The document outlines the various phases of project execution in chemical engineering, specifically focusing on component assembly, transportation, installation, and safety measures. It discusses the differences between prefabricated and site-run piping, detailing their advantages and disadvantages, as well as the importance of planning and testing during the assembly process. Additionally, the text covers commissioning, cleaning, functional tests, and warranty runs to ensure proper plant operation and maintenance.

1. SAJJAD KHUDHUR ABBAS
Chemical Engineering , Al-Muthanna University, Iraq
Oil & Gas Safety and Health Professional – OSHACADEMY
Trainer of Trainers (TOT) - Canadian Center of Human
Development
Episode 22 : PROJECT
EXECUTION

2. Component Assembly
•Transportation of component
•Installation of components at plant site
Police approval
•Large components – used suitable cranes, usually are leased/rent
– electronically controllable by remote control
•Medium/Smaller components
– hoists or fork‐lifts are used
– are ordered to the building site at an early stage and intermediately
stored there.
‐If possible, at the same time, during the assembly of main components, the
assembly of medium/smaller components will begin.
‐Subcontractor is required to provide suitable packaging or tarpaulin cover
(cover for vessel opening such as nozzle, by means of plastic caps)
Transport analysis
‐
‐Headroom of bridge &
tunnel
‐turning circle of vehicle
(U‐turn)

3. Crane
Fork‐lift
Hoist
3

4. PIPE ASSEMBLY
•Begin after the installation of the essential
components has been completed.
• Depend on several factors. Example: Case
of metal pipe, welding work is required.
• The non‐destructive testing also need to
consider.
Prefabricated piping
Two possibilities in the fabrication of the
piping.
Site‐run piping
PREFABRICATED PIPING
Requires a good and detail piping planning.
• Pipe routes are prefabricated on the pipe supplier’s premises.
• Delivered to the building site in the form of a conglomerate of pipe formations.
Advantages
‐ Has a time advantages.
‐ During prefabricated phase,
construction and component assembly
can be excluded.
‐ Building site activities are less.
Disadvantages
‐ The collisions and alterations are
considerable (cause extra cost needed).
‐ Rubber lined pipe systems must
prefabricated (time effort involved).

5. SITE‐RUN PIPING
•With the aid of the piping and instrumentation flow charts the piping routes are
planned and dimensioned.
•Planning effort – lower and CAD systems ‐ no need
• Probability of collisions –lower
• Planning the piping routes ‐no
•The piping documentation has to be integrated or prepared on ‐ site during the
construction phase
• Disadvantage ‐ not suitable at high temperature.
• Advantage ‐ small nominal widths do not require stress calculation.
• fixed flanges
• rotatable flanges
• screwed connections
• glued joints
• welding joints
• other fittings
FITTING AND CONNECTIONS
5

6. ASSEMBLY E/MC TECHNOLOGY
Usually assembly of electrotechnical equipment is independently from the plant
erection because of the control cabinets are accommodated in separated rooms.
More difficult is the installation of measuring instruments and cabling. Since a
large part of measuring instruments is integrated in the pipes, the assembly occurs
within the framework of the piping and fitting assembly.
Cabling will begins with so‐called “cable reels”.
Cable Reels:
 Where cable laid from control station to the individual consumer or measuring
points in the cable trays.
 The cable reel requires an external temperature of more than 5°C. If the external
temperatures are lower, there will be the risk that either the cables break or the
cable trays will be deformed due to the embrittlement of the cable insulation.
 The cable reel can be passed through before the assembly of the actual
consumer.

7. The cable connecting plans generated both from the piping plans and from the
piping and instrumentation diagrams that shows the position of the consumer or
connecting points in the plant.
In the majority of cases, cables are laid in protective conduits as soon as they leave
the cable trays.
Finally the cables are connected to the terminal boxes of the motor.
Usually the cable connection work requires separate scaffolds. Moreover, the
concurrent assembly of components and cable reels bears the risk of damaging the
newly laid cables. This applies especially to the insulation work to be done.
It is advisable to carry out the cable reel work only after the completion of the
assembly.
The usual time pressure, however, does not allow for such a procedure.
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8. •Insulation work start after assembly of the
piping.
•The insulation consist of mineral wool layer.
•For longer vertical pieces, dual grip rings used
which hold the insulation wool to protected
against slipping.
•Finally, insulation caps or moulted parts
mounted after pressure and leakage tests.

9. • Plant Marking and Safety Marking
• Commissioning
• Cleaning
• Pressure Test, Functional Test, System Test
• Cold and Warm Commissioning
• Warranty Run/ Acceptance
9
Presentation Scope

10. Plant Marking
10
1) Marking of the operating resources
2) Pipeline marking
3) Cable marking
4) Safety marking
5) Other markings (at sole discretion of customer)
 Marking of the operating resources may be designed as engraved
labels or profile rails with individual letters being inserted.
 Fixing of the labels occurs by means of clamps, rivet joints, cable
ties etc
 For the pipes, marked are done with banderols either directly
glued on to the pipes or on to the insulation
 Colour of the banderol represent media carried by the pipeline

11. Comprises the marking of hazardous material according to the
Ordinance on Hazardous Substances.
– hazardous substances symbols in yellow/black (skull for toxic
media, etched hand for acids etc.).
– instruction signs in blue/white (eye protection, breathing
protection, ear protection)
11
Safety Marking

12. Commissioning
12
 The commissioning coincides with the residual work of the
assembly
 The person mainly responsible ~ commissioning manager
 C.M should be able to use their considerable experience gained in
other projects.
 It also is subjected to a time schedule that should be adhered to.
 Depends on the philosophy of the plant manufacturer.
 The considerations regarding commissioning of a plant should
already be integrated in the beginnings of the plant engineering.
 Furthermore, the optimum implementation of the commissioning
activities requires competent commissioning management .
 After all, insights gained in the commissioning process should be
absolutely documented to draw advantages for future projects.

13. Cleaning
13
• After completion of the assembly work the preliminary cleaning of
the building site and the plant has to be carried out. The inside
cleaning of the plant is considerably more difficult.
• The containers and apparatus have to be cleaned from inside and
then the piping will be purged.
• In order to protect sensitive plant components, in particular pumps,
measuring instruments and control valves, during the flushing
process it is advisable to shut them off by means of blanks.
a) Sensitive measuring instruments can be removed. The
orifices are to be closed by blind flanges or caps.
b) For control valves, flushing inserts can be ordered and
installed.
c) Pumps can be protected by installing blanks on the suction
and pressure side.

14.  After completion of the assembly work the preliminary cleaning of
the building site and the plant has to be carried out. The inside
cleaning of the plant is considerably more difficult.
 There is the alternative to protect sensitive plant parts through
the installation of so – called start - up strainers or flushing
sieves.
 Usually, it is flushed from the pumps in the direction of the
vessels or apparatuses.
 In order to enable the removal of coarse impurities, interval
flushing is advantageous. The flushing conduit will be opened and
kept open for a determined interval and will finally be closed again.
This procedure can be repeated several times.
14
Cleaning

15. - Generally limited to the assembled pipes.
1) The system is filled and then evacuated at the highest point.
2) Pressure test applied and time-related pressure drop will be recorded.
3) Visual test of all connecting points also carried out.
4) Eliminate leakages and finally discharge water from the pipes.
Functional Test
- The individual aggregates and measuring points are tested for their correct function
- Examples of functional test applied
1) Pump
2) Fixtures and fittings
3) Apparatus – agitators, centrifuges and etc.
4) Black boxes – self contained and operative small plants
5) Measuring instruments
15
Pressure Test

16. System Test
- Carry out after functional test on each individual aggregates and
measuring points
- The controls of the main system will be tested whether the entire
system function work properly or not.
Cold and Warm Commissioning
 Cold Commissioning
 After inspection of all system controls
 Liquid processing plant first filled with water up to
control levels
 Individual system controls are activated
 Flow-through and level controls can be tested and optimized
 Timing elements have to be optimized
16

17. Cold and Warm Commissioning
• Warm Commissioning
 Testing and optimizing of plant components ( heat supply/heat
removal )
 Application of the real media
 Warming up of the steam pipes
 Shut off discharge valve ( no more condensate )
 Connect condenser
 Heating of the respective heat exchanger
 Warm Dry Run
 Cooling water system ( with water in the plant )


Plant discharged
Optimization tasks
measurements
real starting material for 1st time
inter alia, calibration of all quality
17

18. Warranty Run/Acceptance
Main Objective
- To verify the proper function of constructed plant
Warranty Run
1. Before
2. During
3. After/Acceptance
1) Operating condition during test run must be agreed with operator
2) Different loading conditions of the plant are shown and guaranteed
qualities are measured
BEFORE
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19. o Several minor failure or one major failure
1) Restart the test run
2) List of defect, retrofitting measures and deadlines have to be determined
3) If retrofit not success, plant manufacturer face claim for relevant penalty
o Major defect that cannot be remedied by retrofit
1) Entitle operator to reject the whole plant
DURING
AFTER
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o During warranty period
1) Plant manufacturer to remedy them but not covered damages caused
by operator due to improper handling
2) Plant manufacturer refer deficiencies to relevant subcontractor
o After warranty period
1) Plant deficiencies is the responsibility of customer and insurances policy
o Operation
1) The operation of plant is taken over by operator staff

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