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
This program addresses in an integrated manner the key activities involved in the safe, effective and timely commissioning and start-up of a new plant or facility. Start Up and Commissioning of new plant and equipment presents both a major technical and management challenge. An organisation’s personnel must familiarise themselves with new equipment, processes and technologies, develop the relevant operating and safety procedures.
At the same time there is the requirement to execute an exceptionally large scope of work – much of it complex when compared to routine operations - over a short period of time, with equipment and plant which is as yet unproven and that may pose significant risks to personnel, environment and profitability.
This 5 day training course addresses the technical issues of commissioning and starting up various equipment and asset types commonly found in processing plant environments, the development of specific commissioning procedures, process and facility wide commissioning strategies. The course will also address the broader managerial issues of commissioning and start up planning, resourcing, budgeting and cost control, risk management – safety, environmental, financial and operational, problem solving and trouble shooting.
Front End Engineering Design (FEED) Project Control TrainingDEVELOP
DEVELOP Training Center (TM) conducts Front End Engineering Design (FEED) Project Control Training, which is very useful to gain skills on how to plan & control projects, as well as navigate and optimize the Project execution.
This training will be useful to gain skills on how to plan & control projects, as well as navigate and optimize the FEED Project execution, such as : FEED Work Order-Scope,FEED Stakeholder identification,FEED Project Deliverables,FEED Multidiscipline Man-hour Calculation-productivity,Engineering-Procurement-Construction Project Contract technical issues-investment Cost Estimation ,FEED Review Cycle,EPC Long lead items,FEED Close out Report-Lessons Learnt
This program addresses in an integrated manner the key activities involved in the safe, effective and timely commissioning and start-up of a new plant or facility. Start Up and Commissioning of new plant and equipment presents both a major technical and management challenge. An organisation’s personnel must familiarise themselves with new equipment, processes and technologies, develop the relevant operating and safety procedures.
At the same time there is the requirement to execute an exceptionally large scope of work – much of it complex when compared to routine operations - over a short period of time, with equipment and plant which is as yet unproven and that may pose significant risks to personnel, environment and profitability.
This 5 day training course addresses the technical issues of commissioning and starting up various equipment and asset types commonly found in processing plant environments, the development of specific commissioning procedures, process and facility wide commissioning strategies. The course will also address the broader managerial issues of commissioning and start up planning, resourcing, budgeting and cost control, risk management – safety, environmental, financial and operational, problem solving and trouble shooting.
Front End Engineering Design (FEED) Project Control TrainingDEVELOP
DEVELOP Training Center (TM) conducts Front End Engineering Design (FEED) Project Control Training, which is very useful to gain skills on how to plan & control projects, as well as navigate and optimize the Project execution.
This training will be useful to gain skills on how to plan & control projects, as well as navigate and optimize the FEED Project execution, such as : FEED Work Order-Scope,FEED Stakeholder identification,FEED Project Deliverables,FEED Multidiscipline Man-hour Calculation-productivity,Engineering-Procurement-Construction Project Contract technical issues-investment Cost Estimation ,FEED Review Cycle,EPC Long lead items,FEED Close out Report-Lessons Learnt
I am Pravin Xavier, I had around 12 years experience in Oil and Gas. right now I am looking for a job. I have good knowledge in Production / Process and commissioning so If any openings kindly let me know. I ready to join immediately.
During the past and present career, experienced in the following areas.
1) Commissioning, 2) Jetty Operation, 3) Well Head Operations, 4) Separators, 5) Crude Oil Stabilization Unit, 6) Oil & Gas Gathering Station, 7) Gas Dehydration & Amine Sweetening unit, 8) Gas Plant Operation 9) Hot Oil Unit, 10) Boiler & heater Treatment 11) Central Production Facility and Tank Farm, 12) DCS experience, 13) Compressors, 14) Pump Operation 15) Pigging Operation 16) Chemicals Handled
Thanks & Regards
PRAVIN XAVIER .R
Mob. - 0091 9994774530
Skype - pravinxavier.r
THIRTEEN (13.4) years of extensive experience as Mechanical ,Piping , Shutdown project, Material Inspection/Material Prevention in Laydown Area or site area/ Structural QA/QC Inspector & QC Supervisor in Mechanical field of construction in various projects like Oil & Gas Industries, Petro chemicals, Chemical Plants, high rise building and infrastructure sector.
I would like to enroll in your esteemed organization as a candidate for an opening in the field of QA/QC Manager . I expect to here from your end in near future.
Excellent planner and strategist with proven abilities in surveying the projects of all kinds of earth works, power plant, chemical plant, water treatment plant, oil & gas plant etc.
Strong analytical and Organizational abilities with skills to plan and implement novel ideas
I am Pravin Xavier, I had around 12 years experience in Oil and Gas. right now I am looking for a job. I have good knowledge in Production / Process and commissioning so If any openings kindly let me know. I ready to join immediately.
During the past and present career, experienced in the following areas.
1) Commissioning, 2) Jetty Operation, 3) Well Head Operations, 4) Separators, 5) Crude Oil Stabilization Unit, 6) Oil & Gas Gathering Station, 7) Gas Dehydration & Amine Sweetening unit, 8) Gas Plant Operation 9) Hot Oil Unit, 10) Boiler & heater Treatment 11) Central Production Facility and Tank Farm, 12) DCS experience, 13) Compressors, 14) Pump Operation 15) Pigging Operation 16) Chemicals Handled
Thanks & Regards
PRAVIN XAVIER .R
Mob. - 0091 9994774530
Skype - pravinxavier.r
THIRTEEN (13.4) years of extensive experience as Mechanical ,Piping , Shutdown project, Material Inspection/Material Prevention in Laydown Area or site area/ Structural QA/QC Inspector & QC Supervisor in Mechanical field of construction in various projects like Oil & Gas Industries, Petro chemicals, Chemical Plants, high rise building and infrastructure sector.
I would like to enroll in your esteemed organization as a candidate for an opening in the field of QA/QC Manager . I expect to here from your end in near future.
Excellent planner and strategist with proven abilities in surveying the projects of all kinds of earth works, power plant, chemical plant, water treatment plant, oil & gas plant etc.
Strong analytical and Organizational abilities with skills to plan and implement novel ideas
Pre Commissioning Testing Training and Maintenance of Instrumentation Analyzer, Metering Skid, Crude Oil Samplers, Corrosion, CP Radio Monitoring system, Laser HF and H2S Hydrogen, Oxygen Emerson oxymitter, Emerson Bentely Navada Vibration Analyzers, Thermography, Gas cement Petroleum Analyzers, Gas Chromatograph in Refinery Oil Gas Plants Petrochemical Aramco Sabic.
Extensive coordination between client and supplier in make sure all resolution successfully covered to achieve end client satisfaction.
Brochure on Two Day Workshop on Plant Commissioning and Seamless Start Up By ...HIMADRI BANERJI
Overview of the wokshop:
To gain practical insights into:
Redefining the responsibilities of various departments to ensure a flawless start-up.
Ensuring that safety measures are put in place to
ensure zero LTIs during commissioning and startup.
Benchmarking your commissioning practices
against previous commissioning and start-up experiences.
Acquiring risk management techniques for better
prediction of what can go wrong during the commissioning and start-up process and identify
and plan effective mitigation measures.
Accelerating the ROI of your plant through proper
planning and management of resources during the
commissioning process.
Capturing the essence of commissioning and startup
in Greenfield and Brownfield Scenarios.
Gas Turbines Failures Applications & Root Cause Analysis.pptxHIMADRI BANERJI
SUBJECT PRESENTED AS CLASS ROOM LECTURES FOR ASSTT ENGINEERS OF ELECTRIOCITY GENERATION COMPANY OF BANGLADESH
2014-2017
HIMADRI BANERJI
INTERNATIONAL EXPERT GAS TURBINES
The aims of the O&M of Gas Turbines Workshop is to share the experiences of our internationally renowned expert with an aim to prevent such incidents and also to examine the factors and opportunities to increase plant safety, environmental performance. And improve uptime and availability all factors contributing to higher profitability.
The workshop will also examine scheduled maintenance and turnarounds which are opportunities to increase plant safety and environmental performance. By enhancing the mechanical integrity of HPI facilities, operating companies can achieve and maintain higher uptime and equipment availability; all are factors that contribute to higher profitability. Best-of-class companies hold the mindset that reliability programs provide great benefits. Investing in new monitoring and conditioning systems, along with preventive maintenance and inspection programs, can optimize unit and total facility performance.
The development of dry low NOx (DLN) combustors for gas turbines has cut the industry's consumption of water, while dramatically slashing air emissions. Unfortunately, this environmental enhancement has created an engineering challenge: The lean-burning DLN combustors are prone to flame instability, which can cause pressure pulsations large enough to destroy the combustor, launching debris downstream where it annihilates other hot-gas-path components. To detect and correct flame instability before it causes millions of dollars of turbine damage, savvy users have begun to install advanced sensors and robust software that monitor the combustor dynamics in real time.
High dynamics can limit hardware life and/or system operability. Thus, there have been various attempts to control combustion dynamics, to prevent degradation of system performance. There are two basic methods for controlling combustion dynamics in an industrial gas turbine combustion system: passive control and active control. As the name suggests, passive control refers to a system that incorporates certain design features and characteristics to reduce dynamic pressure oscillations. Active control, on the other hand, incorporates a sensor to detect, e.g., pressure fluctuations and to provide a feedback signal.
Which, When suitably processed by a controller, provides an input signal to a control device. The control device in turn operates to reduce the dynamic pressure oscillations. The workshop will examine the factors and the issues associated with combustor dynamics, and technologies like AMFM/CFM.
Benefits ofAttending
• LEARN best and effective practices in operations and maintenance of Gas Turbine Based Power Plants
• LEARN how to write and use SOPs
• IMPROVE your plants’ energy efficiency and availability
• ACHIEVE productive and safe operation
• NETWORK with other power plant professionals
• RECEIVE practical information for your CAPEX and OPEX expenditure budget planning
• LEARN about strategic procurement of High Value Spares and insurance
Making Artificial Intelligence Work in Managing ChangeHIMADRI BANERJI
“Making Artificial Intelligence (AI) Work In Managing Change ” is a Capability Improvement webinar which has been stitched together by a two member team comprising of a Senior CEO level Oil Gas and Energy Sector business executive who in his professional career spanning over decades has led multiple projects in digital
transformation in decision support systems in top organizations in the country and abroad in the contexts of
competion and uncertainty and an a senior IT expert who has hands on experience in designing the
configurations of hardware and the associated software in Digital Transformations in various areas including
Data Analysis, Machine Learning, Deep Learning, Neural Networks for implementing state of the art Artificial
Intelligence Systems in the Silicon Valley.
Two Day Integrated Workshop on “AI and Machine Learning for
Business Transformation”
It is essential for the success of every organization to stay ahead of the rapidly changing market by having access to
reliable and trustworthy information. Across the AI world, AI challenges are being converted by innovators into
tomorrow's business opportunies.
Success in this environment will depend on the speed of analysis and decision making, addressing customer needs
upskilling workforces and geng the right person to work on the right opportunity.
This one-of-a-kind integrated AI workshop enables you to dive deep into new depths of understanding and insights
into how AI is transforming work in organizaons. This workshop will unlock the right Data-driven AI techniques
and opportunities for project implementation in your organization that will set your business apart.
The methodology and techniques which enable machines to mimic human behavior and nature
are known as artificial intelligence. Machine learning is a subset of AI which allows a machine to
automatically learn from past data without explicit programming.
Risk management in nuclear projects and strategy of small reactors [compatibi...HIMADRI BANERJI
This technical document on risk management as a tool for improving nuclear power
plant (NPP) operations is part of an ongoing project on management of NPP operations in a
competitive environment. The overall objective of this project is to assist the management of
operating organizations and NPPs in identifying and implementing appropriate measures to
remain competitive in a rapidly changing business environment.
Lng project risk and appraisal 2012 final 03092012HIMADRI BANERJI
LNG Terminal is the disruptive technology becoming the most popular solution for countries needing natural gas for their power, fertiliser and transport sectors. This presentation is to understand the Risk Management, Financing, and insurance issues connected with this industry
FSRU (Floating Storage and Regasification Unit) LNG Terminal is the disruptive technology becoming the most popular solution for countries needing natural gas for their power, fertiliser and transport sectors. This presentation is to understand the Risk Management, Financing, and insurance issues connected with this industry
Risk management during start up and commissioning of super critical once thro...HIMADRI BANERJI
The Allowable Water and Steam Chemistry Regimes for Supercritical Units have been identified along with maximum deviations during start up and commissioning. This presentation gives guidelines for contracting norms to avoid damages.It is for the EPC Contractors in charge of construction of these units to understand the risks associated and design organizational skills both in technical and commercial areas to avoid major delays and damages.
FSRU (Floating Storage and Regasification Unit) LNG Terminal is the disruptive technology becoming the most popular solution for countries needing natural gas for their power, fertiliser and transport sectors. This presentation is to understand the Risk Management, Financing, and insurance issues connected with this industry
Managing Smart Grids, Power System Networks with Analytics HIMADRI BANERJI
Big Data is playing a significant role in managing effectively the data analytics requirement from the infrastructure arising out of smart grid implementation n T&D Utilities..The presentation looks at some of the major issues and initiatives.
Liquefied Natural Gas project risk and appraisal HIMADRI BANERJI
Fundamentals of the LNG business value chain and project and risk appraisal. This includes understanding the dynamics of the international LNG market covering the pricing mechanisms, regional and global market drivers, and the behaviour of importing and exporting countries, LNG trade flows, Asian LNG market and indexation mechanisms, various kinds of contracting structure, detailed understanding of derivatives and arbitrage opportunities.
Challenges in building the 21st century energy infrastructureHIMADRI BANERJI
Major Challenges in Building the 21st Century Energy Infrastructure are discussed. The concepts of Risk Management is introduced with subtlety in its impact on meeting such challenges. A treatise on project management with risk mitigation for infrastructure projects, Presentation taken from lectures on Infrastructure Capital Management delivered to the class of 2010-11 at IIM Ahmedabad,
Thermal coal upgradation and conversion in india ibc asia, jakarta april 25, ...HIMADRI BANERJI
PRIORITIES ON ENERGY GENERATION SECTOR ARE:Increased use of Advanced Fossil Fuel Technology, Promote CCT where coal is main stay fuel for Power Generation AND Reduce Atmospheric Pollution from Energy Generating Systems WHILE Ensuring energy security . India's initiatives in using the low rank coals like lignite, or the high ash coals are dicussed.
Clean Coal Technology:Indian Perspective by Himadri Banerji HIMADRI BANERJI
The clean coal technology (CCT) market is likely to see substantial spending over the next decade as governments and industry alike invest in R&D, installation, and operation in this growing market. The emergence of clean coal technologies has created market opportunities for equipment manufacturers and utilities. Presented here is the Indian perspective from the talk given at TREC STEP program on invitation from E&Y at REC Tiruchirapalli on 25th Jan 2012
World Class Manufacturing:Plant Start Up and Commissioning Procedure HIMADRI BANERJI
Essential Ingredient of World Class Manufactring is a procedure for plant start up and commissioning. It is observed that the maximm damage in the life of a plant occurs at start up and the remnant effect of this damage to life an be significant. This presentation 0f 180 slides takes the reader through a step by step procedure which if followed strictly can give a safe and risk free plant start up.
Start Up and Commissioning of Supercritical Power Stations: Risk Management P...HIMADRI BANERJI
Start Up protocols play a major part in risk management for modern Supercritical power plants especially during start-up and commissioning. EPC contractors must be alert to contract conditions set by owners and start up engineers on deviation of steam and water chemistry conditions especially.
Kseniya Leshchenko: Shared development support service model as the way to ma...Lviv Startup Club
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An introduction to the cryptocurrency investment platform Binance Savings.Any kyc Account
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Business Valuation Principles for EntrepreneursBen Wann
This insightful presentation is designed to equip entrepreneurs with the essential knowledge and tools needed to accurately value their businesses. Understanding business valuation is crucial for making informed decisions, whether you're seeking investment, planning to sell, or simply want to gauge your company's worth.
Digital Transformation and IT Strategy Toolkit and TemplatesAurelien Domont, MBA
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Event Report - SAP Sapphire 2024 Orlando - lots of innovation and old challengesHolger Mueller
Holger Mueller of Constellation Research shares his key takeaways from SAP's Sapphire confernece, held in Orlando, June 3rd till 5th 2024, in the Orange Convention Center.
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Improving profitability for small businessBen Wann
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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
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
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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.
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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.
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26. Workshop on Transition from Construction to Flawless Operations
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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.
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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.
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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.
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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;
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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.
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33. Workshop on Transition from Construction to Flawless Operations
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FIRST DAY SESSION 2
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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.
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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.
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36. Workshop on Transition from Construction to Flawless Operations
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FIRST DAY SESSION 2
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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.
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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;
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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.
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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.
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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.
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42. Workshop on Transition from Construction to Flawless Operations
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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.
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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.
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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.
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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
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47. Workshop on Transition from Construction to Flawless Operations
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FIRST DAY SESSION 3
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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.
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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.
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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;
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52. Workshop on Transition from Construction to Flawless Operations
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• 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.
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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.
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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.
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55. Workshop on Transition from Construction to Flawless Operations
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FIRST DAY SESSION 3
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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…
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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.
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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.
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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.
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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.
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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.
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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.
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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;
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DAY 2
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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.
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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.
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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;
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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.
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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;
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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.
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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.
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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.
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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;
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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.
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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).
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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.
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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
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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”;
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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.
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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.
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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.
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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;
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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.
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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);
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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.
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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
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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.
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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.
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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
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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
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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
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96. Workshop on Transition from Construction to Flawless Operations
Himadri Banerji Ex CEO Reliance and International Expert Ernst and
Young
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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
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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
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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
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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
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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
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104. Workshop on Transition from Construction to Flawless Operations
Himadri Banerji Ex CEO Reliance and International Expert Ernst and
Young
11/25/2023
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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
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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
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107. 11/25/2023
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Himadri Banerji Ex CEO Reliance and International Expert Ernst and
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108. 11/25/2023
Workshop on Transition from Construction to Flawless Operations
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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
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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.
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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$
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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
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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
•
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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
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Himadri Banerji Ex CEO Reliance and International Expert Ernst and
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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
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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.
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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
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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)
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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
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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
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123. Workshop on Transition from Construction to Flawless Operations
Himadri Banerji Ex CEO Reliance and International Expert Ernst and
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