FACULTY OF ENGINEERING TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

BIOPRODUCT FACILITY DESIGN

LABORATORY REPORT

COURSE CODE BNN 40104

EXPERIMENT NO. EXPERIMENT 4
PRE-COMMISSIONING,COMMISSIONING AND START
EXPERIMENT TITLE UP
UP OF
OF OSBORNE REYNOLDS
FLOWMETER

DATE 28.10.2019
GROUP NO. GROUP 1
1. Ts. Dr. NUR HANIS HAYATI BINTI HAIROM
LECTURER/INSTRUCTOR/TUTOR 2. PUAN MASAYU BINTI MASLAN
3. ENCIK MOHAMAD SIDIQ BIN MOHD BASIR

DATE OF REPORT SUBMISSION 30.4.2019

ATTENDANCE/PARTICIPATION/DISIPLINE: /5%
INTRODUCTION: /5%
DISTRIBUTION OF MARKS FOR PROCEDURE: /15%
LABORATORY REPORT: DISCUSSION : /50%
CONCLUSION /10%
SUGGESTIONS & RECOMENDATIONS /5%
REFERENCES: /5%
TOTAL: /100%

EXAMINER COMMENTS: RECEIVED DATE AND STAMP:

 STUDENT CODE OF ETHICS

DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

FACULTY OF ENGINEERING TECHNOLOGY

I hereby declare that I have prepared this report with my own efforts. I also admit to not accept or

provide any assistance in preparing this report and anything that is in it is true.

1) Group Leader ________________________________________ (Signature)

Name : AKMAL HAFISZI BIN ABDUL AZIZE
Matrix No. : AN160169

2) Group Member 1 _____________ ___________________(Signature)

Name : JIVASHINI BALASUPUR MANIAM
Matrix No : AN160185

3) Group Member 2 _____________ _____________________(Signature)

Name : NURUL ATIKA BINTI ZAID
Matrix No. : DN160322
 FACULTY : ENGINEERING
EDITION:
TECHNOLOGY

LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
DATE:

1.0 OBJECTIVES

To gain the knowledge and techniques that can be applied in pre-commissioning,

commissioning and start-up of equipment.

2.0 LEARNING OUTCOMES

At the end of the study, student will be able to:

1. Develop high understanding on the commissioning and start-up of bioproduct plant

(C5, PLO4).
2. Display the ability to analyze problems, develop methods for their solutions and begin
to demonstrate a capacity for independent critical thought (P5, PLO2).
3. Demonstrate teamwork skills and lead the team members effectively in conducting
laboratory work and solving problem for the assigned project. (A3, PLO9).

3.0 INTRODUCTION

Flowmeter measurement apparatus is designed to operate together with a basic hydraulic

bench or a water supply. This enables students to familiarize themselves with typical methods
of flow measurement of an incompressible fluid which occur when that fluid flows through
pipes, bends, valves and pipe flow metering devices. Devices that used in the flow
measurement devices are venture and orifice, where each type of the flow measurement
devices has its own advantages and disadvantages.

Venturi which shown in figure 1, is a device that can reduce the pressure when increasing
the velocity by using its tube which is constricted. It can measure both compressible and
incompressible fluid. When fluid flow through any constricted part, the velocity measured
after passing the constricted part is higher than velocity measured before entering the
constricted part. The diameter constricted part is smaller than the diameter of the pipeline,
which cause the different in reading of velocity. Discharge of the fluid can be calculated by
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

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COMMISSIONING,
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COMMISSIONING AND START-UP
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measuring the pressure drop. This venturi meter used Bernoulli principles which state that an
inviscid flow of a nonconducting fluid, an increase in the speed of the fluid occurs
simultaneously with a decrease in pressure or a decrease in the fluid’s potential energy.
Venturi tube is suitable for viscous, clean and dirty liquid. Pressure loss is low and its
viscosity is high.

Figure3.1: Venturi meter

Then, figure 2 shows an orifice meter which made of thin and flat orifice plate which has
a circular hole at the centre of the plate. There is two pressure tap which is tap upstream and
tap downstream. The taps can be placed at three places which each of the place have different
value of coefficient. When the fluid reaches the orifice plate, the fluid is forced to flow
through the hole in the middle of the orifice plate. The flow rate can be obtained from
Bernoulli’s equation by measuring the pressure difference between normal pipe section and
the vena contracta. Vena contracta is the point of the maximum convergence is produced at
the downstream of physical orifice.
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LABORATORY: BIOPRODUCT
REVISION NO:
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COMMISSIONING,
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Figure 3.2: Orifice meter

Besides, other feature of the apparatus includes 90° elbow with pressure tappings. This
feature allows the calculation of the total head loss and loss coefficient when fluid flows
through the 90° elbow. Head loss in a pipe fitting is proportional to the velocity head of the
fluid flowing through the fittings.

Before running the flowmeter measurement apparatus, the pre-commissioning,

commissioning and startup procedures need to be done. Pre-commissioning is conducted in
order to prepare and ensure the overall individual equipment and factory systems which has
been completed in the construction phase can work well according to standards and design. It
involves the activities of flushing and cleaning, drawing check and drying.
Pre-Commissioning activities start when a plant or system achieves mechanical completion.
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
DATE:

Next, commissioning is a process to verify that equipment and systems that have not been
operated before, or have been modified, are brought into operation safely and in the correct
sequence. It is the phase when fluids are introduced to the process. In simple terms,
commissioning a plant means thorough checking of a new plant where it should be matched
with P&IDs, while all pipelines, all control valves are checked and calibrated. Then, startup
the act or process of starting a process or machine. It is the point in a project where process
fluids and conditions are established with the intent of making products. This process
included introduction of feedstock or raw material, and performance testing.

4.0 PROCEDURES

4.1 Pre-commissioning
1. The equipment was checked thoroughly as built against the relevant equipment
flowsheet (drawing checked)

Figure 4.1: Unit assembly of flowmeter measurement apparatus.

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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
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2. Each part of the equipment was checked thoroughly, which are:

a) Manometer tubes
b) Discharge valve
c) Water outlet
d) Water supply
e) Staddle level
f) Rotameter
g) 90° elbow
h) Orifice
i) Venturi
j) Water supply pump
3. The Standard Operating Procedures (SOP) was ensured available and up-to-date.
4. All the group members that involved to carry this experiment was ensured fully
understood on the operation of the equipment.
5. The raw material (water supply) involved to carry out this experiment was checked
available and in correct quality and quantity.
6. The cleaning process was proceeded if required.
7. The leaking testing was carried out and the parts list in step 2 was observed for any
sign of leaking.
8. Equipment was ready for commissioning process.

4.2 Commissioning

1. The apparatus was placed on bench, inlet pipe was connected to bench supply and
outlet pipe into volumetric tank.
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LABORATORY: BIOPRODUCT
REVISION NO:
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EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
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2. With the bench valve fully closed and the discharge valve fully opened, the pump
supply was started up from hydraulic bench. The process fluid was introduced to
the process to observe the result obtained. (should be similar with the theory
involved).

3. The bench valve was slowly opened until it is fully opened.

4. When the flow in the pipe was steady, the exist of trapped bubble was observed in
the manometer tubes. A pen or screw driver was used to depress the staddle valve
at the top right side of manometer board. (Depress staddle valve lightly to allow
fluid and trapped air to escape out. Allow sufficient time for bleeding to allowing
all bubbles escape.)

5. When there is no trapped bubble, the bench valve was closed to reduce the flow to
the maximum measurable flow rate.

6. The water level was observed in the manometer tubes as they started to display
different level of water height.

7. Water level in the manometer board was adjusted using the air bleed screw if they
were too high (out of visible point). Maximum readings on manometers were
retained with the maximum measurable flow rate.

8. Then, the discharge was slowly closed

9. The water level was observed where they started to level into a straight level.

10. Readings on manometers (A - J) was recorded where they displayed almost the
same reading.

11. The equipment was ready for start-up.

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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
DATE:

4.3 Start-up
1. Step 1-10 in commissioning procedure was repeated, but using the correct raw
material involved which is water.
2. The different flow rates were introduced by adjusting both bench valve and
discharge valve.

3. The result obtained was observed. The readings on manometers (I and J) and
measured flow rate were recorded.

4.4 Shut-down

1. Water supply valve and venturi discharge valve were closed.

2. The water supply pump was turned off.

3. The water from the unit was drained off when not in use.
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
DATE:

5.0 DISCUSSION

Pre-commissioning

The experiment start with pre-commissioning activities. Pre-commissioning activities

was prepared according to the previous experiment. Pre-commisioning is run to ensure the
system in a good condition and to identify the defect area of the system. The
pre-commissioning activity started with analysed flowmeter system regarding to the technical
drawing that been provided as shown in Figure 5.1a. Checking the drawing is important step
in pre-commissioning to ensure the system was correctly assembled according to the plan and
to ensure every part in drawing was available. Based on observation, the flowmeter system
were installed properly where not part is missing or not installed according to drawing as
shown in figure 5.1b. Furthermore, each equipment were labelled properly. Labelling is
important to smooth experimental process and understand the flow process of this experiment.

(a) (b)

Figure 5.1: (a) show the technical drawing of flowmeter measurement. (b) show the
actual condition of flowmeter measurement.
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
DATE:

Next, overall pipe connection was checked which including the 90 elbow, venture, orifice,
and all tube connecter. Checking is important to ensure there is no scratch, installed properly
and no possibility to leak during commissioning. Based on the observation, the pipe was
connected properly including 90 elbow, venture, orifice, and all tube connecter as shown in
Figure 5.2.

(a) (b)

(c)

Figure 5.2: (a) show the 90° Elbow, (b) Sump tank connector and (c) manometer tube.
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
DATE:

Moreover, the manometer tube reading were inspected one by one to ensure the glass in a
good condition, no scratch and cracked as shown in Figure 5.3a. This step is important to
ensure the reading is accurate. Next, the condition of sump container was checked for any
cracked that will cause leaking. Based on observation, the sump tank was in a good condition
as shown in Figure 3b, no scratch or broken part that could lead to leaking during experiment.

(a) (b)

Figure 5.3: (a) show the condition of manometer glass and (b) show the condition bottom
sump tank.

Furthermore, electrical supplied were checked it connected properly and the pump were
properly connected to the inlet pipe. The blade have protected with cages to protect blade. The
number series of a pump and the expired date were available as shown in Figure 5.4a. The
pump were functioning as pump sound run smoothly without vibration. Besides, electrical
supply wire is too long, so we need to band it together using strap as shown in Figure 5.4b.
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
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(a) (b)

Figure 5.4: (a) show the detail information of centrifugal pump and (b) show the power
supply wire were tie using tape.

After completing the pre-commissioning, the commissioning process was start by switch on
the power supply and fully open the valve. The commissioning step is important to ensure the
flowmeter system can run effectively without leaking, adjust the parameter, and calibration of
the system. Besides, the pump and control valve is checked in a good condition, which can
control the water flow correctly as shown in Figure 5.5(a). Control valve is important to
regulate flow and induce variable of observation in the manometer level. During the
commissioning, manometer was completely with water by fully open the control valve. Next,
we need ensure there is no bubble in the manometer tube, they will disturb manometer
reading. Additional procedure were taken to reduce the air bubble in manometer since the
bubble air was difficult to remove. Control valve was open to allow high flowrate inside the
system and strong stream will remove all bubbles away. However, the implication of this step
can cause manometer tube breakage because of high pressure of water flow. Other implication
was the water may spill out from the sump tank because pipe connected of outlet was not long
enough to discharge water properly. Then, after the air bubble was removed the calibration
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
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process was taken by switch off the power supply and fully-closed control valve. The value of
manometer must be linear for each tube as shown in Figure 5.5(b).

(a)

(b)

Figure 5.5: (a) show the condition of control flowrate valve and (b) show the commissioning
reading (calibration reading).
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
DATE:

When the calibration of manometer was achieve, the flowmeter system was ready for start-up
procedure. The aim of this experiment was to demonstrate the flow comparison between
rotameter, orifices devices and venture devices. Therefore, few data were collected from
manometer and rotameter reading to be used in calculation. Theoretically, orifice devices
supposed to have higher flowrate than venture meter, due to venture design that have
contraction in size of the throat.

Table 1: show the result of flowrate system

Condition Rotameter
A B C D E F G H I J (L/min)
Commisioning 325 325 325 325 325 325 325 325 325 325 0
Minimum flow 390 385 390 386 396 389 371 371 380 380 5
Maximum flow 450 445 418 434 438 440 440 370 399 398 7

a) Venturi devices

t
t ; At Pressure 1mmHg = 133.32239Pa

Where;
Cd = Coefficient of discharge (0.98)
D2 = Throat diameter = 16 mm
D1 = Inlet diameter = 26 mm
䪸
At = Throat area = 2.011 x t
䪸
A = Inlet area = 5.309 x t
G = 9.81 m/
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LABORATORY: BIOPRODUCT
REVISION NO:
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EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
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Density of water = 1000 kg/

P1 (h1) = Outlet pressure (Pa) (Manometer reading tube E)

P2 (h3) = Throat pressure (Pa) (Manometer reading tube C)

At a minimum flow;

䪸 tt t 䪸 thh h t 䪸 hh t
Q = tth tt t t th t 䪸 ttt

= (0.000197078) (1.0805176345) (2.18714)

=0.4657 t L/min

At maximum flow;

䪸 tt t 䪸 thh h t 䪸 t 䪸
Q = tth tt t t th t 䪸 ttt

= (0.000197078) (1.0805176345) (1.7399)

= 0.370 t L/min

b) Orifice Devices

t
t ; At Pressure 1mmHg = 133.32239Pa

Cd = Coefficient of discharge (0.63)

D7 = Throat diameter = 16 mm
D8 = Inlet diameter = 26 mm
䪸
At = Throat area = 2.011 x t
䪸
A = Inlet area = 5.309 x t
G = 9.81 m/
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EXPERIMENT: PRE- EFFECTIVE DATE:

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Density of water = 1000 kg/

P1 (h1) = Outlet pressure (Pa) (Manometer reading tube I)

P2 (h3) = Throat pressure (Pa) (Manometer reading tube H)

a) Minimum flow

䪸 tt t 䪸 thh t t t 䪸h䪸 t t
Q = tt tt t t th t 䪸 ttt

=0.000126693 (1.0805176345) (2.6786957591)

=0.3666 t L/min

b) Maximum flow

䪸 tt t 䪸 thh h t h 䪸h ht 䪸
Q = tt tt t t th t 䪸 ttt

=0.000126693 (1.0805176345) (4.8083603343)

=0.658 t L/min
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LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB

EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
AMENDMENT
COMMISSIONING AND START-UP
DATE:

6.0 CONCLUSION

The objective of this experiment was achieved which is to to gain the knowledge and
techniques that can be applied in pre-commissioning, commissioning and start-up of flowmeter
measurement. The pre-commissioning, commissioning and start-up is the activity that brigde
between these two phases that includes systems turnover,checkout of systems, commissioning
of systems, performance testing. It gives the member best practice that lead to a more
successful startup of the experiment. In pre commissioning, all the equipment was checked
with the help the drawing shown in figure 4.1.

During commissioning phase, the flowmeter was assembled as a preparation for start up
experiment. It was begun by setting the calibration in the manometer ensuring that the water
level are all in the same level.

Then venturi device showed a high calculated flowrate reading during minimum flowrate
of 0.4657 t L/min than maximum flowrate, 0.370 t L/min. While, the orifice
device showed a higher reading during maximum flow with a reading of 0.658 t
L/min.

7.0 SUGGESTION AND RECOMMENDATION

To ensure an accurate reading is obtain it is always important to carry out pre commissioning
and commissioning. This will ensure that the equipment is functioning properly and for a
better understanding.

Firstly, it is important to ensure a constant and smooth flow before starting the
experiment so that the disturbed flow rate does not effect the final results. Besides that, ensure
the does not contain any air bubble as itt can effect the flowrate.
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LABORATORY: BIOPRODUCT
REVISION NO:
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EXPERIMENT: PRE- EFFECTIVE DATE:

COMMISSIONING,
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COMMISSIONING AND START-UP
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There are also some parallax error while setting rotameter reading and also while reading
manometer reading. Parallax error occurs when the measurement of an object's length is more
or less than the true length because of your eye being positioned at an angle to the
measurement markings. To avoid this, place eye at the level of the appropriate measurement
marking when measuring the level of a liquid in a graduated cylinder. Record the value of the
ower part of the curved surface of the liquid to gain an accurate measurement. The experiment
can also be repeated 3 times and calculate for its average value. This will reduce the deviation
from theoretical results.

8.0 REFERENCES

1. Stauffer, T. B., Johnson, M. C., Sharp, Z. B., & Barfuss, S. L. (2019). Multiple tap sets to
improve Venturi flowmeters performance characteristics with disturbed flow. AWWA
Water Science, 1(3), e1134.

2. Nedeljkovic, M. S., Jankovic, N., Cantrak, D. S., Ilic, D. B., & Matijevic, M. S. (2018,
April). Engineering education lab setup ready for remote operation—Pump system
hydraulic performance. In 2018 IEEE Global Engineering Education Conference
(EDUCON) (pp. 1169-1176). IEEE.

3. Xu, Y., Coxe, D., Peet, Y., & Lee, T. (2018, July). Computational Modeling of Flow Rate
Measurements Using an Orifice Flow Meter. In ASME 2018 5th Joint US-European
Fluids Engineering Division Summer Meeting (pp. V002T14A011-V002T14A011).
American Society of Mechanical Engineers.
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LABORATORY: BIOPRODUCT
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4. Almasi, A., Fox, K., Fischer, R., Zan, C., Blackmer, Wilden, … Jarrett, C. (2018).
Processing plant commissioning considerations. Retrieved from
https://www.processingmagazine.com/processing-plant-commissioning-considerations

5. Frank M. White, “Fluid Mechanics”, McGraw-Hill, New York

6. Kundu, Pijush K.; Cohen, Ira M. (2008), Fluid Mechanics (4th revised ed.), Academic
Press.

7. LMNO Engineering, Researches, and Software, Ltd. Retrieved from:

http://www.lmnoeng.com/orifice.php

8. Pre Commissioning Manual | Pump | Valve. (2019). Retrieved from

https://www.scribd.com/document/333971912/Pre-Commissioning-Manual

Prepared by/Disediakan oleh : Approved by/Disahkan oleh :

Signature/Tandatangan : Signature/Tandatangan :

Name/Nama : NUR HANIS HAYATI HAIROM Name/Nama : PROF. MADYA DR. ISHAK BABA

Date/Tarikh : Date/ Tarikh :