Plant Commissioning

& Start-Up


Aims of Pre-Commissioning
The initial start-up of any plant, irrespective of size, type or industry, is a
unique occurrence.
Therefore, start-up poses some special problems.
Lack of experience in dealing with these problems has frequently resulted in
prolonged and costly start-ups.
This presentation will provide guidelines for all those involved in the
execution of a project on how to achieve a successful plant commissioning &
start-up.
The requirements for start-up oriented thinking at all stages of the project,
from engineering to commissioning, will be demonstrated.
Emphasis is on effective planning and use of available resources, both
material and manpower.
Troubleshooting performed during the actual start-up can be very expensive
and must be done as effectively as possible.
Effective trouble shooting can minimize the time and cost of going from the
initial start-up to full production.



Aims of Pre-Commissioning

Ensure the Plant is constructed as designed.
Ensure the Plant is clean.
Ensure all the instrumentation, safety systems and
machinery are fully functional.
Ensure all vessel internals is installed correctly.
Ensure the Plant is leak tight.


Key to Effective Pre-Commissioning

Planning and Preparation-milestone & progress report
Work closely with the Construction Group
Divide the Plant into small sections and pre-commission
each one as it becomes available.
Hold regular pre-commissioning meetings to check progress
and to keep all parties informed.


Typical List of Systems

Electricity
Portable/Cooling water
Nitrogen
Fuel gas/liquid
Plant/Instrument air
Hot oil/Steam system
Other utility systems (AHU)
Tankage Area
Security system


Planning & Preparation

Master drawings for cleaning.
Master drawings for instrument checks.
Identify needs for vendor representatives and outside
contractors.
Ensure sufficient manpower available.
Ensure sufficient materials are available.


Planning & Preparation

Prepare systems breakdown and mark-up on a master P&ID.
Agree systems with construction.
Agree timing for hand over of each system (installation-
commissioning-training).
Prepare pre-commissioning plan for each system.


Pre-commissioning Plan

Marked-up P&ID showing cleaning points, instruments to be
removed, etc.
Description of system plan.
Schedule for activities.
List of consumables required.
Requirement for vendor representative.
Special safety activities.


Plant Inspection

Inspect the plant by system:
Main output is a punch list of items to be put right
Punch list items should be categorized
-AMust fix
-BCan be delayed
Perform regular updates of the punch list
A weekly punch list review meeting should be held to
monitor progress


Plant Inspection

Drawing check
Piping check
Equipment check
Electrical check
Laboratory check


Plant Inspection Drawing Check

Plant check against P&ID:
Positioning of instruments, equipment, valves, pipe
branches.
Materials of construction-comply to specification.
Pipe dimensions
Equipment check


Plant Inspection Piping Check

Check runs are provided with expansion loops, spring
supports and anchor points as required.
As heat applied to plant, ensure:
-Spring supports correctly set
-Heat exchangers have sufficient expansion allowance.
When plant at normal temperature, check there are no
piping irregularities.


Plant Inspection Equipment Check

Vessels: -
-Erected as Engineering Datasheet
-Gaskets, clips, bolts, and nuts are correct material and
fitted correctly
-Demisters fitted correctly and no gaps between wall and
pad
-All flanged connections secure and gaskets of correct
material
-Nozzles clear
-Vessel clean


Plant Inspection Equipment Check

Vessels (cont)
-Trays and distributors
-Tracing and insulation
-Earth bonding must be checked
-Take photographs of the internals for future reference


Plant Inspection Safe Vessel Entry

Safest option is to have NO N2 on site during pre-comm.
Remove the max. amounts of toxic vapors or gas
Before allowing entry to a vessel:
-Vessel must be isolated from the rest of the plant and
open to the atmosphere
-Vessel must be completely free of combustibles and toxic
gases
-Combustible and oxygen gas tests must be taken
throughout the vessel
-Maximum ventilation must be provided
-Entry permit must be issued valid for the day of entry

Plant Inspection Safe Vessel Entry

If at any time there is a doubt over excessive gas, then the
work should be stopped.
Station someone outside the vessel if the workers safety
could be jeopardized
Purpose is to firstly call for assistance NOT to enter
Keep vessels that contain self-igniting deposits wet until
rendered safe
Safe structure outside the vessel to ensure easy
access/egress
Vessel should be closed after inspection to prevent
unauthorized entry

Plant Inspection Equipment Check

Heat Exchangers:
-Sliding supports check to ensure free operation
-Shipping stops and supports removed from expansions
bellows
-Check heads of large exchangers are clean
-Inspect tube sheet and tubes if possible



Plant Inspection Equipment Check

Pumps:-
-Aligned correctly and rotational direction correct
-Seal and lubrication systems installed, clean and working
-Pump suctions flushed clean prior to initial operation
-Switch pumps regularly during initial operation and clean
the suction filter

Plant Inspection Equipment Check

Compressors:
-Seal and lubricant systems checked against P&IDs, installed
and working correctly
-Oil flushing is completed to compressor vendor satisfaction
-Follow vendor instrument for operation, start-up, pre-
comm., commissioning and maintenance

Plant Inspection Electrical Check

Electrical Pre-comm. Checks Mostly in Switch Room
-Main switches labeled
-Overload cut-outs set to protect motors from overheating
Electrical Checks During Construction:
-Testing cable continuity
-Current leak testing
-Direction of motor rotation
-Electrical earthing of machinery, piping, etc.

Plant Inspection Electrical Check

All such checks are the responsibility of the
Construction/Plant Electrical Engineer
Commissioning/Operating personnel required to be familiar
with layout and function of electrical equipment.
Suitable training to be organized on site.

Plant Inspection Laboratory Check

Lab equipment fully in place and operational
Lab staff suitably trained and familiar with equipment
operation
Pre-comm. checks will be carried out by the commissioning
chemist
Exercise tests on all analytical procedures errors free
results
Plant sample point location check installation and
identification
Thank You
Prepared by:- Aditya Gupta