Commissioning of Combined Heat and Power Plants

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<ul><li><p>Commissioning of Commissioning of Combined Heat and Power Plants:Combined Heat and Power Plants: </p><p>Lessons LearnedLessons LearnedJuly 1, 2008</p><p>Presented by Abbe Bjorklund, PE, LEED APSebesta Blomberg &amp; Associates</p><p>andBruce Nicholson</p><p>Cooperative Consulting Services, Inc.</p></li><li><p>Topics Covered</p><p> Beneficial commissioning processes Roles and responsibilities Benefits, costs and challenges of a formal </p><p>startup/commissioning process Coordination and conflict between </p><p>construction startup/commissioning OEM coordination issues and how to address</p><p>PresenterPresentation NotesRoles and Responsibilities through the design, construction, and startup/commissioning phases of the project.The benefits, costs, and challenges of a formal startup and commissioning process for a campus sized project.Coordination and conflicts between construction and startup/commissioning organizations.OEM coordination issues and how to address: From pre-purchase through construction and startup/commissioning.Beneficial Commissioning Processes from Construction through Systems Testing, Performance Testing, Environmental Testing, and Reliability Testing.</p></li><li><p>Beneficial Commissioning Processes Beneficial Commissioning Processes from Construction through Systems from Construction through Systems </p><p>Testing, Performance Testing, Testing, Performance Testing, Environmental Testing, and Reliability Environmental Testing, and Reliability </p><p>TestingTesting</p></li><li><p>Beneficial Commissioning Processes</p><p> Design Purchase Install Construct Turnover to startup/commissioning Equipment checkout System testing/initial operation and system functional testing Integrated system/plant functional testing Performance testing Environmental/compliance testing Reliability/acceptance testing Turnover to the Owners/plant final acceptance</p><p>PresenterPresentation NotesDesignPurchaseInstallConstructSome testing takes place as construction completes equipment installation and the construction of a system.Pressure testsInsulation resistance testSome vendor testingGenerally, if to perform the testing the system needs to be energized or if permanent plant equipment is placed in operation the system should be turned over to Startup/Commissioning before the testing takes place.System turnover packages should be assembled as each system is completed by Construction.Turnover to Startup/CommissioningStartup and the Commissioning Agent review the turnover packages. All documentation should be complete and in the package up to this point in time.Installation recordsSubcontractor recordsVendor recordsConstruction, Startup and the Commissioning Agent will walk down the system to verify it has been built per design and is complete enough to support startup/commissioning activities.The most likely will be outstanding issues/exceptionsThe number of exceptions need to be reviewed to ensure the system is ready for acceptance by Startup/Commissioning.Equipment checkoutEach piece of plant equipment is tested or checked out. Typically checksheets and datasheets are completed, following general test procedures. The completed datasheets and checksheets are placed in the system turnover package.Most of the checkouts at this level of testing are static the equipment is not in operation.System testing/initial operation and system functional testing.The controls, interlocks and protection for a given system is verified.The system is placed in initial operation and all of the equipment and design features are functionally checked.Generally a specific test procedure is used, written for the given system and followed step by step. There are typically sign-off blocks provided in the body of the procedure for major sections or steps which are signed as that section/step is completed. The procedure may also have checksheets and datasheets. The completed datasheets and checksheets remain with the test procedure. The completed test procedure is placed in the system turnover package.Integrated system/Plant functional testingEach system is tested and placed into operation. Eventually the plant or facility is placed into operation for functional testing of the plant as a whole.Performance testingThe plant is tested to ensure it meets the contractual performance guarantees.Environmental/Compliance testingThe plant is tested to ensure it meets the regulatory requirements.Reliability/Acceptance testingThe plant is tested to ensure it meets the contractual guarantees for reliability.Turnover to the Owners/Plant Final AcceptanceThe Owners will review the turnover packages. All documentation should be complete and in the package at this point in time.Startup, the Commissioning Agent and the Owners will walk down the system to verify it has been built per design and is complete.</p></li><li><p>Roles and ResponsibilitiesRoles and Responsibilities</p></li><li><p>Roles and Responsibilities</p><p> Clearly define roles and responsibilities through design, construction, startup/commissioning Designer Constructor Independent Commissioning Authority/Agent Startup Engineer Owner</p><p>PresenterPresentation NotesThe Roles and Responsibilities through the design, construction, and startup/commissioning phases of project need to be identified.Each organization has a different role. From project to project the roles and responsibilities will change. The project specific roles and responsibilities for each group must be clearly defined.DesignerConstructorIndependent Commissioning Authority/AgentStartup EngineerOwnerConstruction and StartupWhere does Construction end?Where does Startup begin?Need to define formally for each project.Construction Testing vs. Startup TestingStartup and CommissioningWhere does Startup end?Where does Commissioning begin?Need to define formally for each projectExamples from typical projectsProject Organization ChartRoles &amp; Responsibilities by major phaseResponsibility Matrix Construction PhaseResponsibility Matrix Startup &amp; Commissioning Phase</p></li><li><p>Roles and Responsibilities</p><p> Construction and Startup Where does construction end? Where does startup begin? Need to define formally for </p><p>each project Construction testing vs. </p><p>Startup testing</p><p>PresenterPresentation NotesThe Roles and Responsibilities through the design, construction, and startup/commissioning phases of project need to be identified.Each organization has a different role. From project to project the roles and responsibilities will change. The project specific roles and responsibilities for each group must be clearly defined.DesignerConstructorIndependent Commissioning Authority/AgentStartup EngineerOwnerConstruction and StartupWhere does Construction end?Where does Startup begin?Need to define formally for each project.Construction Testing vs. Startup TestingStartup and CommissioningWhere does Startup end?Where does Commissioning begin?Need to define formally for each projectExamples from typical projectsProject Organization ChartRoles &amp; Responsibilities by major phaseResponsibility Matrix Construction PhaseResponsibility Matrix Startup &amp; Commissioning Phase</p></li><li><p>Roles and Responsibilities</p><p> Startup and Commissioning Where does startup end? Where does commissioning begin? Need to define formally for each project</p><p>PresenterPresentation NotesThe Roles and Responsibilities through the design, construction, and startup/commissioning phases of project need to be identified.Each organization has a different role. From project to project the roles and responsibilities will change. The project specific roles and responsibilities for each group must be clearly defined.DesignerConstructorIndependent Commissioning Authority/AgentStartup EngineerOwnerConstruction and StartupWhere does Construction end?Where does Startup begin?Need to define formally for each project.Construction Testing vs. Startup TestingStartup and CommissioningWhere does Startup end?Where does Commissioning begin?Need to define formally for each projectExamples from typical projectsProject Organization ChartRoles &amp; Responsibilities by major phaseResponsibility Matrix Construction PhaseResponsibility Matrix Startup &amp; Commissioning Phase</p></li><li><p>Roles and Responsibilities</p><p> Examples from typical projects Project Organization Chart Roles &amp; Responsibilities by Major Phase Responsibility Matrix Construction Phase Responsibility Matrix Startup &amp; Commissioning </p><p>Phase</p></li><li><p>Example: Project Organization Chart</p></li><li><p>Example Roles &amp; Responsibilities </p><p>Major Phases Design Phase Construction Phase Startup &amp; Commissioning Phase Design Procure Install Construction </p><p>Completion Construction Testing </p><p>Turnover Package </p><p>Turnover to SU&amp;C </p><p>Component Testing </p><p>System Testing </p><p>Plant Testing </p><p>Turnover to Owners </p><p>Engineering Engineer of record Commissioning Agent </p><p> Startup &amp; Commissioning Management </p><p> Construction Manager </p><p> Construction Management </p><p> GTG Vendor Construction Startup &amp; Commissioning Support HRSG Vendor Construction Startup &amp; Commissioning Support General Contractor </p><p> Construction Startup &amp; Commissioning Support </p><p> Inst &amp; Controls Construction Startup &amp; Commissioning Support Electrical Contractor </p><p> Construction Startup &amp; Commissioning Support </p><p> Mechanical Contractor </p><p> Construction Startup &amp; Commissioning Support </p><p> Piping Contractor </p><p> Construction Startup &amp; Commissioning Support </p></li><li><p>Example Responsibility Matrix </p><p>Construction PhaseActivity SU&amp;C CONSTRUCTION ORGANIZATION OWNER </p><p>Startup and Commissioning Program Development </p><p>CXing Agent </p><p>CM Mech Piping Elec I&amp;C HRSG GTG Representative</p><p>Typically 50 to 75 items such as: Review systems turnover package list X X X X X X X X X Review scoped turnover package documents X X X X X X X X X Review Project Punchlist procedure X X X X X X X X X Construction Completion Typically 20 to 30 items such as: Complete Required Data Sheets and Test Records X X X X X X X Prepare System Completion punchlists X X X X X X X Perform System As-Built X X X X X X X Construction Testing Typically 25 to 50 items such as: Perform Nondestructive Testing X X X X Perform Pressure Testing X X Verify Installation of Instruments and Controls X X Schedule Vendors Required for Construction Testing X Alignment of Rotating Equipment X X X Megger Cables and Equipment X X Verify Installation is in accordance with Design X X X X X X X Required Equipment Maintenance X X X X X X X Interface with Startup on Systems Ready for Turnover X X X X Assemble Initial Turnover Packages and records X X X X X X Perform Turnover Walkdown and Exception Lists X X X X X X X X X Initial System Turnover (to SU&amp;C) X X X X X X X X X </p></li><li><p>Example: Responsibility Matrix Startup &amp; Commissioning Phase</p><p>SU&amp;C Startup &amp; Commissioning Support Team Owner Activity CXing </p><p>Agent CM Mech Piping Elec I&amp;C HRSG GTG Operations</p><p>Component Testing Typically 40 to 50 items such as: Administer Startup Safety Tagging Program X X Inspect, Test, and Calibrate Instruments and Loops X X X Test major Electrical Equipment X X Megger Testing, Motor Rotation X X System Testing Typically 10 to 20 items such as: Interface with local Utilities X X Lineup System for Operation X X X X X X X X Initial Energization of Power Supply Systems, X X Rotating Equipment Initial Run In X X X Functional checks of Controls, Equipment &amp; Systems X X Plant Testing Typically 40 to 50 items such as: Perform Final HVAC Balancing X X Fine Tune Combustion Controls X X X Final Tuning of Instruments, Controls, and Valves X X Finalize controls &amp; tuning settings, software X X X X X Execute System Functional Test Procedures X X X X X Performance, Emissions, Reliability Testing X X X X Project Completion Typically 20 to 40 items such as: Finalize System Turnover Packages X X X X X X X X Finalize Project Punchlist X Perform Turnover Walkdowns with Owners X X </p></li><li><p>Benefits, costs and challenges of a Benefits, costs and challenges of a formal startup and commissioning formal startup and commissioning </p><p>processprocess</p><p>PresenterPresentation NotesThe benefits, costs, and challenges of a formal startup and commissioning process for a campus sized project.BenefitsTypically a formal program will ensure that an organization with commissioning experience is put in place. A formal program will include:formal turnover processwell-documented functional performance criteriaO&amp;M documentationOperator training programAble to track deliverables.The deliverables are identified early in the project.The deliverables are a part of the Contract SpecificationsThe deliverables are formally tracked.Able to track progress of construction and commissioning with tools that are developed and implemented that allow for tracking the overall process easily.Master Tracking MatrixNotification scheduleDeliverables listIntegrated Construction and Startup/Commissioning scheduleProject punchlistSystem turnover exceptions listsCostsTurnover process may require an additional person to manage.Formal documentation of testing activities may require an additional amount of time.May take some additional time to develop formal test procedures, checklists and datasheetsThe actual manhours for testing are relatively the sameMay take some additional time to formally document test data and resultsTypical cost of a Startup &amp; Commissioning Program is 2 to 5% of the overall project.Many of these costs would be incurred without a formal programSome of the costs may be assigned to the Construction budgetOverall any increase in cost should be offset at the end of the project.By having a formal program with system turnover packages and documentation in place the review and acceptance of the project is streamlined.The plant and associated documentation can be walked down and reviewed on a system by system basis.The system boundaries are defined, each organization has the same understanding of the scope of each system.Owner's representatives can spot check the progress and results by reviewing documentation with less time spent actually witnessing testing in the field.With formal and complete documentation packages, at each major step in the process, warranty claims can be handled smoothly. Both during the startup/commissioning phase and after acceptance by the owners.Typically vendors will ask for test data such as:vibration analysis, meggar records, system cleaning records, lubrication records.With formal and complete documentation packages, troubleshooting can be performed more quickly and accurately.The controls system historian and test data can be used to help identify the root cause of a problem.ChallengesDeveloping a cxing plan early on in project that clearly defines roles and responsibilities and identifies holes that need to be filled.Being involved early enough in the process to develop detail...</p></li></ul>

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