Workshop on Plant Commissioning and Seamless Startup final.pdf

Workshop on Transition from Construction to Flawless
Operations
Himadri Banerji
Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex
CEO Reliance and International Expert Ernst and Young
11/25/2023 1
Day 1 Session 2: Tactical Elements in Plant Commissioning

11/25/2023
Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO
Reliance and International Expert Ernst and Young
2
 Planning and Budgeting,
 Mechanical Completion,
 P&ID Checking,
 Pre-commissioning,
 Commissioning,
 Start-up,
 Initial Operation,
 Performance Testing,
 Post Commissioning,
 Managing Commercial Warranties and
Guarantees ,
 Commissioning Documentation

Standard implementation path is shown here
Workshop on Transition from Construction to Flawless Operations
Himadri Banerji Ex CEO Reliance and International Expert Ernst and
Young
11/25/2023 3

Preparation and
planning
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
Young
11/25/2023 4

Preparation and
planning
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
• Appointment of Commissioning
Manager or Lead Commissioning
Engineer
• Appointment of Commissioning
Team
Members and Support Staff
• Training
• Information Compilation
• Safety and Risk Assessment
• Commissioning Strategy
Development;
• Procedures and Checklist
Development
• Post Commissioning
• Detailed Plan and Budget
Preparation;
Young
11/25/2023 5

 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
Young
11/25/2023 6

 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.
Young
11/25/2023 7

 Are various part of the process too dependent 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.
Young
11/25/2023 8

 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
Young
11/25/2023 9

 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.
Young
11/25/2023 10

 Utilities commissioning
 Lube and Seal-Oil Systems Cleaned
 Instrumentation and Control Loops Proven
 Piping,Towers andVessels Cleaned
 Boil-Out, Dry-Out and Acid Cleaning
 Turbine, Motor and Pump Run-Ins
 Nitrogen Purge andTightnessTesting
Young
11/25/2023 11

Corporate
Knowledge Base
Best Practice
Benchmarking
Industry
Standards
Legislation
Process Design Specific
Machinery &
Equipment
Procedures and
Check sheets
Improvement
Processes
Experience
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Young
11/25/2023 13

 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.
Young
11/25/2023 14

 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.
Young
11/25/2023 15

 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.
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Young
FIRST DAY SESSION 2
11/25/2023 17

Preparation and
planning
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
• Inspection
• Pressure testing
• Cleaning and Flushing
• Machinery checkout
Young
11/25/2023 18

 Distillation Towers/Fractionation Towers
 Reboilers & 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
Young
11/25/2023 19

 Pumps
 SteamTurbines
 GasTurbines
 Compressors
 Gas Engines
 Electric Motors
Young
11/25/2023 20

 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.
Young
11/25/2023 21

 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 coloured “highlighter”pens to
indicate different services.
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 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 swingable blinds in place,
 correct rating.
 Check all tag numbers.
 Punchlist any non-conformances.
Young
11/25/2023 24

 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.
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 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.
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 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.
Young
11/25/2023 29

 Inspection after cool-down:
• Check that sliding supports have returned to original
positions;
• Establish that equipment can expand and contract as
required.
Young
11/25/2023 30

 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;
Young
11/25/2023 31

 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.
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Young
FIRST DAY SESSION 2
11/25/2023 33

 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.
Young
11/25/2023 34

 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.
Young
11/25/2023 35

Young
FIRST DAY SESSION 2
11/25/2023 36

 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.
Young
11/25/2023 37

 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;
Young
11/25/2023 38

 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.
Young
11/25/2023 39

 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.
Young
11/25/2023 40

 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.
Young
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11/25/2023 42

 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.
Young
11/25/2023 43

 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.
Young
11/25/2023 44

 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.
Young
11/25/2023 45

 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).
Mechanical Completion and Integrity Checks Done
Young
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Young
FIRST DAY SESSION 3
11/25/2023 47

Preparation and
planning
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
• Steam and other utilities
commissioned and introduced;
• Dry running trials;
• Hot running trials;
• Safe-fluid dynamic testing;
• Solvent dynamic testing;
• Process fluid tests.
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11/25/2023 49

 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.
Young
11/25/2023 50

 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;
Young
11/25/2023 51

Young
• 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.
11/25/2023 52

 Steam usually represents the first “hazardous”fluid
introduced into the “new”system;
 Admit steam slowly into the distribution system with
atmospheric bleeds open, and all drains kept 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.
Young
11/25/2023 53

 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.
Young
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Young
FIRST DAY SESSION 3
11/25/2023 55

 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; leveling 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…
Young
11/25/2023 56

 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.
Young
11/25/2023 57

 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.
Young
11/25/2023 58

 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.
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 Progresses through several stages;
 Dry runs of individual items of equipment
 Hot testing of individual items of equipment and systems;
 Several stages of DynamicTesting of:
• Individual items of equipment;
• Individual Systems/processes in isolation;
• The whole new process plant installation.
Young
11/25/2023 62

 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.
Young
11/25/2023 63

 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.
Young
11/25/2023 64

 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;
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Young
DAY 2
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Young
11/25/2023 67

 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.
Young
11/25/2023 68

 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.
Young
11/25/2023 69

 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;
Young
11/25/2023 70

 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.
Young
11/25/2023 71

 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 tor risks from
over-pressuring, over loading temperature-shocking
and stressing equipment;
Young
11/25/2023 72

 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.
Young
11/25/2023 73

 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.
Young
11/25/2023 74

 Simulated operations will 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.
Young
11/25/2023 75

 At the end of the simulation, water should be
drained - equipment dried and purged;
 Depending on the process - drying may not be
necessary - but purging will always be required;
Young
11/25/2023 76

 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.
Young
11/25/2023 77

 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).
Young
11/25/2023 78

 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.
Young
11/25/2023 79

 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, reboiler and condensation systems into
operation
Young
11/25/2023 80

 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”;
Young
11/25/2023 81

 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.
Young
11/25/2023 82

 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.
Young
11/25/2023 83

 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.
Young
11/25/2023 84

 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;
Young
11/25/2023 85

 Consists of pressuring and de-pressuring with
nitrogen several times, until at least <3% oxygen is
reached;
 Vacuum systems should be evacuated and then
repressurIzed 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.
Young
11/25/2023 86

 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);
Young
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Preparation and
planning
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
• Introduction of process fluid
• Start-up and initial operation
• Trouble-shooting and
problem correction.
• Plant taken to full operations.
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 Most plants in petrochemical/chemical industry have
the following “general ”form.
Start Up from the
End of the Process
andWork back
Reaction
Feed
Preparation
Recovery Product
refining
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 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.
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 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.
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 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;
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 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.
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 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;
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Young
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Preparation and
planning
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
• Performance trials;
• Formal Acceptance test
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 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.
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 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.
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 Physical operation, capability and capacity of plant
and equipment;
 Energy and mass balance;
 Process chemistry;
 Efficiencies, yields and quality;
 All to specification.
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 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
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 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.
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 FormalAcceptance 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.
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Preparation and
planning
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning
• From plant on-stream to settled
down and in regular production;
• Adjustments, modifications and
fault correction;
• Completion of outstanding
punchlist items
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.)What is Flawless –What are Flaws ?
2.) Consequences –What can go wrong ?
3.)Typical Flaws
4)When to doWhat - Front-End-Loading?
5.) Plant Performance –Typical vs. Flawless
•6.) Implementation Sequence
7.) How to start –The 11Q’s
8.) Flawlist Methodology
•9) Generic Flawless Delivery Road Map
•0.)Elements of Q-Assurance Plan
11) Q-CaptainsAction
12)Generic Q-Captain Road Map
13) Flawless DeliveryQ AssuranceTool
14.)Conclusion
15.)Where it went right
16.) Sakhalin Energy – as an example
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All projects have “flaws” ( Organization, People, Assets)
Most flaws present themselves in Start-Up Phase (on critical path)
Many flaws are similar and repeats of other projects
The effect of flaws results in
Culmination of delays
Increased risk for failures with high severity impact
loss of production, HSE, business, reputation
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Each project phase can produce flaws
If these flaws are not identified within the project phase in which they occur
then they get passed onto the next project phase….they may or may not be
captured in the next phase
If flaws remain until the CSU project phase then schedule delays and additional
rectification costs will be incurred. In many cases these will be significant
Delays = lost revenue = not recoverable for project economics
The best method of identifying these flaws is from past projects and lessons
learned i.e. backward integration into the project phases
Clearly a structured process is needed to assist in identifying and mitigating
against these flaws.
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Avoiding problems:
Chemicals complex, cleanliness problems – rework and production losses >$30 million
Chemicals complex, prototype effluent water handling – repairs
($3 million), production loss >$20 million and additional operating costs (> $2 million per
month)
Refinery, start-up delays caused by instrumentation problems – production losses >>$60
million
Refinery, inadequate cleaning followed by wrong preservation – rework and production losses
(delay) worth >$100 million
Improving on performance:
In addition: Structuring the work-processes: time-saving typically more than one month, worth
>30 million US$
Improving on performance:
In addition: Structuring the work-processes: time-saving typically more than one month, worth
>30 millionUS$
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• Leaking flanges/valves, gasket failures, wrong or no gaskets, misaligned
flanges, cross contamination of liquids,
• Blocked fine bores… filters, burner tips, instrument tappings catalyst beds,
• Non functional systems, equipment, instrumentation, components
• Poor or in-operability of systems, equipment….many alarms, trips etc
• Incidents with HSE consequences
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• Non recognition of new technology, new equipment, new components
• Non recognition of complex systems requiring significant organisational input
etc
• Lack of sequenced testing of components, equipment systems, units
• Inexperienced organisation or inexperience on new unit/system/equipment
•
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• More than 50% of flaws originate
from the development phases.
• Resolution clearly requires back
integration of these flaws into early project
phases….lessons learned.
• Clearly if these flaws remain until
last project phases then significant delay
and cost will be the result.
SCOUT/BOD/BDP PS EPC CSU
45 10 40 5
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1. Damage due to shipping
2. Verify ship loose items (misplaced, lost in transit, never shipped, etc...)
3. Shims not laser cut and/or are the wrong size
4. Motor does not have 8 jacking bolts
5. Suction/discharge/drain flanges are not covered with a metal closure
6. Water present in the case and drain lines
7. Oil mist lubricated bearings preserved with grease
8. Mounting pads do not meet the level requirements of API 610 and Purchase
Order
9. Baseplate lacks levelling screws
10. Motor is bolt bound
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Preservation {Pre Installation}
Important to have constant surveillance as conditions on a construction site
change daily with work activities, weather, etc.
Heated indoor storage and constant auditing are best preservation program
(API 686 Ch 3 par 1.5.1-1.5.19)
Assign ownership of program early {our experience went through 2
preventative maintenance companies during project}
Define on an equipment tag basis what equipment needs what type of PM;
have PM Cards and an overall database; follow up with regular inspection.
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Key Learning’s from Construction
Job site demands and tasks are ever changing and daily meetings with owner
inspection team is vital
Need a strong relationship between Construction Contractor, Operations and
Project Team to ensure clear communication and for rise and resolution of
issues
Our monthly workshops were excellent forums to get alignment and increase
trust in building working relationships
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Vendor Representation on site full time to approve NCR’s for immediate
implementation is vital to construction phase success
API 686 tolerance of 0.002” per foot is a tight tolerance to achieve
Ensure all pressure vessels related to rotating equipment (filters, seal pots,
etc.) have proper ABSA registration and Canadian registration numbers
Ensure all tubing related to rotating equipment receives proper documented
pressure testing as per requirements stated in Pressure Equipment Safety
Regulation Section 4 criteria defined in B31.3 (pressure tubing is to be tested
as pressure piping)
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Pre-Start-up Issues
Experienced leaks on pump seals due to poor preservation (residual hydro test
fluid)
Flushing of auxiliary lube oil and barrier fluid systems took a lot of time.
Cleanliness issues found
Motor Bump testing done to IEEE Standard for (TEFC) Totally Enclosed Fan
Cooled Squirrel Cage Induction Motors found high vibration issues, resulting in
additional stiffening support being required
The need to loop check and fully function check all instrumentation prior to start
up is critical and takes a great deal of effort and time
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Start-up Issues and Outcome
Issues
Unanticipated high vibration of pumps running off of BEP
Minor cavitation issues
Very few leaks, casing, tubing, instrumentation, etc
Mechanical Seals preservation damage (residual hydro test fluid)
Minor vibration of motor bases
Strainers with a weak delta pressure design
Outcome
Plant was commissioned and Start-up in Spring of 2011
No major incidents, and start-up progression achieved a Flawless Start-up
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Workshop on Plant Commissioning and Seamless Startup final.pdf

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