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Workshop on Plant Commissioning and Seamless Startup final.pdf

Mr. Himadri Banerji a graduate of the prestigious Indian Institute of Technology has over 35 years of industry experience in Steel, Process and Thermal Power Plants in India and Europe. After a stretch of 22 years in Tata Steel continued his career with such illustrious companies as Rolls Royce, Torrent and Reliance. His expertise includes planning, building, testing, and start up and commissioning, besides operating and maintaining Large Process Plants, Steel Plants, Petrochemicals, Dyes and Paints, Cryogenic Gases, Steam and Electric Power. Mr. Banerji brings a diverse range of experience in successful commissioning, having personally led start up and commissioning teams for plants consisting of large High Speed Rotary Equipment like Axial and Radial Compressors, Steam and Gas Turbines, Water Pumps, Temporary Power Solutions with Medium and Large Diesel and Gas Engines, Static Systems like Chemical Reactors, Air Separation Units, Process Instrumentation and Control, CFBC, AFBC and PF Steam Generators. His work also encompasses other Plants like Water Treatment, Effluent Treatment Plants, Reverse Osmosis and De-mineralising and Desalination Plants. He has also recently designed and implemented chemical regimes for Control of Steam and Water Cycle Chemistry during Start-up of Super-critical Power Plants based on Union of the Electricity Industry – EURELECTRIC guidelines an association of the Electricity Industry within the European Union. Dr Banerji regularly chairs and speaks at international conferences and workshops on Procedures and Systems for Managing Risk during Start-up and Commissioning of plants. He has lectured widely in various countries like Singapore, Malaysia, Indonesia, India

1 of 123
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
Workshop on Transition from Construction to Flawless Operations
Himadri Banerji Ex CEO Reliance and International Expert Ernst and
Young
11/25/2023 4
Preparation and
planning
Mechanical Completion
and Integrity checking
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;
Workshop on Transition from Construction to Flawless Operations
Himadri Banerji Ex CEO Reliance and International Expert Ernst and
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
Workshop on Transition from Construction to Flawless Operations
Himadri Banerji Ex CEO Reliance and International Expert Ernst and
Young
11/25/2023 6

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Workshop on Plant Commissioning and Seamless Startup final.pdf

  • 1. 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
  • 2. 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
  • 3. 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
  • 4. Preparation and planning Mechanical Completion and Integrity checking Pre-commissioning & Operational Testing Start Up & Initial Operation Performance and Acceptance testing Post Commissioning Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 4
  • 5. Preparation and planning Mechanical Completion and Integrity checking 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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 5
  • 6.  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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 6
  • 7.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 7
  • 8.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 8
  • 9.  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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 9
  • 10.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 10
  • 11.  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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 11
  • 12. Corporate Knowledge Base Best Practice Benchmarking Industry Standards Legislation Process Design Specific Machinery & Equipment Procedures and Check sheets Improvement Processes Experience Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 12
  • 13. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 13
  • 14.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 14
  • 15.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 15
  • 16.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 16
  • 17. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young FIRST DAY SESSION 2 11/25/2023 17
  • 18. Preparation and planning Mechanical Completion and Integrity checking Pre-commissioning & Operational Testing Start Up & Initial Operation Performance and Acceptance testing Post Commissioning • Inspection • Pressure testing • Cleaning and Flushing • Machinery checkout Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 18
  • 19.  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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 19
  • 20.  Pumps  SteamTurbines  GasTurbines  Compressors  Gas Engines  Electric Motors Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 20
  • 21.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 21
  • 22.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 22
  • 23. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 23
  • 24.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 24
  • 25.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 25
  • 26. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 26
  • 27.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 27
  • 28. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 28
  • 29.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 29
  • 30.  Inspection after cool-down: • Check that sliding supports have returned to original positions; • Establish that equipment can expand and contract as required. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 30
  • 31.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 31
  • 32.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 32
  • 33. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young FIRST DAY SESSION 2 11/25/2023 33
  • 34.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 34
  • 35.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 35
  • 36. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young FIRST DAY SESSION 2 11/25/2023 36
  • 37.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 37
  • 38.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 38
  • 39.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 39
  • 40.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 40
  • 41.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 41
  • 42. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 42
  • 43.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 43
  • 44.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 44
  • 45.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 45
  • 46.  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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 46
  • 47. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young FIRST DAY SESSION 3 11/25/2023 47
  • 48. Preparation and planning Mechanical Completion and Integrity checking 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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 48
  • 49. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 49
  • 50.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 50
  • 51.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 51
  • 52. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and 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
  • 53.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 53
  • 54.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 54
  • 55. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young FIRST DAY SESSION 3 11/25/2023 55
  • 56.  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… Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 56
  • 57.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 57
  • 58.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 58
  • 59.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 59
  • 60. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 60
  • 61. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 61
  • 62.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 62
  • 63.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 63
  • 64.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 64
  • 65.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 65
  • 66. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young DAY 2 11/25/2023 66
  • 67. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 67
  • 68.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 68
  • 69.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 69
  • 70.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 70
  • 71.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 71
  • 72.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 72
  • 73.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 73
  • 74.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 74
  • 75.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 75
  • 76.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 76
  • 77.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 77
  • 78.  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). Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 78
  • 79.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 79
  • 80.  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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 80
  • 81.  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”; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 81
  • 82.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 82
  • 83.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 83
  • 84.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 84
  • 85.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 85
  • 86.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 86
  • 87.  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); Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 87
  • 88. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 88
  • 89. Preparation and planning Mechanical Completion and Integrity checking 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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 89
  • 90.  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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 90
  • 91.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 91
  • 92.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 92
  • 93.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 93
  • 94.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 94
  • 95.  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; Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 95
  • 96. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 96
  • 97. Preparation and planning Mechanical Completion and Integrity checking Pre-commissioning & Operational Testing Start Up & Initial Operation Performance and Acceptance testing Post Commissioning • Performance trials; • Formal Acceptance test Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 97
  • 98.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 98
  • 99.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 99
  • 100.  Physical operation, capability and capacity of plant and equipment;  Energy and mass balance;  Process chemistry;  Efficiencies, yields and quality;  All to specification. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 10 0
  • 101.  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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 10 1
  • 102.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 10 2
  • 103.  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. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 10 3
  • 104. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 10 4
  • 105. Preparation and planning Mechanical Completion and Integrity checking 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 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 10 5
  • 106. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young .)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 11/25/2023 10 6
  • 107. 11/25/2023 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 10 7
  • 108. 11/25/2023 Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 10 8
  • 109. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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 11/25/2023 10 9
  • 110. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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. 11/25/2023 11 0
  • 111. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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$ 11/25/2023 11 1
  • 112. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young • 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 11/25/2023 11 2
  • 113. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young • 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 • 11/25/2023 11 3
  • 114. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young • 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 11/25/2023 11 4
  • 115. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 11 5
  • 116. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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 11/25/2023 11 6
  • 117. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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. 11/25/2023 11 7
  • 118. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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 11/25/2023 11 8
  • 119. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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) 11/25/2023 11 9
  • 120. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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 11/25/2023 12 0
  • 121. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 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 11/25/2023 12 1
  • 122. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 12 2
  • 123. Workshop on Transition from Construction to Flawless Operations Himadri Banerji Ex CEO Reliance and International Expert Ernst and Young 11/25/2023 12 3