Commissioning Procedure for System Engineer power plant

7/29/2019 Commissioning Procedure for System Engineer power plant

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PROCESS FOR AN COMMISSIONING

ACTIVITIES :-

Prepared by

Chethan Kumar.G

COTMAC


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STEP TO BE TAKEN IN COMMISSIOINING TIME PERIOD

:-

Planning/Preparation for an Site Visit.

Safety Materials.Discussion with the Project Team.

Plan to Pay Your Kind Attention Towards Your Project.

Initial Supervision of Dcs System After Reaching Site & Plan for

Dcs System Power-On.

Supervision in field for Erection Activities.

Loop Test.Drive Checking.

Closed Loop & Open Loop Checking.

Pid Tuning.

Take Backup in a Regular Intervals.

Try to Maintain Official Relationship with Customer.

Maintain Your Documents.

Conduct SAT with Customer & Handover the system to

customer.


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1. PLANNING/PREPARATION FOR AN SITE VISIT :-

Whenever engineer Plans to move from an site Visit. He have to carry

certain Necessary Materials with him. Which is Related Document to thatProjects. Doc. Are Like :-

Project I/O List.

BOM Copy Stands for Bill Of Material.

HDM Copy Stands for Hardware Design Manual.

SDM Copy Stands for Software Design Manual.

FAT Doc. Copy Stands for Factory Acceptance TestReport.

KOM Copy Stands for Kick Off Meeting Copy.

FAT MOM Copy Stands for FAT Minutes of Meeting

Copy.

System Architecture Copy.

System Integration Datasheet Copy.

Power-On Checklist.

SAT Document Copy.

CLCS Loop Protocol Stands for Closed Loop Protocol.
http://localhost/var/www/apps/conversion/tmp/Doc's/IO_LIST.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/BOM.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/HDM.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/SDM.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/SIGNED_FAT_DOC.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/SIGNED_FAT_DOC.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/FAT_MOM.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/FAT_MOM.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/SYSTEM_INTEGRATION_DATASHEET.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/POWER_ON_CHECKLIST.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/SAT.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/CLCS_PROTOCOL.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/CLCS_PROTOCOL.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/CLCS_PROTOCOL.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/SAT.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/SAT.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/POWER_ON_CHECKLIST.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/POWER_ON_CHECKLIST.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/POWER_ON_CHECKLIST.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/POWER_ON_CHECKLIST.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/SYSTEM_INTEGRATION_DATASHEET.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/SYSTEM_INTEGRATION_DATASHEET.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/FAT_MOM.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/FAT_MOM.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/FAT_MOM.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/SIGNED_FAT_DOC.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/SIGNED_FAT_DOC.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/SIGNED_FAT_DOC.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/SDM.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/SDM.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/HDM.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/HDM.pdfhttp://localhost/var/www/apps/conversion/tmp/Doc's/BOM.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/BOM.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/IO_LIST.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/IO_LIST.xls


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1. PLANNING/PREPARATION FOR AN SITE VISIT :-

DRIVE Protocol Copy.

Instrument Protocol Copy.Commissioning Status Loop wise Protocol Copy.

Weekly Progress Report Copy.

Timesheet Copy.

HSE Report Copy.

The above mentioned doc are necessary to bring at site

for a commissioning Activities. This doc. Can tell the realstate what exactly happened during Fat Time Period. This

will be proof for us. So, In case customer are trying to

demand something from us. We can show this doc. So, this

is necessity for all Engineer to bring doc. With them to Site.
http://localhost/var/www/apps/conversion/tmp/Doc's/DRIVE%20PROTOCOL.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/INST_PROTOCOL.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/Orn.XXXXXXXX_Commisoning%20status%20Loop%20wise.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/Weekly%20Progress%20Report%200n%2008-10-2012%20to%2013-10-2012.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/June_month_Expenses%20(1).xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/June_month_Expenses%20(1).xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/June_month_Expenses%20(1).xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/Weekly%20Progress%20Report%200n%2008-10-2012%20to%2013-10-2012.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/Weekly%20Progress%20Report%200n%2008-10-2012%20to%2013-10-2012.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/Orn.XXXXXXXX_Commisoning%20status%20Loop%20wise.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/Orn.XXXXXXXX_Commisoning%20status%20Loop%20wise.xlshttp://localhost/var/www/apps/conversion/tmp/Doc's/INST_PROTOCOL.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/INST_PROTOCOL.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/DRIVE%20PROTOCOL.dochttp://localhost/var/www/apps/conversion/tmp/Doc's/DRIVE%20PROTOCOL.doc


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2. SAFETY MATERIALS :-

It is must and clear to all the engineer who is working in automation Field

must have to carry certain Safety materials with him to protect Themselvesfrom accidents. Those Materials are :-

Safety Helmet

Safety Shoes

Safety Goggle

Safety Glues

Ear-Plugs

This are all the small Safety Materials which can save Your Life From

Unpredictable Accident. So, Always work with Safety and go with Green.

Maintain Honeywell Hse Report Properly. Try to get work from Our sub-

contractor with Safety. Conduct meeting in a regular interval with sub-

contractor and check there safety status.


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3. Discussion with Project Team :-

Before Planning to visit for commissioning. Let u discuss with your

particular Project Team. (Lead Engineer, Engineer Manager, Project

Manager Exceptional case u can discuss have few discussion with

Operational Manager in Honeywell also).

Get backup from the lead-engineer, Cross-check those Backup which

you received from the lead. Try to get there Number/Mail Id in case if any

queries or clarification requires You can call and get Solution from them.

Cross-check the backup which You have received from the Lead. Discuss

with team regarding your role in commissioning. Also discuss about loop

hole of Honeywell Dcs system which Honeywell was hided in front of

customer.

Get the Customer details Ex Reporting Person (Name, Phone No, Mail

Id)

Discuss with team regarding your role in commissioning.

Get the Sub-contractor details Supervisor (Name, Phone No, Mail Id)


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4. Plan to Pay Your Kind Attention Towards Your Project. :-

First of all get details about customer from Honeywell they might have

experienced with customer during the time period of pre-fat and fat.

Get the details about Reporting Time and Relieving Time from Site.

Make Yourself Prepared on the same Manner.

Plan to present Yourself in a well dressed Manner.

Whenever you will plan to visit for a site. Plan according to keep entireproject related doc with You.

Plan to pay Official Hours at site premises. And also try to avoid taking

unwanted leaves.


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5. Initial Supervision of Dcs System After Reaching Site :-

At the Initial supervision of Dcs system. Check the room temperature.

Whether room temperature is well maintained. Alternatively check for dust-free in control Room. And check for falls sealing and flooring system

readiness. If this three points are well-Maintained/Prepared then we can

start Proceeding remaining Process.

Check the panel internal Design . Whether system has been prepared

as per the HDM copy.

Check the grounding system. Whether entire grounding has done

properly in Panel (SG, FG)

Locate / Allign the System, Panels, Printers, Third-Party Devices as Per

Complexity diagram.

Check entire System & Marshalling Cabinets Dressing in all Panels, if itsnot well dressed then supervise the dressing. And make it done Before

Planning for a system Power-on


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Check entire Devices Ferruling/Tagging are given Properly if Not then

supervise the Tagging Activities. And make it done Before Planning for a

system Power-on

Cross verify the Ups incomer Voltage and current as per our Power-on

Checklist. Also Check the PDB Incomer Voltage and current. EX - Vpn,

Vne, Vpe.

Connect the Fte, Fta, Internal Power-loop Connections (Tubes, Fans,

FTA cards Supply, BPS, Pmio Power Supply, Controller Supply (DBK), Wet

Contact Relay Supplies as per System Integration, Hdm copy and cross-

verify its tagging and ferruling .

Cross-verify the grounding system. Check whether signal & Frame

Ground are given properly as per HDM copy In Panel. Connect signal &

frame grounding cable to panel bus-bar (individual bus bar already

allocated for each panel). Also Cross-verify every signal grounds are loop

internally, check the continuity for signal ground. As same like signal

grounds frame ground has to have to same continuity with each other.

Note :- Frame & Signal should not have continuity with each other. This is

Very Important checkpoint has to be taken care before planning for a

power-on


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Check the preparation of earth pit whether customer/sub-contractor has

made/prepared as per Honeywell standard. If its made then start to

megger resistance with that pit. As per Honeywell standards SG-


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6. Initial Supervision of Dcs System After Reaching Site :-

Plan to supervise field with Sub-contractor supervisor at initial stage and

get planned from him about allocation of Man Power, Completion Date,

Etc.,

Cross- check Honeywell Materials which is received by Customer (Cross

check with BOM).

Plan to supervise status of the field activities with Sub-contractor

supervisor at initial stage.

Plant to do the in parallel. Try to allocate manpower in parallel areas.

Work has to show progress in all areas. Guide technically to all Electrician.

Try to Supervise there work. If any problems it can be solved on the

instant.


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7. Loop Test :-

Normally in Dcs there are two types of loop checking system are there.

They are :-

Cold-Loop Checking

Hot-Loop Checking

Hot-Loop Check :-

During the Hot-Loop Checking the signals will be checked from field (JB-

Junction Box, Mcc- Electrical Feeder) to dcs. Through the way of checking

connectivity/ By the way of checking cores in a cable.

Cold-Loop Check :-

During the Cold-Loop Checking the signals will be checked from TB

Terminals Block to the system. It can be checked by the way of loopingcable in TB and observing bit changeover in Dcs system.


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Before starting to take trail of all drives, closed Loop, system. The Loops

signals should clear from field to avoid time loss during trail time period. It

is mandatory to check the Loop signals from field to Dcs after System

Power-on.

The signals which have to be loop tested from Field (JB- Junction Box,Mcc- Electrical Feeders to Dcs. They are :-

Digital Input signals.

Digital Output Signals. ( Pfc, Wet contact 230v ).

Thermocouple Signals

Rtd Signals

Analog Input Signals. (2 Wire system (24v) , 4- Wire system(Pfc) ).

Once the signals will be loop tested from field to Dcs then the Dcs

system will be ready to take trail.


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8. Drive / Motors / Pumps Checking :-

For drive checking initially the logics shall be checked with customer.

Before Proceeding for taking trail certain things also needed to check from

our end like Contacts of relay. Whether feeder requires (Pfc, 230v WetContact Relay ). As per the demand we can provide relay contact. Same

inform You can get from Electrical Mcc Diagrams. Once logics & Relay

Contact will be checked then we can proceed for taking trial a feeder

(Meant to say Motor/drive) through Dcs.

Hardly drives have two types :-

AC DrivesDC Drives

Drives are mainly used for controlling the speed of a motor. Like rolling

of a kiln roller. we can control the roller by varying its speed (Analog Output

from dcs (4-20 MA)

For Motors & Pumps Checking :-

For Motor and Pump, it will be same as like drive initially you can

cross-verify logics with customer. Once logic will be finalized. Then you can

go-ahead to take trial from Mcc feeder. For Motor and Pumps different

application available as per process. Like :-

1. Conveyor

2. Fans3. Motors


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Normally in automation Sector certain Motors/Pumps are used based on

application. Based on Application the Specification for particular machine

will vary.

Initially whenever you are planning to take trial from Mcc Feeder

Requested the concern Electrical Engineer to Switch off the Power Circuit.

Once Power Circuit if Off. We can take trail From Dcs through control

circuit. Supply will not reach till to field. But, feeder will be running. By this

way we can take trial of a feeder.

There are two classification of motor are available in Power Sector :-

LT Motor Low Torque Motor.

HT Motor - High Torque Motor.

This classification between motors applies for application. Based on

Application the Motors are classified.

LT Motor :-

LT Motor stands for Low Torque Motor. To start this motor it requires

less initial torque. (Ex :- Conveyors)

HT Motor :-

HT Motor stands form High Torque Motor. It requires High Initial

Torque to start. (Ex :- ID Fan)


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9. Closed Loop & Open Loop Checking :-

Closed Loop :-

Example for an closed Loop Is PID Loop.

Pid stand for Proportional + Integral + Derivative Loop Control

Pid can be loop tested through Dcs by applying (4-20 ma) from

Dcs. By the way of varying o-100 Command. And parley we have to cross

check with its position feedback which is an analog input will tells the

Control valve opening/closing status. So as per the command we need to

get the position feedback from field.

Once this Loop tune finishes we can make Pid in auto mode.

And we can vary set point as per process. Pv-sp = op based on thisphilosophy the controller will control the Pid loop.

In power sector certain Process applies Closed Loops Like :-

1. Drum level Control.

2. Combustion Control.

3. Atemperator Control. ( Temperature, Pressure )

4. Hot well Level Control.

5. Deaerator Level Control.This are all certain Parameters in a Power Plant which will be controlled by

Pid Loop.


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Open Loop :-

Example for an Open Loop Is Damper Control.

Open loop can be tested through Dcs by applying (4-20 ma) from Dcs. By

the way of varying o-100 % Command. And parley we have to cross check

with its position feedback which is an analog input, tells the Control valveopening/closing status. So as per the command we need to get the

position feedback from field.

In power sector certain Process applies Open Loops. They are :

1. ID Fan Damper Control.

2. FD Fan Damper Control.

These are all certain Parameters in a Power Plant which will be controlled

by Open Loop.


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10. PID Tuning :-

PID Tuning :-

Example for an closed Loop Is PID Loop.

Pid stand for Proportional + Integral + Derivative Loop Control

Please refer. The attached above Picture which is clearly mentioned how

the Pid works. Pid is basically an closed loop circuit.

Set point (SP) :- Set point is an parameters (Temperature, Flow, Pressure,

Level). Operator use to feed this set point to maintain the process

parameter.Process Value (PV) :- Process Value / Control Value Is an parameter

reading which comes from field (Transmitter) it can be either (Temperature,

Flow, Pressure, Level).

Output (OP) :- Pid Controller Output In the form of 0-100 % / 4-20 ma.

Which operates the Control Value By using I2P Convertor / Positiner

OP = PV-SPERROR


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10. PID Tuning :-

PID Tuning :-

For Pid Tuning mainly 3 terms are used. They are :-

1. Proportional .2. Integral.

3. Derivative.

Proportional :- (Gain Factor) :- Proportional is a gain factor for a Pid

control which control the control valve stock length speed. Default it will be

1. If stock will be fast then this gain factor can be reduce. By reducing thisgain factor the control stock length can be controlled.

Integral :- (Offset Time) :- Integral is an Offset Time for a Pid control

which control the offset time between process value with set point. By

Increasing/decreasing this offset time Pid sp = Pv Equalization can be

done soon.

Derivative :- (Unstable Condition) :- Derivative is an Unstable Condition

for a Pid control which makes the normal Pid in unstable condition.Before Tuning a Pid Control set the op Limit

(Lower, Higher Limit). Which can save the plant

from the unwanted trip.


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11. Take Backup in a Regular Intervals. :-

Try to backup in a regular Intervals. If some unexpected things we can

be in a safe zone. It is a good way to take backup daily and even it will

secure for us. In Honeywell system certain system backup can be taken

on site on daily basis. They are :-Erdb

Emdb

Host Files

Exported Files

Checkpoint

Qdb

Graphics

Log Report

Exported Assets

Alarm Groups

R400

Menu & Toolbars.

Station File.

How to take backup in Honeywell System
http://localhost/var/www/apps/conversion/tmp/Doc's/Honeywell%20Backup%20HOW%20TO%20TAKE.xlsxhttp://localhost/var/www/apps/conversion/tmp/Doc's/Honeywell%20Backup%20HOW%20TO%20TAKE.xlsx


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12. Try to Maintain Official Relationship with Customer. :-

Try to Maintain Official Relationship with Customer :-

Represent Yourself in a good Manner.

Try to avoid speaking regional language with Customer. If You will speak

in a regional they may demand to do some Extra Work Not in an officialmanner in a Personal way. So, Always try to make Conversation in English

with Customer.

Try to follow the company Timing on Site.

Dont do any extra activities which is not known by your Team.

Dont commit anything by verbal Communication. Whatever,

Commitment You will give to Customer do it in Official Manager By the way

of giving a detailed mail to entire Team Members.

Dont take any big discussion by your oneself. Let you give a mail to

company. Let them take a discussion and give you confirmation. Then you

can proceed for that.


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13. Maintain Your Documents :-

Maintain Your Documents :-

Always give much priority for documentation works. Only

documentation can tell how much activities u have done on site. In

Honeywell We have certain Doc. Which need to be taken signed fromcustomer after completion of particular activities. Those doc. are :-

Weekly Progress Report

Time-sheet

Power-on Checklist

Drive Protocol

Instrument Protocol

Closed Loop Protocol

HSE Report

Commissioning status Protocol

Mom Copies

SAT Procedure Copies.

Site Change Report (Honeywell SCR Report)


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14. Conduct SAT with Customer & Handover the system to

customer :-

Conduct SAT with Customer & Handover the System to Customer :-

After Finishing the entire Commissioning activities. Request

Customer to give permission for Conducting SAT Procedure at Site. Before

conducting sat in front of Customer. Let u check our system first whether

entire redundancy system is ok (Pre-sat) If You will get Satisfaction then

declare a day for conduct sat at site. Conduct sat in front of Customer and

show them the redundancy of Dcs system and other check-up which is

cleared mentioned in sat procedure. After completion of this procedure, sit

with customer and make a final mom and get signed from customer in satand mom copies.


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THANK YOU

Thank you all to spend your precious time for mypresentation