Commissioning & Interface With Engineering

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Commissioning & Interface With Engineering

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Commissioning & Interface With Engineering

  1. 1. PRE-COMMISSIONING & COMMISSIONING A discussion on Pre-commissioning / Commissioning & Start Up of Projects1
  2. 2. Contents  Objective  Common work at process plant at pipe line  Definition of Mechanical Completion  Pre-Commissioning Definition and Procedure2
  3. 3. Contents(Continued)  Activities (Piping & vessels, Mechanical, Electrical, Instrumentation, Operations)  Check Sheets  Punch Listing  Completion Activities3
  4. 4. Objectives  Start-up and hand-over of the completed plant to the Client.  To support client in operation of plant .4
  5. 5. COMMISSIONING & START-UPMECHANICALCOMPLETION SYSTEM / OPERATIONInclusive of PLANT COMMISSIONING PACKAGE STAFFPre-commissioning START-UP HANDOVER TRAININGActivities 5
  6. 6. Commissioning Works At Process Plants PIPING / VESSEL ELECT / INSTRUM•Flushing/Blowing •Preliminary Check•Chemical Cleaning •Calibration•Reinstatement •Circuitry Check•Gross leak with N2 •Continuity Check•Drying •Loop Test•Inerting • Energization (Power Up)•Hydrocarbon In •Performance Tests MANAGEMENT •Systems Breakdown •Preparation of Procedures •Loop Folder •Circuit Folder •Test Packs CONTROL SYSTEM ROTATING EQUIPMENT •SCADA / PCS SAT•Alignment •Fire & Gas System•Belt Tensioning •Safety Shutdown Sys.•Motor Run in Test •Alarm Set-Up & Test•Vibration Test •Simulation Test 6
  7. 7. Commissioning Works At Pipe Lines PRECOMMISSIONING SPECIALIZED PIPELINE CLEANING•Cleaning •Dewaxing•Flooding •Descaling•Hydro testing •De-oiling•Dewatering & Drying •Pit cleaning•Flushing •Chemical cleaning•Nitrogen Inserting •Combined cleaning methods ASSOCIATED SERVICES PIPELINE INSPECTION•Temporary pipeline repair •Geometry inspection•On-site supervision •Metal loss inspection•Cathodic protection •Crack detection•Hot tapping & stoppling •Leak detection and location•Flow assurance Etc. •Profile monitoring and mapping 7
  8. 8. Definition of Mechanical Completion & Construction Completion  Mechanical Completion: A series of activities that MUST be completed prior to the commencement of Commissioning and Start-up of a Utility System or Main Process Unit.  Mechanical Completion ALSO includes ALL pre-commissioning activities.8
  9. 9. Pre-Commissioning Overview  Process: Confirmation of Loops according to P& ID’s  Vessels: Internal Inspection & Box up  Piping: Hydro testing, reinstatement & verification of main gaskets.  Stationary Equipment: Tightening and Final Box Up.  Rotary Equipment: Leveling, Rotation,9 Alignment & lubrications
  10. 10. Pre-Commissioning Activities – Piping & Vessels  Field checks as per isometrics and P&ID’s  Verification of hydro testing  Verification of flushing , blowing & drying  Internal inspection of equipment as required10
  11. 11. Pre-Commissioning Activities – Piping & Vessels(Continued)  Verification of Internals  Re-instatement of all flanges, control value, orifices, Psv’s and steam traps.  Verification of blinds / spades installation and / or removal  Box up: Pre-commissioned and closed11
  12. 12. Pre-Commissioning Activities – Mechanical Discipline  Verification of coupling and belt alignment  Pumps / compressor checks  Bearing lubrications  Inspection / checking of filters & strainers12
  13. 13. Pre-Commissioning Activities – Electrical Discipline  MCC & UPS installation  Field electrical installation – Cable Meggering (Continuity) – Termination of wiring; end devices to JB’s & MCC – Termination & Glanding according to area classification.13
  14. 14. Pre-Commissioning Activities – Electrical Discipline(Continued)  Motor installation – Resistance maggering – Rotation confirmation – No load test run14
  15. 15. Pre-Commissioning Activities - Instrumentation  Instrument installation checks  PSV calibration  Calibration of transmitters and switches  Loop checking of device end to PLC  Function testing of PLC & ESD systems15
  16. 16. Pre-Commissioning Check Sheets  Vessel & Piping Check Sheets  Mechanical Check Sheets  Electrical Check Sheets  Instrumentation Check Sheets16  Operation / Process Check Sheets
  17. 17. Punch Listing  Punch Lists are created and sorted as per disciplines – Piping and Vessels – Mechanical – Electrical – Instrumentation – Operations  Punch Lists are categorized on a priority basis – Category “A”; MUST be completed prior to Commissioning – Category “B”; MUST be completed prior to Start-up – Category “C”; Signifies end of job  Construction Contractor MUST have a coordinated management plan of Punch Listing including categorizing of punch list items17
  18. 18. Completion Activities  Flushing Blowing Certificates  Box Up Certificate  Mechanical Completion Certificate for each Utility and Process Unit  Handover Certificate18
  19. 19. COMMISSIONING  Definition  Utility Description  Commissioning Activities  Check Sheets  Commissioning / Start Up Procedure19
  20. 20. Systems Description Commissioning of The Following Systems  Air Compression System  MCC & Plant Lighting System  UPS, PLC & Plant ESD System  Fire Water System  Fire & Gas Detection System20
  21. 21. Systems Description  Instrument Air Package  Inert Gas Package  Fuel Gas System  Closed Drain & Waste Water Systems  Condensate Transfer System  Process Units; Reactor21
  22. 22. Commissioning Check Sheets  Commissioning check sheets are given in the Commissioning Protocol.22
  23. 23. START-UP OF PROCESS UNITS  Utilities in Service  Introduction of Raw material (Vacuum Residue Feed)  Introduction of Process Air & Steam  Production of required grades of products  Maintaining required proportion of off gases as per specs  Achievement of required steam temperature  Obtaining steam temperature compatible to system steam temperature.23
  24. 24. Issues for Discussion.  Less re-work SS304, 304L  Carbon filter back flow  Go for the standard packages  15 KM pipeline24
  25. 25. THANK YOU25

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