World Class Manufacturing:Plant Start Up and Commissioning Procedure

Workshop on “Plant Commissioning and
Start-Up Procedures”
Dr. Himadri Banerji
MD EcoUrja Ex Reliance and Tata
Organized By :

Standard Implementation Path is show here

The Commissioning Process Key State

Preparation and
planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

Start Up & Initial
Operation

Performance and
Acceptance testing

Post Commissioning

The Commissioning Process Detail - 1
Preparation and • Appointment of Commissioning
planning Manager or Lead Commissioning
Engineer
Mechanical • Appointment of Commissioning Team
Completion Members and Support Staff
and Integrity checking • Training
Pre-commissioning & • Information Compilation
Operational Testing • Safety and Risk Assessment
Start Up & Initial • Commissioning Strategy
Operation Development;
• Procedures and Checklist
Performance and Development
Acceptance testing
• Post Commissioning
Post Commissioning
• Detailed Plan and Budget Preparation;

The Commissioning Process Details – 1
Facility Commissioning Issues

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

Developing Startup Procedures
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.

Issues Considered

Are various part of the process too depend 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.

System Level Activities

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

Equipment Level Activities

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.

What can be done before mechanical
completion

Utilities commissioning

Lube and Seal-Oil Systems Cleaned

Instrumentation and Control Loops Proven

Piping, Towers and Vessels Cleaned

Boil-Out, Dry-Out and Acid Cleaning

Turbine, Motor and Pump Run-Ins

Nitrogen Purge and Tightness Testing

Building Organisational Learning

Best Practice
Benchmarking Improvement
Industry Processes
Standards
Corporate Procedures and
Knowledge Base Check sheets
Legislation
Experience

Process Design Specific
Machinery
&Equipment

World Class Manufacturing:Plant Start Up and Commissioning Procedure

Procedures

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.

Commissioning / Startup Logic

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.

BY DR.HIMADRI BANERJI MD ECOURJA
EX. RELIANCE AND TATA Copyright www.ecouja.com 15

Commissioning / Startup and Shutdown Issues

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.

Mechanical Completion and Integrity Checking

Mechanical Completion and Integrity Inspection

Preparation and
planning
• Inspection
Mechanical Completion • Pressure testing
and Integrity checking • Cleaning and Flushing
• Machinery checkout
Pre-commissioning &
Operational Testing

Start Up & Initial
Operation

Performance and
Acceptance testing

Post Commissioning

Categories of Process Equipment

Distillation Towers / Fractionation Towers
Re-boilers & 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

Machinery / Rotating Equipment

Pumps

Steam Turbines

Gas Turbines

Compressors

Gas Engines

Electric Motors

Mechanical Completion and Integrity
Inspection

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.

Inspection Procedure
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 colored “highlighter” pens to indicate different
services.

Mechanical Completion and Integrity Inspection
Every line must be walked! Physically see every

Inspection Procedure Hints / Tips

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 swing able blinds in place,
correct rating.
Check all tag numbers.
Punch list any non-conformances.

Pipe Stressing

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.

Piping and equipment support

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.

Typical Piping Support Methods

Piping and Equipment Supports

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.

Piping and Equipment Supports

Inspection after cool-down:

• Check that sliding supports have returned to original
positions;

• Establish that equipment can expand and contract as
required.

Inspection of Spring Supports

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;

Inspection of Spring Supports

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.

Inspection of Vessels and Columns

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.

Inspection of Vessels and Columns

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.

Pressure Testing - Objectives

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.

Pressure Testing – Responsibilities

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;

Pressure Testing - Procedures

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.

Pressure Testing – Vacuum Systems

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.

Pressure Testing – Procedures 2

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.

Cleaning and Flushing

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.

Cleaning and Flushing

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.

Flushing

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.

Flushing

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).

Pre-Commissioning and Operational Testing

The Commissioning Process Detail - 3

Preparation and
planning

Mechanical • Steam and other utilities
Completion commissioned and introduced;
and Integrity checking • Dry running trials;
• Hot running trials;
Pre-commissioning & • Safe-fluid dynamic testing;
Operational Testing • Solvent dynamic testing;
• Process fluid tests.
Start Up & Initial
Operation

Performance and
Acceptance testing

Post Commissioning

Commissioning Utilities

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.

Commissioning Utilities – Broad Guidelines

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;
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.

Commissioning Utilities
Introducing Steam

Steam usually represents the first “hazardous” fluid
introduced into the “new” system;

Admit steam slowly into the distribution system with
atmospheric bleeds 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.

High Pressure Steam Systems
Specific Issues
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.

Machinery and System Check-Out

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; levelling 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…

Commissioning Electrical Systems
The following checks are typical of what is required

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.

Commissioning Electrical Systems – 2
The Following checks are typical of what is required
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.

Commissioning Electrical Systems – 3
The following checks are typical of what is required

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.

Operational Testing

Progresses through several stages;

Dry runs of individual items of equipment

Hot testing of individual items of equipment and systems;

Several stages of Dynamic Testing of:
• Individual items of equipment;
• Individual Systems/processes in isolation;
• The whole new process plant installation.

Dry Runs and Hot Tests

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.

Hot Testing Equipment
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.

Hot Testing Procedures

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;

Dynamic Testing

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.

Safe-Fluid Dynamic Testing

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.

General Principles for Testing

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;

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.

General Principles for Testing

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 for risks from over-
pressuring, over loading temperature-shocking and stressing
equipment;

Cautions During Testing

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.

Dynamic Testing – Simulated Operations
Safe Fluid Testing
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.

The Value of Dynamic Testing –
Simulated Operations

Value of simulated operations will be to 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.

Dynamic Testing – Simulated Operations

Dynamic Testing with a Solvent

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.

Dynamic Testing with Process Solvent

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).

Dynamic Testing with a Solvent

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.

Stages of Dynamic Testing with a “Solvent”

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, re-boiler and condensation systems into
operation


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”;

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.


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.

Closed Loop Dynamic Testing with Process Fluid

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.

Preparing to Introduce Process Fluid

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;

Pressure Testing and Purging

Consists of pressuring and de-pressuring with nitrogen
several times, until at least <3% oxygen is reached;

Vacuum systems should be evacuated and then re-pressured
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.

Dehydrating by Circulation

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);

Start Up and Initial Operation

Preparation and
planning

Mechanical Completion

Pre-commissioning &
Operational Testing • Introduction of process fluid
• Start-up and initial operation
• Trouble-shooting and
Start Up & Initial
Operation
problem correction.
• Plant taken to full operations.

Performance and
Acceptance testing

Post Commissioning

Most plants in petrochemical/chemical industry
have the following “general ”form.

Feed Reaction Recovery Product
Preparation refining

Start Up from the End of the Process and Work back

Start Up Logic

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.

Into the Initial Operation

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.

Ramping up the Plant

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;

Coordination and Supervision
During Start Up
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.

Trouble Shooting

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;

Performance and Acceptance Trails

Preparation and
planning

Mechanical
Completion

Pre-commissioning &
Operational Testing

Start Up & Initial
Operation

Performance and • Performance trails;
Acceptance testing • Formal Acceptance test

Post Commissioning

The Performance Trials

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.

Before the Trails of Performance Run
Need to Ensure that…

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.

Need to Verify …

Physical operation, capability and capacity of plant and
equipment;

Energy and mass balance;

Process chemistry;

Efficiencies, yields and quality;

All to specification.

Acceptance

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

Acceptance Testing

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.

Commercial Significant of Acceptance

Formal Acceptance 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.

Preparation and
planning

Mechanical
Completion

Pre-commissioning &
Operational Testing

Start Up & Initial
• From plant on-stream to settled down
Operation
and in regular production;
Performance and • Adjustments, modifications and fault
Acceptance testing correction;
• Completion of outstanding punch list
Post Commissioning items

Post Commissioning

Covers the period immediately after Acceptance;

Outstanding punch-list items are completed;

The first routine maintenance checks are performed, findings
evaluated and reported;

Process equipment and items covered by warranty are
scrutinized for signs of premature wear-out or problems;

Operating data is collected and evaluated to ensure
consistent plant operations are maintained and sustainable.

WORKSHOP ON PLANT START UP AND
COMMISSIONING

SEQUENTIAL START UP
AUTOMATION IN PLANT START UP AND COMISSIONING

BY DR. HIMADRI BANERJI
(EX RELIANCE AND TATA)
www.ecourja.com


Automation for Controlled Start Up

To advocate the usage of process integration in industrial
practice, it is important to be able to

guarantee not only robust control during near steady state
operation, but also to provide

procedures for generating fast and reliable start-up
sequences.


Sequential Start Up and Shutdown Using
Automation in Plant…Burner Management System
1. Burner Management System in Power Plants
General

The Burner Management System must be designed to ensure a safe, orderly
operating sequence in the start-up and shutdown of fuel firing equipment and
to reduce possible errors by following the operating procedure.

The system is intended to protect against malfunction of fuel firing equipment
and associated systems. The safety features of the system shall be designed
to provide protection in most common emergency situations, however, the
system cannot replace an intelligent operators reasonable judgment in all
situations.

In some phases of operation, the BMS shall provide permissive interlocks only
to insure safe start-up of equipment. Once the equipment is in service, the
operator must follow acceptable safe operating practices.


Sequential Start Up…BMS Functions
The BMS shall be designed to perform the following functions:
1.Prevent firing unless a satisfactory furnace purge has first been completed.
2. Prohibit start-up of the equipment unless certain permissive interlocks have first
been completed.
3. Monitor and control the correct component sequencing during start-up and shut-
down of the equipment.
4. Conditionally allow the continued operation of the equipment only while certain
safety interlocks remaining satisfied.
5. Provide component condition feedback to the operator and, if so equipped, to
the plant control systems and/or data loggers.
6. Provide automatic supervision when the equipment is in service and provide
means to make a Master Fuel Trip (MFT) should certain unacceptable firing
conditions occur.
7. Execute a MFT upon certain adverse unit operating conditions.


Furnace Explosions

A common cause of furnace explosions is

“Fuel leakage into an idle furnace and the ignition of the
accumulation by a spark or other source of ignition”.

Proper attention to the design of the interlocks and trip
system to provide a safe light up of the boiler furnace is
required.


Furnace Purge…Permissives

Before any fuel firing is permitted, either initially or after a boiler
trip, a satisfactory furnace purge cycle must be completed.

Prior to starting a furnace purge cycle, the operator must
ensure that the following purge requirements are satisfied[i]:

1. Drum level within operating range (not high, not low)

2. Instrument air header pressure within operating range

3. Fan is in service

4. Purge airflow capable of a minimum of 70% of the full load
airflow established through the unit[ii].


Furnace Purge…Permissives

5. All flame scanners reading "No Flame“
6. Natural gas block valves are proven closed
7. Fuel oil block valves are proven closed
8. Air dampers are in the fully open position
9. Natural gas, or fuel oil, header pressure upstream of block
valve is satisfactory
10. Pilot gas header pressure is satisfactory
11. Burner Control System is energized
12. A "No Master Fuel Trip condition" condition is established

Pre Purge Permissives
Pre purge permissive condition checks and furnace purge are to be
initiated by the operator from the local BMS panel (you may see detailed
guidelines on cold starting using fuel oil, cold starting using natural gas
from operating manuals).

Purge air flow: The total furnace airflow shall not be reduced below the
purge rate airflow (70% of the maximum continuous airflow capacity).

Reducing airflow below these limits will lead to a MFT, and a new furnace
purge will be required.

Suggested color design:
Purge Permissives indicating lights: white

Purge Available indicating light: green

Purge in progress indicating light: amber

Purge complete indicating light: white

MFT reset indicating light: red


Main Flame Start-Up Sequence

The main flame start-up sequence, from the lighting the of
the pilot flame through main flame light-off, is an automated
sequence.

Once the start-up sequence has begun, only the “BOILER
STOP” switch and the “EMERGENCY STOP” will interrupt
the start-up sequence.

Any interruption of the start-up sequence requires a post-fire
purge prior to attempting to start the boiler again.

To initiate the start-up sequence, the operator activates the
“START BOILER” switch.


Pilot Flame Light-Off

Before the burner can be started, satisfactory light-off
conditions for the pilot and main burners must be met. This is
accomplished when the following conditions are satisfied:

For the pilot igniter:
1. MFT relay reset
2. Pilot gas header pressure normal

For natural gas:
1. All of the above mentioned for the pilot igniter
2. Natural gas pressure normal
3. Natural gas control valve is in light-off position



For fuel oil:
1. All of the above mentioned for the pilot igniter
2. Oil gun is in place in the burner
3. Oil pressure is normal
4. Fuel oil atomizing interlocks are satisfied
5. Fuel oil atomizing medium is provided to the burner
6. Oil control valve is in light-off position

Other Conditions:
1. No MFT condition after purge
2. All flame scanners report no flame
3. All natural gas, or all fuel oil, block valves shown closed
4. All air dampers are in light-off position



Failure to meet any of these conditions shall prevent the
burner light-off operation.

To light the pilot flame, the pilot header vent valve, and, for
natural gas fuel, the natural gas vent valve shall be closed by
the boiler control system. Then, sequentially, the igniter
transformer is energized, the pilot gas block valves are open
and a 10 second pilot ignition timer starts counting down.
When ignition timer cycle is completed, the igniter
transformer is de-energized and the pilot flame scanner is
checked by the control system. If the pilot flame is present,
the main flame light-off sequence continues.



If the pilot flame fails, the boiler control system initiates a pilot
flame failure shutdown. Additional attempts of pilot light-off
are permissible provided a successful pilot light-off is made
within 10 minutes after the furnace purge.

Note that if the pilot flame continues to fail after several
attempts, the boiler should be inspected to determine the
fault and the condition corrected.


Main Flame Light-Off

Once the pilot flame is made, the boiler control system opens the
header block valves for the selected fuel.
A main flame light-off timer begins a 15 second countdown for
natural gas, or 20 seconds for fuel oil, to establish and stabilize the
main flame.
At 5 seconds before time out, the boiler control system closes the
pilot block valves and opens the pilot vent valve.
The remaining 5 seconds are used to detect the main flame. For
the typical dual flame scanner design, a main flame failure
shutdown is initiated if both flame scanners return a “no flame”
signal to the burner control system.
This will generate a boiler trip, and another furnace purge will be
required.
Once the burner is lit, the system is in the NORMAL RUN
CONDITION and combustion controls should be released to
modulation control


Shutdown

Shutdown
Per NFPA 8501, section 6-2.4.5, “The normal shutdown cycle for the boiler
shall accomplish the following in the order listed:
(a) Shut off fuel supply to the main burner.
(b) Interrupt spark and shut off fuel supply to igniters, if in operation.
(c) For oil:
1. Where used, open the recirculating valve.
2. Shut off atomizing medium, if desired.
(d) For gas, vent piping between safety shutoff valves to atmosphere.
(e) Perform a post purge of the boiler furnace enclosure.
(f) Shut down fan, if desired.”
For a safety shutdown, a manual reset is also required.
Normal Boiler Shutdown
A normal shutdown is initiated by operating BOILER SHUTDOWN switch. This
will initiate the shut down sequence listed above.


Boiler Master Fuel Trip

Any of the following conditions shall cause a boiler trip to
occur. This results in the shutdown of all fuel and requires
another furnace purge cycle before any attempt at re-lighting.
For fuel oil:
1. Excessive steam pressure.
2. Low water level.
3. Low fuel pressure.
4. Low oil temperature.
5. Loss of combustion air supply.
6. Loss of flame.
7. Loss of control system power.
8. Loss of atomizing medium, if used.



For natural gas:

1. Excessive steam pressure or water temperature.
2. Low water level.
3. High or low gas pressure.
4. Loss of combustion air supply.
5. Loss of flame.
6. Loss of control system power.



In the event of an MFT, the control system shall initiate the
following:

1. Execute a shut down as listed above.
2. Illuminate the appropriate indicator lights and alarms.
3. Return the system to the pre-purge state

Boiler restart will be inhibited until all pre-purge requirements
are satisfied.


Alarms

The following is a list of recommended alarm conditions:

1. Any boiler or burner trip signal
2. High or low water level
3. High furnace pressure
4. Partial Loss of flame (For the typical two scanner system,
one indicates “no flame”)
5. Main fuel shutoff valves closed
6. Loss of control system power
7. Unsuccessful burner shutdown


Interface with the Combustion
Control System (CCS)

The following list, at a minimum, of signals should be sent
to the Combustion Control System:
1. Controls to purge position
2. Controls to light-off position
3. Normal run condition: release controls to modulation
4. Main natural gas block valve open: permissive to place gas
control valve in automatic.
5. Master fuel trip: run boiler load to zero and place combustion
controls in manual.
6. Oil recirculation signal
Under the provisions of NFPA 8501, section 6-5.2.3, for a single
burner boiler, the BMS and CCS may reside in the same
processor. This option can reduce the integration complexity
and increase the BMS to CCS interface reliability.


Operator Interface

The above describes a traditional operator interface using
discrete switches and indicator lights. The control designer is
encouraged to incorporate a graphical user interface or
similar options in order to enhance the ease of use and
readability of the boiler control system operator interface

Workshop on Start Up and Commissioning Dr. Himadri Banerji
MD EcoUrja, Ex Reliance and Tata www.ecourja.com

SEQUENTIAL START UP AUTOMATION
DESIGN PRINCIPLES OF BURNER
MANAGEMENT SYSTEM


Design Principles of Sequential Start-Up…
Case Study in Burner Management System Design
Introduction
Burner Management System Objectives
BMS Design Standards and Definitions
BMS Logic
BMS Strategies and Hardware
◦ Types of Burner Management Systems
BMS Interface to SCADA Systems
Summary


Introduction

Burner
Management
Systems..

..a starting point.


Introduction

What is a BMS?
A Burner Management System is defined as the following:
◦ A Control System that is dedicated to boiler safety,
operator assistance in the sequential safe starting and
stopping of fuel preparation and burning equipment, and
the prevention of mis-operation of and damage to fuel
preparation and fuel burning equipment. 1

1. From NFPA 8501 “Standard for Single Burner Boiler
Operation”


Burner Management Objective

Sequence burner through safe start-up

Insure a complete pre-purge of boiler

Supervise safety limits during operation

Supervise the flame presence during operation

Sequence a safe shutdown at end of cycle

Integrate with combustion control system for proper fuel
and air flows


BMS Design Standards

Each Burner Management System should be designed in
accordance with the below listed guidelines to control and
monitor all sequences of the start-up and shutdown of the
burner
◦ National Fire Protection Association (NFPA 8501 /8502
or others)
◦ Industrial Risk Insurers (IRI)
◦ Factory Mutual loss prevention guidelines
o Each burner management system should be designed to
accomplish a safety shutdown in the event of an unsafe
condition. (FAIL SAFE)


BMS Design Standards

U.S. National Fire Protection Association (NFPA)
◦ Governs safety system design on virtually all boilers
(regardless of the process to be used to combust the
fuel)
◦ Requires the separation of the Burner Management
System from any other control system
◦ Requires the use of a hardwired backup tripping scheme
for microprocessor based systems
◦ Requires that a single failure NOT prevent an
appropriate shutdown
◦ Factory Mutual loss prevention guidelines.


NFPA 8501

NFPA 8501 Standard for Single Burner Boiler
Operation

◦ Single Burner Boilers with fuel input greater than 12.5
mBTU/Hr (Approx. 250 BHP)

◦ Single Fuel or Combination of Fuels (Common being
Natural Gas / No.2 Oil / No. 6 Oil)

◦ Simultaneous Firing


NFPA 8502

NFPA 8502 Standard for Prevention of Furnace Explosions /
Implosions in Multiple Burner Boilers

◦ Multiple Burner Boilers with fuel input greater than 12.5
mBTU/Hr

◦ Single Fuel or Combination of Fuels including Pulverized Coal

◦ Emphasis on implosion protection (larger boilers with induced
draft systems)


BMS Definitions

Furnace Explosions
◦ “Ignition of accumulated combustible mixture within the
confined space of a furnace or associated boiler passes,
ducts, and fans that convey gases of combustion to the
stack”1
◦ Magnitude and intensity of explosion depends on
relative quantity of combustibles and the proportion of air
at the time of ignition

1. From NFPA 8502 “Prevention of Furnace Explosions /
Implosions in Multiple Burner Boilers”


BMS Definitions

Furnace Explosions can occur with any or a combination
of the following:1
◦ Momentary loss of flame followed by delayed re-ignition
◦ Fuel leakage into an idle furnace ignited by source of
ignition (such as a welding spark)
◦ Repeated Light-off attempts without proper purging
◦ Loss of Flame on one Burner while others are in operation
◦ Complete Furnace Flame-out followed by an attempt to light
a burner



BMS Definitions

Furnace Implosions
◦ More common in large Utility Boilers
◦ Caused by any of the following:
Malfunction of equipment regulating boiler gas flow
resulting in furnace exposure to excessive induced
draft fan head capability
Rapid decay for furnace gas temperature and pressure
due to furnace trip



BMS Basic Definitions

Common Terminology
◦ Supervised Manual
Manual Burner Light-off with Interlocks

◦ Automatic Recycling (Single Burner Only)
Automatic Burner Start and Stop based on preset
operating range (ie.. Drum pressure)

◦ Automatic Non Recycling (Single Burner Only)
Automatic Burner Start and Stop based on Manual
command to start.


Types of Flame Scanners

Infrared (IR) Detectors
◦ Single Burner Applications
◦ More Suitable with Oil Burning Flames
Ultra-Violet (UV) Detectors
◦ Multiple Burner Applications
◦ More Suitable for Gas Burners and Combination Gas /
Oil Burners
Self Check Scanners
◦ Flame Signal is interrupted at set intervals to verify
proper operation of scanner


Single Burner BMS Inputs
Low Low Drum Level (D)
High Steam Pressure (D)
(D)
Purge Purge Air Flow
Minimum Air Flow (D)

(D)
Limits Made
Flame / No Flame
Hold to Purge

SCRL RESET MO DE

BURNER FUEL SELECT FD FAN
OFF ON GAS OIL HAND OFF AUTO

(D)
Fuel Oil Temp Low
Fuel Oil Temp High (D)
(D)
Fuel Oil Press Low
Fuel Oil Flow (A)
(D)
Atomizing Medium Flow > Min
Atomizing AE TE
(D) Medium
Common Alarm Output
Press Low (D)

Remote Annunciator
(By Others) FEEDWATER
PSH

PSL STEAM
PT PSH
FT

IGNITER
Safety Shut Off
GAS LSLL
& Vent Valves

LSLL

Fuel Fuel
Gas Gas FT PSL TSH TSL FS
Press Press
Low High
(D) (D) PSL PSL
OIL Safety Shut Off Control
Valves Valve

ATOMIZING Control Valve &
MEDIUM Shut Off Valve (D) - Descrete Signal Used By Flame Safeguard System

FT PSL PSH

GAS Safety Shut Off & Control
Vent Valves Valve


BMS Logic

Burner Management Systems can be broken down
into “Interlock Groups”

Typical BMS Interlock Groups:
◦ Boiler Purge
◦ Igniter Header Valve Management
◦ Main Fuel Header Valve Management
◦ MFT (Master Fuel Trip) Logic


Purge Interlocks
BOILER TRIPPED

AND PURGE / RESET PB

START-UP
TIMER

START FD FAN

PERMISSIVES SATISFIED:
- MAIN FUEL VALVES CLOSED
- NO FLAME PRESENT
- FD FAN RUNNING AND
- MINIMUM AIR FLOW SWITCH MADE
- WATER LEVEL SATISFACTORY
- ATOMIZING MEDIUM ON
- FUEL SUPPLY PRESSURE NOT LOW

ENERGIZE FUEL RELAY

NOT AND

PURGE SIGNAL TO CCS

PURGE AIR FD DAMPER IN
FLOW SWITCH AND FULL OPEN
MADE POSITION

PURGE TIMER SET

PURGE COMPLETE
NO
YES

REMOVE PURGE TO CCS SYSTEM TRIP


Igniter Interlocks
PURGE COMPLETE

AIR DAMPER IN LOW FIRE FUEL VALVE IN LOW FIRE
AND
POSITION POSITION

ENERGIZE IGNITER AND
IGNITER HEADER VALVES

10 SECOND DELAY

10 SEC PILOT TRIAL
FOR IGNITION

TIMER COMPLETE
FLAME
PROVEN NOT

AND

SYSTEM TRIP
PERMIT FOR MAIN
FLAME


Main Flame Interlocks

IGNITER TIMER
COMPLETE

FLAME
AND
PROVEN
ENERGIZE MAIN
FUEL VALVES

10 SEC MAIN FLAME
TRIAL

TIMER COMPLETE

NOT

AND

DE-ENERGIZE
IGNITION
COMPONENTS

RELEASE TO
MODULATE TO CCS SYSTEM TRIP


Single Burner Main Fuel Trip
FOR OIL: FOR GAS:
- LOWFUEL PRESSURE - LOWFUEL GAS PRESSURE
- LOWTEM PERATURE (HEATED OILS) - HIGH GAS PRESSURE
- LOSS OF COM BUSTION AIR - LOSS OF COM BUSTION AIR
- LOSS OF FLAM OR FAIL TO ESTABLISH
E - LOSS OF FLAM OR FAIL TO ESTABLISH
E
- LOSS OF CONTROL SYSTEMENERGY - LOSS OF CONTROL SYSTEMENERGY
- POWER FAILURE - POWER FAILURE
- LOWWATER LEVEL (AUXLEVEL CONTACT) - LOWWATER LEVEL (AUXLEVEL CONTACT)
- LOSS OF ATOM IZING MEDIUM - EXCESSIVE STEAMDRUMPRESSURE
- EXCESSIVE STEAMDRUMPRESSURE
- HIGH OIL TEMPERATURE (HEATED OILS)
OR

OR

TRIP BOILER

TRIP IGNITER, TRIP MAIN FUEL FUEL CONTROL
IGNITER VALVES, VALVES, OPEN VALVE TO
TRIP MFT RELAY
OPEN IGNITER VENT VALVE CLOSED
VENT (GAS ONLY) POSITION


BMS System Types

Early Burner Management Systems
◦ Hardwired Systems
◦ Solid State Systems

Microprocessor Based Systems
◦ Honeywell 7800 series with fixed Logic.

PLC Based Systems
◦ Programmable Logic Controller (PLC) Based
◦ Powerful, versatile, expandable, more reliable.


Early Burner Management Systems

Hardwired Systems
◦ Relay and Timer Driven. Found on older installations
◦ Typical of Late 50’s, 60’s

Solid State Systems
◦ Solid State Processors and Relays
◦ Found on Systems provided in the 70’s and 80’s
◦ Proprietary Hardware (ie.. Forney and Peabody)
◦ Spare Parts are extremely hard to find.


MicroProcessor Based Systems

Microprocessor Based System providing:
◦ Burner Sequencing
◦ Ignition
◦ Flame Monitoring

Fixed Program with Limited Configuration Changes

Components Selected Based on Requirements
◦ Programmers, Flame Amplifiers, Message Displays


Typical BMS Layout

AMPLIFIER
EP PROGRAMMER

AUTOMATIC PRIMARY SAFETY CONTROL

FIELD WIRING
FIELD WIRING

FLAME
SCANNER


Micro Processor Capabilities

Simple, Cost Effective

Features
◦ Selectable Flame Amplifiers / Scanners
◦ Remote Display
◦ Remote Data Communications via Modbus Port
◦ Modernization kits are available to integrate with older
systems
◦ Spare Parts Normally Readily Available


When These Systems are Used

“Simple” Boiler Installations
◦ Packaged Fire tube / Water tube Boilers (Steam / Hot Water)
◦ Single Burner
◦ One Fuel at a Time
◦ No Flue Gas Re-Circulation
◦ Upgrades from Previous MicroProcessor Based Systems


PLC Based Burner Management Systems

PLC Based Features
◦ NFPA 8501, 8502
◦ Watchdog timer
◦ UL 508 Certification

Redundant Scanners

Logic+ Message Center
◦ Shows program status
◦ Displays alarms
◦ Prompts operator


PLC System Basic Design Features

Each PLC based burner management system should
incorporate a number of design techniques which help
detect and act upon unsafe failure modes which can
occur in any microprocessor based system. These
design features include the following:

◦ Critical Input Checking
◦ Critical output channel monitoring
◦ Electro-mechanical Master Fuel Trip (MFT) Relay
◦ Redundant Watchdog Timers
◦ Low Water Cut-out Monitoring During Blow Down


PLC Based System Capabilities

Provision for Multiple Fuel Firing
◦ Capped gas input during curtailment
◦ Changeover from gas to oil at any load
◦ Simultaneous firing of waste and fossil fuels

Redundant Scanners, change scanner with fuel

Single or Multiple Burner Applications

Integration of BMS with SCADA


PLC Based Operator Interfaces

Features
◦ Clear Written Messages to indicate status, required
operator interaction, trip/alarm indication
◦ High Visibility through two lines of display
◦ Messages reduce time consuming troubleshooting
◦ Prioritizes Messages
First Out Alarms
Warning / Alarm Messages
Status Messages / Prompts Operator


PLC System Layout

Door Mounted Lights / Pushbuttons

Logic+ Message
SWITCH SILENCE LIGHT

Display

PLC CPU I/O I/O I/O I/O

COMBUSTION
CONTROL SYSTEM

FLAME AMPLIFIER
(SINGLE /
REDUNDANT)

I/O EXPANSION I/O

FIELD DEVICES


Benefits of PLC Based Systems

Flexibility / Reliability
◦ Programming Software allows changes to system

Choice of PLCs
◦ GE / Modicon / Allen Bradley / Koyo

Choice of Flame Scanners
◦ PPC / Fireye / Honeywell / Iris / Coen

Application Specific

Quantity of Burners / Fuels is not restricted


When to Use PLC Based Systems
“Complex” Boiler Installations
◦ Larger Packaged Units / Field Erected Units

◦ Multiple Burners

◦ Multiple Fuels, On-line Fuel Changeovers

◦ Flue Gas Re-Circulation

◦ Replace Existing Relay Logic Systems

◦ Requirement to maintain consistent control platform (spare
parts, etc..)


BMS SCADA Interface

BMS Systems can be integrated into a SCADA System

◦ Allows Remote Monitoring of Flame Status

◦ Allows Remote Control of BMS

◦ Events (ie.. Burner trip) can be routed to Historical Portion
of SCADA for fault evaluation

◦ Burner Operation can be trended over time


BMS SCADA Interface

Interface Methods:
SCADA PC

MODBUS
COMMUNICATION
PROTOCOL

MODBUS
COMMUNICATION
Communication
PROTOCOL
Interface
(If Necessary)

PLC CPU I/O I/O I/O I/O

BMS LOGIC+ SYSTEM
FIREYE E110 SYSTEM


BMS SCADA Interface


Summary

Benefits Associated with Sequential Start Up Automation
and Burner Management Systems

◦ Help Improve plant safety
◦ Help qualify for reduced insurance cost
◦ Reduce Startup and Down Time with comprehensive
alarming and diagnostics


Summary

Review of Topics Discussed

◦ Sequential Start Up Automation,

◦ Objectives of Burner Management Systems

◦ BMS Design Considerations

◦ Basic BMS Logic

◦ Types of Burner Management Systems

◦ How BMS Systems can be integrated with Plant Wide
SCADA Systems


SAFETY ISSUES

THE WORK PERMIT SYSTEM

(Reference Document : <<AIGA 011/04 >>)

Presented by Dr Himadri Banerji EcoUrja www.ecourja.com

Summary

Acknowledgement

This document is adopted from the European Industrial
Gases Association document TP 10/04 – The Work Permit
System, and acknowledgement and thanks are hereby given
to EIGA for permission granted for the use of their document

Presented by Dr Himadri Banerji EcoUrja www/ecourja.com

The Work Permit System. What is it?
A work permit system consists primarily of a standard procedure
designed to ensure that potentially hazardous routine and non routine
work on industrial installations can be carried out safely. The procedure
should define the need for the following essential steps:
Details of the necessary preparatory work
Clear definition of responsibilities
Appropriate training of the work force
Provision of adequate safety equipment
A formal work permit with or without attached specific checklists.

This work permit:
specifies the work to be accomplished and authorizes it to be
started under the strict observance of consigned work and safety
procedures
After information and agreement of all other concerned parties
(process, safety, customers, suppliers,…)

The Work Permit System :
When?

For all non-routine works,

For hazardous routine works not covered by procedures,

When work is performed:
by your employees
and/or third parties

The Work Permit System (1/2):
For what kind of work?
A work permit is required in case of:
Potential oxygen deficiency or enrichment
Potential flammable/explosive atmosphere
Potential high temperature/pressure
Potential hazardous chemicals, e.g.: toxic substances
Confined space entry, e.g.: tanks, cold box, pit, normally
closed vessels
Bypassing or removing/altering safety devices or equipment
Elevated works
Introduction of ignited sources where not permanently
allowed (fire permit), e.g.: open flame, welding, grinding,
Electrical troubleshooting or repair on live circuits
Maintenance or repairs in areas or to equipment or lines,
containing or supposed to contain hazardous materials or
conditions,

The Work Permit System (2/2):
For what kind of work?
Or also in case of:
Manual or powered excavations
Use of mobile cranes
Insulation or catalysts handling
Use of adapters
Product conversion of stationary or mobile or portable
vessels and containers
Temporary or permanent changes, alterations, modification of
equipment or processes,
Exposure to traffic,
Exposure to moving/rotating machinery
In proximity of vents, liquid of gas
On process lines with gas release
Etc..

The Work Permit System : Why?

1. Because:
In charge of the work, you don’t know everything
about the site and the process around
about the work

Safety measures have to be prepared
You cannot start the work without the OK of the production
personnel or the customer or the supplier
The production needs your OK in order to re-start the plant
after your work is achieved

2. To obtain a safe as well as a quick and cost effective work

The Work Permit System : Why?

In order to define the scope of work for everyone
concerned/involved by and during the work, the Work Permit
must be prepared with:

The person responsible for the work
The person(s) in charge of the production, the customer or
supplier, who will release the process before the work starts
The other work bodies
The person in charge of HSE measures

The Work Permit System : How?

Before issuing the Work Permit, you must:

Describe the work to be done
List all the specifications and drawings which are required
Issue detailed planning with all involved entities
Determine the logging and tagging procedures

Fill-in together the work permit and sign,

The start of the work must be authorized by production and/or
user,

The re-start of the process must take place after the work is
finished.

Review of Flowsheets, Drawings and
Specification

Purpose of the review is to ensure all key persons involved in job
planning have a thorough understanding of the job. It should
include:
Process fluids and materials involved,
Degree of isolation,
Effect of other processes,
Power supply isolation,
Specialist advice,
Location of underground services and pipes,
Location of elevated power cables,
Location of elevated pipelines and walkways,
Purging and lock-out requirements,
Pressure, Temperature,
Valve identification,
Equipment specification,
Operating and maintenance instructions,
Materials of construction and compatibilities

Work site inspection
Anyone involved and signing the Safe Work Permit must
visit the work place in order:

•To inspect the work area
Neighbouring activities, site rules, overhead, underground,
access, natural hazards (flood, rain, snow…), etc,..

•To identify potential hazards
Flammable, oxygen, toxic substances, confined spaces,
electricity, pressure, temperature, moving objects, traffic,
falls/trips/slips, etc,..

Development of Work Procedures
Preparation of a detailed work procedure is essential to ensure the work will
proceed safely in a planned and logical manner:

Following requirements to be considered:
Reference drawings, Timing of various operations, Details of any special
equipment, Needs to inform local authorities, safety precautions and
equipment, Emergency procedures, etc,..

The procedure should include:
Logging and tagging procedures: Electricity, process fluids Instrumentation,
utilities (water, air, oil,…)

Depressurising, Draining, Venting, Purging, Flushing, Isolating, Atmosphere
checking, Disassembly of equipment, Method of repair, Reassembly and
installation, Quality control, Pressure and leak testing, Reinstatement of
equipment, Hand-back procedure, etc..

The Work Permit System : Example form
Appendix 1 EIGA/IGC WORK PERMIT n° ……..

Any attached document or log sheet ? YES NO HOW MANY ………..
List of attached documents ……………….……………………….…………..……………...………………………………………………..

1. WORK ACTIVITY

Plant / Unit :………………...……………….…………………………………………………………………………………………………………..………...…
Description of work to be done………………....……..….………….…………….……………………………………………………………………….......…
Permit valid from :………………………………………………………… Hours/date To :…………………………………………………………………….
Hours/date
Have all relevant departments/personnel been consulted ? YES NOT APPLICABLE

2. POTENTIAL HAZARDS & HAZARDOUS JOBS
YES NO YES NO
. Jobs performed by contractors or temporary workers . Maintenance or repairs in areas, or to equipment or lines,
. Potential oxygen deficiency or enrichment containing or supposed to contain hazardous materials or conditions
. Potential flammable / explosive atmosphere . Manual or powered excavations
. Potential high temperature / pressure . Use of mobile cranes
. Potential exposure to hazardous chemicals (toxic, reactive, . Insulation or catalyst handling
acid, caustic….) . Use of adapters
. Confined space entry . Product conversion of stationary or mobile or portable vessels
. Bypassing or removing/altering safety devices and equipment and containers
. Elevated work . Temporary or permanent changes, alterations, modifications of
. Introduction of ignition sources where not permanently equipment or processes
allowed (fire permit) . Exposure to traffic (road, mail)
. Electrical troubleshooting or repair on live circuits . Exposure to moving / rotating machinery

Others (state) ……………………..……...…………………………………………………………………………

3. SAFETY PRECAUTIONS
YES NO YES NO YES NO
. Draining . Remove hazardous materials . Standby man
. Depressurising . Fresh air ventilation . Elevated work
. Physical Isolation . Atmosphere analysis : . Contractors trained
. Electrical Isolation . Oxygen . Eliminate ignition sources

Work Planning

WORK SCOPE
REVIEW DRAWINGS / FLOWSHEETS
INSPECT WORKSITE
IDENTIFY SAFETY PRECAUTIONS
COMPLIANCE WITH REGULATIONS
DEVELOP WORK PROCEDURE
ASSIGN RESPONSIBILITIES
COMMUNICATION PROCEDURES
WORK EXECUTION

Work Execution

PREPARATORY WORK
ISSUE WORK PERMITS
SUPERVISION MONITORING
WORK COMPLETED
TESTING
RE-INSTATE EQUIPMENT
RETURN WORK PERMIT
HANDBACK PLANT / EQUIPMENT

Permit Issuer’s Responsibilities

INSPECTING WORK AREA
IDENTIFYING HAZARDS
DEFINING SAFETY PRECAUTIONS
OBSERVING PRINCIPLES OF SAFE WORKING
PRACTICES
CREATING WORK PERMIT CONDITIONS
REVIEWING WORK WITH PERMIT ACCEPTOR
ISSUING WORK PERMIT
IMPLEMENTING HANDBACK PROCEDURE

Permit Acceptor’s Responsibilities

UNDERSTANDING OF WORK PROCEDURES
UNDERSTANDING POTENTIAL HAZARDS AND
SAFETY PRECAUTIONS
ACCEPTING THE SAFE WORK PERMIT
OBSERVING PERMIT CONDITIONS
COMPLYING WITH HANDBACK PROCEDURE

In Brief
Many accidents have occurred due to lack of Work Permit or
non observance of its consigned safety measures.

The Safe Work Permit is useful for:
The safety of persons in charge of the work
The safety of persons in charge of the process
The risk management of the process and equipment

It is not one more administrative paper!

Fill in and follow correctly the work permit, because….

It could save your life!

World Class Manufacturing:Plant Start Up and Commissioning Procedure

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