‫شرکت راه اندا زی و بهره ربداری صناعی نفت( ایکو )‬

‫‪Commissioning‬‬
‫‪engineering‬‬

‫تح ق‬
‫مدرییت آموزش‪ ،‬یق و توسعو‬

‫شهریور ‪1391‬‬
Pre--Commissioning and
Pre
C
Commissioning
i i i
Engineering

OICO Commissioning Dept.

STANDARDS
 IPS Iranian Petroleum Standards
 IPS-C-SF:
IPS- SF: Standard for Installation, Inspection and testing
of firefighting systems
 IPS--M-PP-
IPS PP-125:
125: Material and Equipment
q p Standard for
Firefighting
 IGS Iranian Gas Standards

 ASME American Society of Mechanical Engineers

 ASME VIII
VIII:: Pressure
P V
Vessels
l
 ASME IV
IV:: Heating Boiler
 ANSI American National Standard Institute
 ANSI B31.
31.3: Process Piping
 API American Petroleum Institute
 API--610:
API 610: Centrifugal Pump for General Refinery Service
Page 2 OICO Commissioning Dept.
 Commissioning Description

 System
A system is a major subdivision of an installation, being
either process or utility, that performs a major
operational function of the plant. The system includes
all the various equipment that allows it to operate. The
firewater pumps, power generation, control systems,
telecommunications oil,
telecommunications, oil gas,
gas water processing,
processing etc.,
etc
are typical examples of systems.

 Sub-System
Sub- System::
A subsystem is a further subdivision of a system, that
performs a p
p partial operational
p function to the system,
y ,
with no or little interference from the other subsystems.
Several equipment with the same function in the
system main packages are typical examples of
system,
subsystems.
Page 3 OICO Commissioning Dept.
 Time Schedule

Precommissioning

Commissioning

Start up

R ti
Routine Operation
O ti

Performance
Test

Time

Ready For Ready For Ready For Final

Commissioning Start Up O
Operation
ti Acceptance
Certificate
Page 4 OICO Commissioning Dept.
 Subsystems are Ready For Commissioning
when all Precommissioning activities are
complete..
complete

 Subsystems are Ready For Start Start--Up when

all Commissioning activities are complete.
complete.

 Systems or group of Subsystems are Ready

For Operation when all Start-
Start-up activities
are complete.
complete.

Page 5 OICO Commissioning Dept.

 Pre--Commissioning
Pre g

Th Precommissioning
The P i i i physical
h i l scope off work
k
consists, as previously said, in:
in:

 Systematic conformity checks of equipment

items

 Static/de--energised
Static/de tests of equipment
items

 Pipes works flushing, pressure test grouped

by Test Pack
Pack..

Page 6 OICO Commissioning Dept.

Commissioning
g

The Commissioning physical scope of work

consists, as previously said, of:
of:

 The dynamic verification of the elementary

plant functions
p

 The running
running--in and onon--line tests of utilities
system and the running-
running-in and on on--line
tests with inert fluid of process system
system..

 The Piping and Vessels Preparations

Preparations..

Page 7 OICO Commissioning Dept.

Start Up
p

The Start-
Start-up scope of work includes activities
preparation and witnessing of the commissioning
activities
activities.
ti iti . After
Aft th t the
that, th operational
ti l activities
ti iti
properly speaking are split prior to and after
oil/gas introduction
introduction..

 Operational activities prior oil/gas in

 Operational
p activities after oil/gas
/g in.
in.

Page 8 OICO Commissioning Dept.

‫‪Performance and Production tests‬‬

‫‪‬‬ ‫‪Performance tests‬‬

‫ون آﻧﻜﻪ‬
‫ﭘﺎﻻﻳﺸﮕﺎه ‪ 48‬ﺳﺎﻋﺖ ﺑﺑﺪون‬
‫ﻞ ﭘ ﻻﻳ‬
‫‪ ‬ﻫﺮﺮ وواﺣﺪ ‪ 72‬ﺳﺎﻋﺖ و ﻛﻞ‬
‫ﺗﺠﻬﻴﺰ ﻳﺎ واﺣﺪي ‪ shut down‬ﺑﺨﻮرد ﺑﺎﻳﺪ ﺑﻪ ﻃﻮر‬
‫ﻛﺎر ﻛﻨﺪ‪.‬‬
‫ﭘﻴﻮﺳﺘﻪ ﻛﺎ‬
‫ﺘﻪ‬

‫‪‬‬ ‫‪Production Test‬‬

‫‪ ‬ﻛﻞ ﭘﺎﻻﻳﺸﮕﺎه ﺑﺎﻳﺪ ‪ 21‬روز از ‪ 28‬روز را ﺑﺪون وﺟﻮد‬
‫ﻣﺸﻜﻞ‪ ،‬ﺑﻄﻮر ﻧﺮﻣﺎل در ﺳﺮوﻳﺲ ﺑﺎﺷﺪ‪.‬‬

‫‪Page 9‬‬ ‫‪OICO Commissioning Dept.‬‬

Discipline
p
 Electrical

 Instrument
I t t

 Piping

 Mechanical

 Process
Page 10 OICO Commissioning Dept.
‫‪Electrical Tests‬‬

‫‪‬‬ ‫‪Energizing & Functional Test‬‬

‫ﺻﻨﻌﺘﻲ‬
‫ﺘ‬ ‫ﺗﺎﺑﻠﻮﻫﺎي‬
‫ﺷﺪن ﺗﺎ ﻠ ﺎ‬
‫دار ﺷﺪ‬
‫ﺑﺮق ا‬
‫اﺳﺖ ﻛﻪ ﭘﺲ از ق‬ ‫ﺗﺴﺘﻬﺎﻳﻲ ا ﺖ‬
‫ﺗ ﺘﺎ‬
‫ﺟﻬﺖ ﺻﺤﺖ ﻋﻤﻠﻜﺮد ﺗﺎﺑﻠﻮﻫﺎ اﻧﺠﺎم ﻣﻲ ﮔﺮدد‪.‬‬

‫‪‬‬ ‫‪Solo Run‬‬

‫ﺗﺴﺘﻲ اﺳﺖ ﻛﻪ ﺑﺪون ﺑﺎر ﺑﺮ روي ﻣﻮﺗﻮرﻫﺎي اﻟﻜﺘﺮﻳﻜﻲ اﻧﺠﺎم‬
‫ﻟﺮزش‪ ،‬دﻣﺎي‬
‫ﻧﻈﺮ ﻟ زش‪،‬‬
‫ﻣﻮﺗﻮرﻫﺎ از ﻧﻈ‬
‫ﻣﻣﻲ ﺷﻮد‪ ،‬و ﺻﺤﺖ و ﺳﻼﻣﺖ ﻣﻮﺗﻮ ﻫﺎ‬
‫ﺑﻴﺮﻳﻨﮓ ﻫﺎ و ﻣﻴﺰان ﺟﺬب ﺟﺮﻳﺎن را ﻧﺸﺎن ﻣﻲ دﻫﺪ‪.‬‬

‫‪Page 11‬‬ ‫‪OICO Commissioning Dept.‬‬

‫‪Instrument Tests‬‬

‫‪‬‬ ‫‪Loop Test‬‬

‫ﺟﻬﺖ ﺗﺎﻳﻴﺪ ﺻﺤﺖ ﻋﻤﻠﻜﺮد ﺣﻠﻘﻪ ﻫﺎي ﻛﻨﺘﺮﻟﻲ ﺑﻴﻦ‬
‫ﺳﻴﺴﺘﻤﻬﺎي ﻛﻨﺘﺮل و اﺑﺰار دﻗﻴﻖ ﻣﺮﺑﻮﻃﻪ اﻧﺠﺎم ﻣﻲ ﺷﻮد‪.‬‬

‫‪‬‬ ‫‪Functional‬‬
‫‪u ct o a Test‬‬
‫‪est‬‬
‫ﻫﻤﺎﻧﻨﺪ اﻟﻜﺘﺮﻳﻜﺎل اﺳﺖ ﺗﻨﻬﺎ ﺗﻔﺎوت در اﻳﻦ اﺳﺖ ﻛﻪ در‬
‫ﺷﻮد‪.‬‬
‫ﺑﺴﻴﺎر ﺎﭘﺎﻳﻴﻦ اوارد ﻣﻲ ﺷ‬
‫وﻟﺘﺎژﻫﺎي ﺎ‬
‫ﺑﺮق ﺎﺑﺎ ﻟﺘﺎژ ﺎ‬
‫اﻳﻨﺠﺎ ق‬
‫ا ﺎ‬

‫‪Page 12‬‬ ‫‪OICO Commissioning Dept.‬‬

‫‪Piping‬‬
‫‪p g Tests‬‬
‫‪‬‬ ‫‪Leak Test‬‬
‫ﺗﻤﺎم ﺧﻄﻮط ﻫﻴﺪروﻛﺮﺑﻦ )اﻋﻢ از ﮔﺎز ﻳﺎ ﻣﺎﻳﻊ( ﺑﺎﻳﺪ ﺗﻮﺳﻂ ﻧﻴﺘﺮوژن ﺗﺎ ‪ %95‬ﻓﺸﺎر‬
‫ﻃﺮاﺣﻲ ﺗﺴﺖ ﺷﻮد‪:‬‬
‫ﺧﻄﻮط زﻳﺮ ‪ 7 bar‬ﺎﺑﺎ ا‬
‫ﻫﻮا‬ ‫‪ ‬ﺧﻄ ط‬
‫‪ ‬ﺑﺎﻻﺗﺮ از ‪ 7 bar‬ﺑﺎ ﻧﻴﺘﺮوژن‬
‫ﺷﻮد‪.‬‬‫اﻧﺠﺎم ﻣﻲ ﺷ‬
‫ﻳﻮﺗﻴﻠﻴﺘﻲ ﺳﺮوﻳﺲ ﺗﺗﺴﺖ اﻧ ﺎ‬‫ﺧﻄﻮط ﺗ ﻠ‬
‫‪ ‬ﺧﻄ ط‬
‫‪‬‬ ‫‪Pickling‬‬
‫ﻏﺒﺎر‪ ،‬ﭼﺮﺑﻲ و ‪ ...‬ﺎﺑﺎﻋﺚ‬
‫ﻫﺮﮔﻮﻧﻪ ﻏ ﺎ‬
‫ﺣﺴﺎﺳﻲ ﻫﺴﺘﻨﺪ و ورود ﮔ‬
‫ﺗﺠﻬﻴﺰات ﺎ‬
‫ا‬ ‫ﺎ‬
‫ﻛﻤﭙﺮﺳﻮرﻫﺎ‬
‫ﻛ‬
‫آﺳﻴﺐ ﺑﻪ ﭘﺮه ﻣﻲ ﺷﻮد‪ ،‬ﺑﺮاي ﺟﻠﻮﮔﻴﺮي از اﻳﻦ اﻣﺮ ﻣﺴﻴﺮﻫﺎي ورودي را ﺑﺎ اﺳﻴﺪ‬
‫ﺷﺴﺘﺸﻮ ﻣﻲ دﻫﻨﺪ‪.‬‬
‫‪‬‬ ‫‪Inerting‬‬
‫ﺧﻨﺜﻲ ﻫﻤﺎﻧﻨﺪ‬
‫ﺧﻮردﮔﻲ در ﺧﻄﻮط ﻟﻮﻟﻪ ﻫﻴﺪروﻛﺮﺑﻦ از ﮔﺎز ﺧﻨﺜ‬
‫ﺟﻬﺖ ﺟﻠﻮﮔﻴﺮي از ﺧﻮردﮔ‬
‫ﻧﻴﺘﺮوژن اﺳﺘﻔﺎده ﻣﻲ ﮔﺮدد‪.‬‬
‫‪Page 13‬‬ ‫‪OICO Commissioning Dept.‬‬
 ‫‪Mechanical Tests‬‬
‫‪‬‬ ‫‪Chemical & catalyst Loading‬‬
‫ﺷﻮﻧﺪ‪.‬‬
‫ﺷﻴﻤﻴﺎﻳﻲ ﭘﺮ ﻣﻲ ﺷ ﻧ‬
‫ﻣﻮاد ﺷ ﺎ‬
‫ﻛﺎﺗﺎﻟﻴﺴﺘﻬﺎ و ا‬
‫ﺗﻮﺳﻂ ﻛﺎﺗﺎﻟ ﺘ ﺎ‬
‫ﻣﺨﺎزن‪ ،‬ﺗ ﻂ‬
‫ﻛﻨﻬﺎ و ﺨﺎ‬
‫ﻓﻴﻠﺘﺮﻫﺎ‪ ،‬ﺧﺸﻚ ﻛ ﺎ‬
‫ﺑﺮﺧﻲ ﻓ ﻠﺘ ﺎ‬
‫ﺧ‬
‫‪‬‬ ‫‪Oil Flushing‬‬
‫ﺟﻬﺖ ﺷﺴﺘﺸﻮي ﻣﻴﺴﺮ روﻏﻦ در ﻛﻤﭙﺮﺳﻮرﻫﺎ و ﭘﻤﭙﻬﺎي داراي ﺳﻴﺴﺘﻢ روﻏﻦ ﻛﺎري‪ ،‬اﻧﺠﺎم ﻣﻣﻲ‬
‫ﮔﺮدد‪ .‬ﺗﺎ اﻳﻦ ﻣﺴﻴﺮ از ﻫﺮﮔﻮﻧﻪ ﻣﻮاد زاﺋﺪ ﻛﻪ ﺑﺎﻋﺚ آﺳﻴﺐ ﺑﻪ ﻗﻄﻌﺎت ﻣﻬﻤﻲ ﻫﻤﭽﻮن ﺑﻴﺮﻳﻨﮕﻬﺎ و‬
‫‪ ...‬ﻣﻲ ﺷﻮد‪ ،‬ﻋﺎري ﮔﺮدد‪.‬‬
‫‪‬‬ ‫‪Fan Adjustment‬‬
‫ﺗﺴﺘﻲ اﺳﺖ ﻛﻪ ﺑﺮاي ﺧﻨﻚ ﻛﻨﻨﺪه ﻫﻮا ﺟﻬﺖ ﺗﻨﻈﻴﻢ ﭘﺮه ﻫﺎ و ﻣﻮﺗﻮر ﺑﻪ ﺻﻮرﺗﻲ ﻛﻪ ﻟﺮزش‪،‬‬
‫ﺷﻮد‪.‬‬
‫اﻧﺠﺎم ﻣﻲ ﺷ د‬
‫ﺑﺎﺷﺪ اﻧﺠﺎ‬
‫ﺟﺪاره و ‪ ..‬ﻧﺪاﺷﺘﻪ ﺎﺷﺪ‬
‫ﺗﻤﺎس ﺎﺑﺎ ﺟﺪا ه‬
‫ﺗ ﺎ‬
‫‪‬‬ ‫‪Final Alignment‬‬
‫ﺑﻌﺪ از اﻧﺠﺎم ‪ solo run‬ﺑﻪ دﻟﻴﻞ اﻣﻜﺎن اﻳﺠﺎد اﻧﺤﺮاف و ﺟﺎﺑﻪ ﺟﺎﻳﻲ‪ ،‬ﻣﺠﺪدا ﭘﻤﭗ و ﺗﺠﻬﻴﺰ را‬
‫ﺗﺮاز ﻣﻲ ﻛﻨﻨﺪ‪.‬‬
‫‪‬‬ ‫‪Final Box Up‬‬
‫ﺗﺠﻬﻴﺰات ﺛﺎﺑﺖ از ﻧﻈﺮ ﻧﺼﺐ اﺑﺰار دﻗﻴﻖ‪ ،‬اﺗﺼﺎل ﻛﻠﻴﻪ ﺧﻄﻮط ﻟﻮﻟﻪ‪ ،‬ﻋﺪم ﺗﻤﺎس ﺑﺎ ﻫﻮاي آزاد و ‪...‬‬
‫ﻛﻨﺘﺮل ﻣﻲ ﺷﻮد‪.‬‬
‫‪Page 14‬‬ ‫‪OICO Commissioning Dept.‬‬
‫‪Process Tests‬‬
‫‪‬‬ ‫‪Dry Out‬‬
‫ﻫﺎ و آﻛ ﺎ‬
‫رآﻛﺘﻮرﻫﺎ‬ ‫ﺑﻮﻳﻠﺮﻫﺎ‪ ،‬ﻛﻛﻮره ﺎ‬
‫رﻓﺘﻪ در ﻠ ﺎ‬
‫ﻛﺎر ﻓ‬
‫آﺟﺮﻫﺎي ﻧﺴﻮز ﺑﻪ ﻛﺎ‬
‫ﺧﺸﻚ ﻛﻛﺮدن آ ﺎ‬
‫ﻣﺨﺼﻮص ﻚ‬
‫ﻣﻲ ﺑﺎﺷﺪ‪.‬‬

‫‪‬‬ ‫‪OTP‬‬
‫ﺑﻌﺪ از اﻧﺠﺎم ﻛﻠﻴﻪ ﺗﺴﺘﻬﺎي ﻣﻜﺎﻧﻴﻚ ﺗﺠﻬﻴﺰات دوار‪ ،‬ﺻﺤﺖ و ﺳﻼﻣﺖ ﻛﺎرﻛﺮد‬
‫ﺳﻴﺎل ﻧﺰدﻳﻚ ﺑﻪ آآن ﻛﻨﺘﺮل ﻣﻲ ﮔﮔﺮدد‪.‬‬
‫اﺻﻠﻲ و ﺎﻳﺎ ﺎ‬
‫ﺳﻴﺎل ا ﻠ‬
‫ﺗﻮﺳﻂ ﺎ‬
‫ﺗﺠﻬﻴﺰ‪ ،‬ﻂ‬

‫‪‬‬ ‫‪Dehydration‬‬
‫‪y‬‬
‫ﺟﻬﺖ ﺑﻪ ﺣﺪاﻗﻞ رﺳﺎﻧﻴﺪن رﻃﻮﺑﺖ در ﺧﻄﻮط ﭘﺮوﭘﺎن ﻳﺎ ﺧﻄﻮﻃﻲ ﻛﻪ دﻣﺎي ﻛﻤﺘﺮ از‬
‫‪ 7C‬دارﻧﺪ اﻳﻦ ﺗﺴﺖ اﻧﺠﺎم ﻣﻲ ﺷﻮد‪.‬‬

‫‪‬‬ ‫‪Degreasing / Boil-‬‬

‫‪Boil-Out‬‬
‫ﻣﺴﻴﺮﻫﺎ و‬
‫ﺑﺨﺎر‪ ،‬ﻴﺮ‬
‫يﺑ ر‬‫دﻳﮕﻬﺎي‬
‫يو ﻳ ﻬ‬
‫ﻓﺮآﻳﻨﺪي‬
‫ي ﺮﻳ‬ ‫ﺳﻴﺴﺘﻤﻬﺎي‬
‫ﻴﻞ ﻛﻒ درر ﻴ ﻬ‬
‫ﻴﺮي ازز ﺗﺸﻜﻴﻞ‬
‫ﺟﻠﻮﮔﻴﺮي‬
‫يﺟﻮ‬‫ﺑﺮاي‬
‫ﺑﺮ‬
‫ﺗﺠﻬﻴﺰات ﺑﺎ ﻣﺤﻠﻮل ﻗﻠﻴﺎﻳﻲ ﺷﺴﺘﺸﻮ ﻣﻲ ﮔﺮدد‪.‬‬
‫‪Page 15‬‬ ‫‪OICO Commissioning Dept.‬‬
‫ﭘﺮوژه راه اﻧﺪازي ﻓﺎزﻫﺎي ‪ 17‬و ‪ 18‬ﭘﺎرس ﺟﻨﻮﺑﻲ‬

‫‪Page 16‬‬ ‫‪OICO Commissioning‬‬

‫‪Dept.‬‬
 Off h
Offshore
– Four Wellhead Facilities
– Two 32
32”” undersea pipelines
– Two
o 4” ppipeline
pe e ((MEGG Piggyback
ggybac line)
e)

 Onshore
– Two Phases, each phase has two trains
Design Capacity: 2000 MMSCFD

Page 17 OICO Commissioning Dept.

Offshore Facilities

 Offshore operation:
– Water
Water--Gas Separation
– Multiphase
M lti h Transportation
T t ti to
t the
th PlPlantt
– MEG injection for Hydrate Inhibition

Page 18 OICO Commissioning Dept.

Page 19 OICO Commissioning Dept.
Page 20 OICO Commissioning Dept.
Page 21 OICO Commissioning Dept.
 System 59

 Subsystem 782

 BOQ 66000
 Electrical: 9200
 Piping: 1000
 Instrument: 53000
 Mechanical: 1400
 Process: 950

Page 22 OICO Commissioning Dept.

On--Shore
On

 Utility Units

 Process Units

 Offsite Units

 Miscellaneous Units

Page 23 OICO Commissioning Dept.

Utility
y Units
• Electricity (Power Generation)
• Steam generation
• Fuel gas
• Instrument & Service air A/B/C
• Nitrogen Generation
• Water
 Sea water intake & Booster
 Sea water Desalination
 Polishing water
 Potable water
 Cooling Water
• Waste Effluent Disposal
• Fire water system
• Diesel Oil

Page 24 OICO Commissioning Dept.

 Process Units
• Reception facilities
• G ttreating
Gas ti unitit
• MEG Regeneration & injection
• Condensate Stabilization
• Dehydration & Mercury Guard
• Ethane Recovery y
• Export Gas Compression & Metering
• NGL Fractionation
• Sulfur Recovery (SRU & TGTU)
• Sour Water Stripping
• B
Back
Back-
k-up Stabilization
St bili ti
• Propane Refrigeration
• Caustic Regeneration
• Propane / Butane / Ethane treatment & drying
Page 25 OICO Commissioning Dept.
Offsite units

• Flares and Blow down

• Drains
• Burn pit
• Condensate storage and Export
• Sulfur storage and Solidification
• Propane
p Refrigeration
g storage
g
• Chemicals storage
• Propane
p storage
g
• Butane storage

Page 26 OICO Commissioning Dept.

Miscellaneous Unit
• Interconnection and Sub
Sub--Interconnections
• Control room
• Laboratory
• Fire Fighting Building
• Work shop
• Non--process Building
Non
• RTU’s , PCS , MTU
• Radios
• Telecommunication
• Fire & Gas
• ESD
• Technical Room (substations and ITR)

Page 27 OICO Commissioning Dept.