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