Process Plant Startup,

Commissioning And
Troubleshooting Course

By Eng. Jamal Khaled Amer

Commissioning
➢Commissioning is NOT just turning up the day after construction
is complete and pressing the BIG GREEN BUTTON !

➢Commissioning is a series of checks that confirm newly

constructed chemical plant is fit for purpose, these checks being
made at all stages of a project's life, not just after construction is
complete.
Commissioning
➢Commissioning is the use of a disciplined, systematic and
professional methodology:
1-To convert newly constructed process plant into a fully integrated
and operational unit in the most safe, efficient, cost effective and
timely of manners.
2-To achieve start up and production targets “right first time".
Commissioning Terminologies
Dry Commissioning:
Tests and procedures that are conducted where there is
no process or safe chemicals yet introduced to the plant.

Examples of these activities would be:

• Interlock and emergency shutdown tests
• Control system sequence checks.
• Potentially initial running of major motors of such as
Compressor, Oil lubrications systems, uncoupled from the
turning mechanism.
Wet Commissioning:

➢ Water or some other relatively safe medium has been

introduced to the process and initial commissioning of
the system and its major plant items can be undertaken.

➢ Putting the process through its operating scenarios to

replicate in the most suitable manner possible the
normal operation of the unit
Commissioning
• Commissioning is usually the phase in a project when design process fluids
are introduced to the systems.

• Sometimes commissioning means running the systems with a safe fluid

only.

PSSR= Pre Start-Up Safety Review

Start-Up:
• The phase in a project where the entire plant (all systems and sub-
systems) are taken into operation.
• Process fluids are introduced and process conditions are established with
the intent of making products.

Initial Operation:
• The phase in a project after start-up of the complete plant in order to adjust
and optimize and prepare the plant for the performance testing phase.
Hot Commissioning / Live Commissioning:
• Design process fluids are introduced in the systems and sub-
systems.
Performance Testing:
• Check if the plant meets the specifications under normal operating
condition.
Post Commissioning:
• Solving of outstanding punch points after the plant has been
handed over to the client.
De-Commissioning:
• Means taking out of active use and dismantling of an industrial
plant.
Safety and Environmental Considerations
During Commissioning stages there are hazard that could cause damage
to the Newly installed equipment, Injury People , Impact Environment .

These Hazards could be caused and initiated by :

• People: Lack of experience.
• Pre-commissioning & Commissioning activities: Hydrostatic Pressure
testing.
• Environment: Hot weather.
Safety & Environmental Consideration-
• The safe and environmentally friendly commissioning of any new asset
should always be of highest priority and integral with every check-sheet
and procedure written during the preparation and execution of the
commissioning process.
• The safety of personnel plus the environmental implication must always
be the first consideration of any commissioning activity .
• Schedules must be considered and constructed in a way that sufficient
time is allocated to each and every commissioning activity.
• Safety implication can be neglected during intensity and critical time of
the commissioning and start up phases
Safety & Environmental Consideration
During commissioning and whilst introduction of energy to the plant :
• The various process area must be clearly identified , barricaded or fenced
off and tagged appropriately.
• Clearly identifying the nature of the activities before commence in the area.
• All electrical items at field; devices and motor control centers MCC must be
clearly labeled, locked out.
• The commissioning team must undergo all relevant training required by the
site to which the project is being worked.
• The commissioning organization should establish safe system of work at
work location ;These safe systems include permit to work systems ,
confined space entry permits, and hot permits.
Safety & Environmental Consideration
• The commissioning personnel must make themselves familiar with all site
regulatory procedures and works instructions such as ;Environment
impact assessments , job safety analysis , major job review , job method
statement , pre-task planning , safe and unsafe acts audits.
• Discussion must takes place between the contracting and site client
personnel to ensure no transgression or site violation takes place within
the initially commissioning the new facility; examples:
• Opening process valves potentially from an existing operation area.
• Starting electrical equipment.
• The finding from the discussion must be fully documented within the
commissioning manual and subsequent commissioning procedure and
strictly adhered to during the actual commissioning activities
Control Measures to Eliminate Risk & Incidents:
➢ Training programme should be available and conducted to all
commission team members (Operation, Maintenance , Contractor , and
vendors).
➢Hazop Study must be conduct for pre-commissioning and
commissioning activities
➢Sufficient time is allocated to each and every commissioning activity
➢Process areas must be clearly identified
➢Areas must be taped, barricaded or fenced off and tagged appropriately.
➢ The nature of the activities MUST clearly identifying .
 Control Measures to Eliminate Risk & Incidents:
➢Performing audit during construction and commissioning phases.
➢Sufficient commissioning staff must be made available on site
➢All electrical items at field devices and motor control centers (MCC) must
be clearly labeled, locked out and tracked in a safe-and-sound manner.
➢The commissioning personnel must make themselves familiar with:
✓the procedures and works instructions
✓environmental impact assessments, job safety analysis, job method
statements, pre task planning,
✓safe and unsafe acts audits etc…
Commissioning
Successful Commissioning of a chemical plant is divided into
three main Categories:
 Commissioning
Pre-commissioning: Activities
carried out during construction that
prepare and enable the unit to move to
the main commissioning phase.
Pre-commissioning activities include:
• Installation of filters,
• Packing of distillation columns,
• Filling a reactor with catalyst,
• Cleaning pipes and equipment,
• Vendor and factory acceptance
testing, Punch listing and
instrument,
• Electrical and motor loop testing.
Commissioning:
1-various systems and items of equipment
are first put into initial operation.
to gain the confidence that when process Start-up,
chemicals are introduced the plant will
operate as designed and intended.
• Utility systems, instrument air, cooling The plant is
water and general purpose water are brought into
made live. actual
• The unit is leak tested, started up, shut operation.
down, distillation columns and
scrubbing columns put into use,
Most commissioning activities fall into the following key headings:
• System configuration check.
• Instrumentation system check verification of alarms and trips.
• Flushing and cleaning of lines and vessels with water.
• Assessment of ancillary equipment.
• Calibration of vessels and instrumentation.
• Start-up protocol.
• Shut-down protocol.
• Chemical trials.
• Handover.
Commissioning Process:
Commissioning Process is delivered in three distinguished Stages

Prepare Implement Close Out

All the steps within each stage should be considered for any project, of any
size, to ensure all of the commissioning activities required are included in
the management system to get successful plant start-up.
The Commissioning Phases
Prepare:
Activities to be taken to set commissioning up, gather information, select the
commissioning team, develop the schedule and create documentation.
Implement:
This phase, is “commissioning”, examines the facets that address the installation,
checking and start-up of the new equipment.

Close out:
The final stage of the commissioning process: ensuring that all paperwork systems and
trials are complete, and that the plant or equipment has met its acceptance criteria,
enabling the plant to be handed to the ongoing operations group.

The commissioning team will then be closed down.

Overview of Commissioning Stages
 Prepare Stage:
• Appoint the Commissioning Manager.
• Define the commissioning scope.
• Systemize the plant utilizing the project Piping and Instrument Diagrams (P&lD) and other
relevant documents Including layout drawings and mechanical flow diagrams, into
commissioning system Integrate commissioning systems into the engineering documents, line
tables, Instrument index, P&IDs, equipment lists and procurement plans.
• Input to design

• The commissioning team upon agreement With the Project Manager and Commissioning
Managers Will attend the following reviews:
P&ID, Piping isometric, Plant Layout, Constructability, 3-D model, Schedule, SIL, LOPA and
action upon alarm
• Compile the Commissioning Schedule

• Compile the Commissioning Estimate/Budget

Prepare Stage:
• Agree interface/handover procedure With project, client and construction groups
• Obtain pertinent and relevant documents and establish electronic libraries
• Attend Hazard Study
• Compile Initial Commissioning Plan
• Set up Site base and compile commissioning consumables list
• Determine initial fill chemicals, Simulants and procure
• Create Commissioning Manual
• Compile Standard Operating Procedures (SOPs)
• Compile training packages
• Agree Safe Systems of Work With all interested parties
• Compile Commissioning Procedures
• Give input as required to the User Requirement Specification (URS) for a Distributed Control
System (DCS)
• Compile Decontamination Procedures
Thank You