medium may have to be raised gradually;

Time required for a hot test must be established inTime required for a hot test must be established in

advance;advance;

Establish a uniform temperature in all parts ofEstablish a uniform temperature in all parts of

equipment that are supposed to be uniformly hotequipment that are supposed to be uniformly hot

during operation to avoid setting up stresses;during operation to avoid setting up stresses;


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Slide 63

Dynamic TestingDynamic Testing


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Slide 64

Dynamic TestingDynamic Testing

Involves operating the equipment, before introducingInvolves operating the equipment, before introducing

liveliveprocess fluid;process fluid;

During dynamic testing, we progress through:During dynamic testing, we progress through:

SafeSafe--fluid dynamic testing;fluid dynamic testing;

Dynamic testing with solvent;Dynamic testing with solvent;

Closed loop testing with process fluid.Closed loop testing with process fluid.

Once process fluid is introduced, normal plant safetyOnce process fluid is introduced, normal plant safetyprocedures must come into effect as if it were a liveprocedures must come into effect as if it were a live

operating plant.operating plant.


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Slide 65

SafeSafe--Fluid Dynamic TestingFluid Dynamic Testing

Closed loop dynamic testing with safe fluids consists ofClosed loop dynamic testing with safe fluids consists of

operating equipment systems with air, water, inert gasesoperating equipment systems with air, water, inert gases

etc.etc.

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

Establishes performance while there is still time to modifyEstablishes performance while there is still time to modify

the plant;the plant;

FamiliarisesFamiliarises operators with the operation of the equipmentoperators with the operation of the equipmentbefore hazardous materials are introduced;before hazardous materials are introduced;

Gets rid of a lot of dirt which would be more difficult toGets rid of a lot of dirt which would be more difficult to

clear once the process fluid has been introduced.clear once the process fluid has been introduced.


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Slide 66

General Principles for TestingGeneral Principles for Testing

For most plants, a period of 2For most plants, a period of 2--3 weeks is usually sufficient3 weeks is usually sufficient

for operational testing, after the mechanical dry running offor operational testing, after the mechanical dry running of

individual pieces of equipment and hot testing complete;individual pieces of equipment and hot testing complete;

Air and water tests should be set up in a closed loop withAir and water tests should be set up in a closed loop withfluids continuously recycled, with loops as large asfluids continuously recycled, with loops as large as

possible;possible;

The loop should ideally be the same loop that will beThe loop should ideally be the same loop that will be

subject to solvent testing;subject to solvent testing;

Tests should continue for several days in order to give allTests should continue for several days in order to give allshifts a chance to conduct the same tests;shifts a chance to conduct the same tests;

All shifts should be given the opportunity to start up andAll shifts should be given the opportunity to start up and

shutdown each closed loop test.shutdown each closed loop test.


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Slide 67

General Principles for TestingGeneral Principles for Testing

A rough flowA rough flow--sheet should be developed for airsheet should be developed for air

and water tests, predicting all information thatand water tests, predicting all information that

normally appears on a process flow sheetnormally appears on a process flow sheet -- flow,flow,

temperature, pressure, heat transfer, power etc.temperature, pressure, heat transfer, power etc. will assist in alerting commissioning team towill assist in alerting commissioning team to

risks from overrisks from over--pressuring, overloading,pressuring, overloading,

temperaturetemperature--shocking and stressing equipment;shocking and stressing equipment;


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Slide 68

Cautions during TestingCautions during Testing

Dynamic testing may lead to:

Unusual or unforeseen differential expansions;Unusual or unforeseen differential expansions;

Corrosion;Corrosion;

Excessive weight of liquid into parts of theExcessive weight of liquid into parts of the

system;system;

Care must be taken not to collapse or burstCare must be taken not to collapse or burst

pressure vessels and tanks:pressure vessels and tanks: ensure there is always adequate venting;ensure there is always adequate venting;

avoid pulling a vacuum.avoid pulling a vacuum.


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Slide 69

Dynamic TestingDynamic Testing -- Simulated OperationsSimulated Operations

Safe Fluid TestingSafe Fluid Testing

Auxiliary services must be brought into operationAuxiliary services must be brought into operation

first:first:

water cooling, inert gas generators, boilerwater cooling, inert gas generators, boilerfeedwaterfeedwater, firewater, steam production, etc., firewater, steam production, etc.

Water is pumped through the process (exceptWater is pumped through the process (except

where special conditions do not permit it) andwhere special conditions do not permit it) and

boiled up in columns;boiled up in columns; Compressors and blowers should be operated onCompressors and blowers should be operated on

air or inert gas.air or inert gas.


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Slide 70

The Value of Dynamic TestingThe Value of Dynamic Testing --

Simulated OperationsSimulated Operations Value of simulated operations will be to allow operator toValue of simulated operations will be to allow operator to

become familiar with the operation of the process, beforebecome familiar with the operation of the process, before

hazardous fluids are introduced;hazardous fluids are introduced;

Equipment deficiencies can become apparent duringEquipment deficiencies can become apparent duringdynamic testing;dynamic testing;

Failures and problems more easily corrected with safeFailures and problems more easily corrected with safe

fluids presentfluids present

Leaks should be found and tightened;Leaks should be found and tightened;

Instruments can be placed into serviceInstruments can be placed into service -- although selectionalthough selection

of setof set--points will have to be deferred;points will have to be deferred;

Inspect the plant for evidence of design and constructionInspect the plant for evidence of design and construction

errors.errors.


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Slide 71

Dynamic TestingDynamic Testing -- Simulated OperationsSimulated Operations

At the end of the simulation, water should beAt the end of the simulation, water should be

draineddrained -- equipment dried and purged;equipment dried and purged;

Depending on the processDepending on the process -- drying may not bedrying may not benecessarynecessary --but purging will always be required;but purging will always be required;


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Slide 72

Dynamic testing with a solventDynamic testing with a solvent

After safe fluid testing and subsequent repairs andAfter safe fluid testing and subsequent repairs and

modifications, we are ready for dynamic closedmodifications, we are ready for dynamic closed

loop testing with a solvent;loop testing with a solvent;

TheThe solventsolvent is a relatively safe fluid whoseis a relatively safe fluid whose

properties are close to that of the process fluid, orproperties are close to that of the process fluid, or

the process fluid itself;the process fluid itself;

In order to allow for continuous reIn order to allow for continuous re--circulation ofcirculation ofthe solvent and the use of different solvents inthe solvent and the use of different solvents in

different parts of the plant, temporary lines willdifferent parts of the plant, temporary lines will

need to be installed.need to be installed.


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Slide 73

Dynamic Testing with Process SolventDynamic Testing with Process Solvent

Introduce the process solvent. (if there is more thanIntroduce the process solvent. (if there is more than

one, introduce only one at this stage);one, introduce only one at this stage);

The dynamic testing procedure used for the safeThe dynamic testing procedure used for the safe

fluid test is repeated for the process solvent dynamicfluid test is repeated for the process solvent dynamictesting;testing;

After operations with the first solvent have beenAfter operations with the first solvent have been

brought completely under control, should the secondbrought completely under control, should the second

solvent be introduced (if there is one).solvent be introduced (if there is one).


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Slide 74

Dynamic testing with a solventDynamic testing with a solvent

The purpose of dynamic testing with a solvent is toThe purpose of dynamic testing with a solvent is to

check out equipment and instrument loops at, orcheck out equipment and instrument loops at, or

near design conditions prior to the introduction ofnear design conditions prior to the introduction of

more hazardous process fluid;more hazardous process fluid; No reactions should be allowed to occur duringNo reactions should be allowed to occur during

these tests, so as to ensure that test fluids remainthese tests, so as to ensure that test fluids remain

predictable in composition and properties;predictable in composition and properties;

Guidelines used for safeGuidelines used for safe--testing apply;testing apply;

Need to plan how solvent will be fed into theNeed to plan how solvent will be fed into the

system and later removed.system and later removed.


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Slide 75

Stages of dynamic testing with aStages of dynamic testing with a solventsolvent

Drain safe fluid and purge air used in the previous test fromDrain safe fluid and purge air used in the previous test from

the system;the system;

Dry out equipment where safe fluid was water. Check flowDry out equipment where safe fluid was water. Check flow

sheets for where water is likely to accumulate.sheets for where water is likely to accumulate.

Fill systems with the solvent. Ensure provisions made forFill systems with the solvent. Ensure provisions made for

venting and drains closed;venting and drains closed;

When adequate levels established, place pumps andWhen adequate levels established, place pumps and

compressors online to complete filling;compressors online to complete filling;

Start closed loop circulation;Start closed loop circulation;

Heat up the systems to simulate operating conditions byHeat up the systems to simulate operating conditions by

placing reflux,placing reflux, reboilerreboilerand condensation systems intoand condensation systems into

operationoperation


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Slide 76


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

After instruments have checked out, place as many asAfter instruments have checked out, place as many as

possible on automatic control;possible on automatic control;

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

DynamicDynamic solventsolvent testing offers the best opportunity fortesting offers the best opportunity for

operator training before theoperator training before the real thingreal thing;;

Operate equipment as near as possible to design capacities;Operate equipment as near as possible to design capacities;

Reliability of emergency shutdown systems and alarmsReliability of emergency shutdown systems and alarms

must be proven;must be proven;

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


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Slide 77


Deliberately operate equipment near its limits:Deliberately operate equipment near its limits:

Flood columns;Flood columns;

Ease compressors into mild surges and plot surge curves;Ease compressors into mild surges and plot surge curves;

Overload condensers;Overload condensers; Do not fear blowing a relief valve or two!Do not fear blowing a relief valve or two!

After tests have been completed, plant should be ready forAfter tests have been completed, plant should be ready for

initial operation.initial operation.


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Slide 78

Closed Loop Dynamic Testing withClosed Loop Dynamic Testing with

Process FluidProcess Fluid Finally, introduce process fluid;Finally, introduce process fluid;

During this step, instruments should be calibratedDuring this step, instruments should be calibrated

to cover their full range of flow, temperature andto cover their full range of flow, temperature and

pressure;pressure;

Ensure that instruments, processEnsure that instruments, process analysersanalysers andand

safety devices are kept work properly during thesesafety devices are kept work properly during these

processes;processes;

After operations with process fluid are broughtAfter operations with process fluid are brought

completely under control should the final stage ofcompletely under control should the final stage of

startstart--up be attempted.up be attempted.


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Slide 79

Preparing to introduce process fluidsPreparing to introduce process fluids

Before introducing hazardous liquids into theBefore introducing hazardous liquids into the

plant, we complete additional pressure testing andplant, we complete additional pressure testing and

purging;purging;

Need to check that the stresses and strains ofNeed to check that the stresses and strains of

dynamic testing has not caused any leaksdynamic testing has not caused any leaks -- thesethese

must be found and fixed;must be found and fixed;


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Slide 80

Pressure testing and purgingPressure testing and purging

Consists of pressuring and deConsists of pressuring and de--pressuring withpressuring with

nitrogen several times, until at least


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Slide 81

Dehydrating by CirculationDehydrating by Circulation

It is usually not possible to waterIt is usually not possible to water--free equipmentfree equipment

simply by draining;simply by draining;

Only positive method to waterOnly positive method to water--free processfree process

equipment is oil circulation followed by repeatedequipment is oil circulation followed by repeateddraining of low points;draining of low points;

Ensure sufficient low point drains are provided onEnsure sufficient low point drains are provided on

piping, control valve loops, vessels and processpiping, control valve loops, vessels and process

machinery;machinery; Startup linesStartup lines -- deliver oil to upper part (trays) ofdeliver oil to upper part (trays) of

distillation towers (size for 20% of net distillatedistillation towers (size for 20% of net distillate

product rate);product rate);


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Slide 82

Start Up and Initial OperationStart Up and Initial Operation


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Slide 83

Start Up and Initial OperationStart Up and Initial Operation


Performance and

Acceptance testing

Post Commissioning

Introduction of process fluidIntroduction of process fluid

StartStart--up and initial operationup and initial operation TroubleTrouble--shooting andshooting and

problem correction.problem correction.

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



Pre-commissioning &

Operational Testing

Start Up & Initial

Operation


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Slide 84

Starting Up the PlantStarting Up the Plant

Productrefining

RecoveryReactionFeedPreparation

Most plants in petrochemical/chemical industryMost plants in petrochemical/chemical industry

have the followinghave the following generalgeneral form.form.

Start Up from theStart Up from the

End of the ProcessEnd of the Process

and Work backand Work back


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Slide 85

Start Up LogicStart Up Logic

It is common practice to buy in product and startIt is common practice to buy in product and start

up the last past of the process first and workup the last past of the process first and work

backwards to the front. E.g.backwards to the front. E.g.

Start up refining, get this working and inStart up refining, get this working and in

control;control;

Then possibly start up reaction and recovery;Then possibly start up reaction and recovery;

Finally, feed preparation.Finally, feed preparation.


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Slide 86

Into the initial operationInto the initial operation

Once raw materials are fed into the plantOnce raw materials are fed into the plant -- usuallyusually

at reduced rate until reaction conditions have beenat reduced rate until reaction conditions have been

established;established;

As each section is started up, establish as quicklyAs each section is started up, establish as quicklyas possible that process conditions are as expected;as possible that process conditions are as expected;

If potentially serious problems develop, thereIf potentially serious problems develop, there

should be no hesitation on going into anshould be no hesitation on going into an

emergency shutdown.emergency shutdown.


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Slide 87

Ramping up the plantRamping up the plant

Plant is brought slowly to design feedPlant is brought slowly to design feed--rates andrates and

operating conditions;operating conditions;

Usually done in steps with operating dataUsually done in steps with operating data

evaluated and verified as OK at each step;evaluated and verified as OK at each step;

Plant and laboratory data are now being collectedPlant and laboratory data are now being collected

and should be being evaluated promptly;and should be being evaluated promptly;


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Slide 88

Coordination and Supervision duringCoordination and Supervision during

start upstart up Additional personnel, both supervisory andAdditional personnel, both supervisory and onon--

thethe--groundground are required at this stage;are required at this stage;

Cooperation between startup personnel and plantCooperation between startup personnel and plantsupervisory personnel is critical at this stage:supervisory personnel is critical at this stage:

Need a daily meeting at least;Need a daily meeting at least;

Often, a briefing each shift.Often, a briefing each shift.


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Slide 89

Trouble ShootingTrouble Shooting

At this stage, many problem with equipment of theAt this stage, many problem with equipment of the

process itself may become apparent;process itself may become apparent;

The commissioning process goes through what isThe commissioning process goes through what isoften an intense (and hopefully short) period ofoften an intense (and hopefully short) period of

problem trouble shooting, problem solving,problem trouble shooting, problem solving,

engineering correction and plant modification;engineering correction and plant modification;


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Slide 90

Performance and Acceptance TrailsPerformance and Acceptance Trails


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Slide 91

Performance and Acceptance TestingPerformance and Acceptance Testing


Performance and

Acceptance testing

Post Commissioning

Performance trails;Performance trails;

Formal Acceptance testFormal Acceptance test



Pre-commissioning &

Operational Testing

Start Up & Initial

Operation


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Slide 92

The Performance TrailsThe Performance Trails

Once the plant is fully operational, the finalOnce the plant is fully operational, the final

proving trailproving trail or performance run is performed inor performance run is performed in

order to prove the plant can do what it is supposedorder to prove the plant can do what it is supposed

to do;to do; The values or range of values for each independentThe values or range of values for each independent

variablevariable -- flow, temperature, pressure, level,flow, temperature, pressure, level,

concentrations, etc. to which the plant must beconcentrations, etc. to which the plant must be

operated to are determined;operated to are determined; The plant is brought up to those conditions and theThe plant is brought up to those conditions and the

prepre--agreed trial period begins.agreed trial period begins.


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Slide 93

Before the trail or performance run needBefore the trail or performance run need

to ensure thatto ensure that Control of plant operating conditions has beenControl of plant operating conditions has been

achieved. I.e. temperature, pressures, levels andachieved. I.e. temperature, pressures, levels and

analyses are reasonably constant or in the case of aanalyses are reasonably constant or in the case of a

batch process, there is repeatability;batch process, there is repeatability;

Daily material and energy balanced can beDaily material and energy balanced can be

performed and that these agree withperformed and that these agree with officialofficial

production figures;production figures;

Product specifications are being achievedProduct specifications are being achieved

consistently.consistently.


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Slide 94

Need to verifyNeed to verify ..

Physical operation, capability and capacity of plantPhysical operation, capability and capacity of plant

and equipment;and equipment;

Energy and mass balance;Energy and mass balance; Process chemistry;Process chemistry;

Efficiencies, yields and quality;Efficiencies, yields and quality;

All to specification.All to specification.


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Slide 95

AcceptanceAcceptance

When the plant has met the Performance andWhen the plant has met the Performance and

Acceptance test requirements designed by theAcceptance test requirements designed by the

commissioning team there is usually a formalcommissioning team there is usually a formal

acceptance process involving signing of acceptanceacceptance process involving signing of acceptance

certificates;certificates;

Once the plant is accepted it is officially part of theOnce the plant is accepted it is officially part of the

normal operationsnormal operations -- the responsibility of operationsthe responsibility of operations

and maintenance;and maintenance;

Commissioning is officially over;Commissioning is officially over;

The may still be outstandingThe may still be outstandingpunchlistpunchlist itemsitems


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Slide 96

Acceptance TestingAcceptance Testing

It is common practice to prove performanceIt is common practice to prove performance

repeatability and plant integrity as part of therepeatability and plant integrity as part of the

performance test. That is:performance test. That is:

Shutdown and Start Up the plant on severalShutdown and Start Up the plant on severaloccasions and bring it up to test conditions tooccasions and bring it up to test conditions to

prove repeatability. Also ramp down and ramp upprove repeatability. Also ramp down and ramp up

while online;while online;

ReRe--inspection of critical process equipmentinspection of critical process equipment --particularly columns to ensure they have not beenparticularly columns to ensure they have not been

damaged by the performance run.damaged by the performance run.


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Slide 97

Commercial Significant of AcceptanceCommercial Significant of Acceptance

Formal Acceptance represents formal acknowledgmentFormal Acceptance represents formal acknowledgment

that thethat the

Contractor has fullContractor has full--filled their contractualfilled their contractual

obligations;obligations;

Commissioning team have fullCommissioning team have full--filled theirfilled their

obligations;obligations;

Completion of the Capital Project and transfer toCompletion of the Capital Project and transfer to

Operations;Operations;

Expenses and costs from acceptance onwards are nowExpenses and costs from acceptance onwards are now

operating expenses not capital project costs;operating expenses not capital project costs;

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


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Slide 98

PostPost--CommissioningCommissioning


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Slide 99

Post CommissioningPost Commissioning




Pre-commissioning &

Operational Testing

Start Up & Initial

Operation

Performance and

Acceptance testing

Post Commissioning

From plant onFrom plant on--stream to settledstream to settled

down and in regular production;down and in regular production;

Adjustments, modifications andAdjustments, modifications andfault correction;fault correction;

Completion of outstandingCompletion of outstanding

punchlistpunchlist itemsitems


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Post CommissioningPost Commissioning

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

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

The first routine maintenance checks are performed,The first routine maintenance checks are performed,

findings evaluated and reported;findings evaluated and reported;

Process equipment and items covered by warrantyProcess equipment and items covered by warranty

are scrutinized for signs of premature wearare scrutinized for signs of premature wear--out orout or

problems;problems;

Operating data is collected and evaluated to ensureOperating data is collected and evaluated to ensure

consistent plant operations are maintained andconsistent plant operations are maintained and

sustainable.sustainable.

plant commissioning start up procedure

Documents

upplant commissioning

commissioning activities

overall plant startup

asystematic procedure

startup engineersreview

construction companies

various systemsrelationships

various parts of thetime