PLANT Commissioning Bases

Introduction to Process Plant Start-up Introduction to Process Plant Start-up and Commissioningand Commissioning

Plant Start-up and CommissioningPlant Start-up and Commissioning

● Plant commissioning is the first of many start-ups● Potentially hazardous: ability to operate not proven● Many unknown factors● First startup & subsequent shutdowns and startups● Excellent experience and expertise building for

operators and maintenance personnel.

Start-up and Commissioning apply to Start-up and Commissioning apply to

● Entire facilities in Greenfield projects● Major expansions or additions to existing plants● Re-commissioning of plants and equipment;● Individual items of plant, eg

● Boilers● Instrument air compressors etc

Delays in Startup & Commissioning Delays in Startup & Commissioning expensive!expensive!

● slow start-ups reduce the Return on Investment● delayed revenue stream● Increased cost of delivery● Financial viability

● ~20-25% of construction time (good planning)● Causes of delays:

● 75% due to equipment failure● 20% from inadequate equipment● 5% from process failure

Details vary depending on plant butDetails vary depending on plant butprocedure remains the sameprocedure remains the same

● prepare, plan and execute startup ● commissioning management● Preparation of specific plant procedures● Management of risks ● Safety & environmental compliance

Construction & CommissioningConstruction & CommissioningHow we would like it …..How we would like it …..

Construction

Pre-commissioning, Inspection and Operational Testing

Start up and Performance testing

Post commissioning

Mechanical completionProvisional

acceptance Acceptance

Construction and CommissioningConstruction and CommissioningHow it happens …..How it happens …..

Construction

Pre-commissioning, Inspection and Operational Testing

Start up and Performance testing

Post commissioning

Mechanical completionProgressive provisional

acceptance Progressive acceptance

Commissioning in practiceCommissioning in practice

● Progressive mechanical completion and concurrent commissioning creates challenges:

● Coordination and planning● Safety and risk● Isolation● Testing● Integration into operating plant

From construction to commissioningFrom construction to commissioning

● what constitutes mechanical completion?● on completion, start-up can officially commence● problems when part of a plant are commissioned

while construction not yet finished.

The Commissioning ProcessThe Commissioning ProcessKey StagesKey Stages

Preparation and planning

Mechanical Completion and Integrity checking

Performance and Acceptance testing

Start Up & Initial Operation

Post Commissioning

Pre-commissioning & Operational Testing

The Commissioning Process Detail - 1The Commissioning Process Detail - 1






● Appointment of Commissioning Appointment of Commissioning Manager or Lead Commissioning Manager or Lead Commissioning Engineer;Engineer;

● Appointment of Commissioning Team Appointment of Commissioning Team Members and Support Staff;Members and Support Staff;

● Training;Training;● Information Compilation;Information Compilation;● Safety and Risk Assessment;Safety and Risk Assessment;

Post Commissioning







● InspectionInspection● Pressure testingPressure testing● Cleaning and FlushingCleaning and Flushing● Machinery checkoutMachinery checkout

Post Commissioning





● Steam and other utilities Steam and other utilities introduced;introduced;

● Dry running trials;Dry running trials;● Hot running trials;Hot running trials;



Post Commissioning




Post Commissioning

● Introduction of process fluidIntroduction of process fluid● Start-up and initial operationStart-up and initial operation● Trouble-shooting and Trouble-shooting and







Post Commissioning

● Performance trails;Performance trails;● Formal Acceptance testFormal Acceptance test










Post Commissioning

● From plant on-stream to settled From plant on-stream to settled down and in regular production;down and in regular production;

● Adjustments, modifications and Adjustments, modifications and

What makes commissioning & start-up What makes commissioning & start-up difficult ...difficult ...

● planning, coordination and management;● massive coordination of construction, contractors,

vendors, commissioning team, operations and maintenance – all working to aggressive timelines.

● the commissioning team, operations and maintenance must become familiar with extensive range of equipment and technology, very quickly.

The Commissioning ProcessThe Commissioning Process





Post Commissioning


● Organisation and roles;Organisation and roles;● Information Information

Management;Management;● Procedure developmentProcedure development● Safety and risk Safety and risk

management;management;● Permit systemsPermit systems● Job safety analysisJob safety analysis

● Planning and control;Planning and control;● Budgeting and cost Budgeting and cost

control;control;● Commissioning strategy.Commissioning strategy.

Management Issues Technical Issues● Plant preparation and Plant preparation and

isolation;isolation;● Utilities and Electrical Utilities and Electrical

System CommissioningSystem Commissioning● Equipment Specific Equipment Specific

Commissioning IssuesCommissioning Issues● Machinery/ Rotating Machinery/ Rotating

EquipmentEquipment● Vessels, Towers and Vessels, Towers and

pipe work etc.pipe work etc.● Removal of hazardous Removal of hazardous

substances and purgingsubstances and purging● Instrumentation Instrumentation

commissioningcommissioning

Task force responsibilitiesTask force responsibilitiesDuring design stageDuring design stage

● Review design for safety and operability● Carry out HAZOP and other safety studies● operating procedures & maintenance manuals● Familiarization with the plant● Check compliance with design, intent and standards● Documentation for commissioning, operation & training;● Arrange modifications required● Recruitment, training of operations & maintenance personnel.

Typical Operating Instruction ManualTypical Operating Instruction Manual

● The Process● Conditioning and Special Equipment● Starting Procedures● Shutdown Procedures

Maintenance ResponsibilitiesMaintenance Responsibilities

● Publish work and safety procedures;● Specify maintenance activities● Select and purchase maintenance supplies and spare parts;● Negotiate with vendors and contractors;● Keep up maintenance records;● Make detailed designs of any changes and additions made

during commissioning;● Storage of spare parts and supplies;● Schedule routine daily work and that for planned

shutdowns.

Safety in Maintenance - 1Safety in Maintenance - 1● Detailed procedures for maintenance work and work to be

done when executing the commissioning procedure ● Need to cover each major piece of equipment & system● take into account all possible hazards● Include:

● Instructions for isolating (blinding, draining, venting, purging) process and utility systems;

● Locking out electrical systems● Instructions covering atmospheric testing, type of test and

permissible limits of contaminants.

Safety in Maintenance - 2Safety in Maintenance - 2

● Definition of type of permit required to carry out work● Type of equipment required for maintenance● Description of personal protection equipment required● Instructions regarding emergency equipment ● Instructions on potential hazards● Emergency procedures

Spare Parts and MaintenanceSpare Parts and Maintenance Minimum Inventories for Commissioning and Start-upMinimum Inventories for Commissioning and Start-up

● manufacturer’s recommended spare parts for motive equipment - avoid duplication

● gaskets for vessels and heat exchangers. ● Pipe fittings, valves and gaskets (approx. 5% of

total of each in the plant should be sufficient)● Instrument air tubing, plus adequate fittings

Spare Parts and Maintenance - 2Spare Parts and Maintenance - 2Minimum Inventories for Commissioning and Start-upMinimum Inventories for Commissioning and Start-up

● Pressure gauges of appropriate ranges● Thermometers and any special instrument parts● Rupture disks● Pipe insulation materials including jacketing● Lubrication oils and greases● Spare parts for electronic & analytical equipment.

Process Plant Machinery Commissioning Process Plant Machinery Commissioning Failure Problems Failure Problems

in decreasing order of problem frequencyin decreasing order of problem frequency

1. Centrifugal compressors

2. Steam turbines

3. Large gear speed increaser units

4. Electric motors in size categories above 1000 HP

5. Reciprocating compressors

6. Gas turbines

7. Gas expanders

Commissioning Team Information RequirementsCommissioning Team Information Requirements

● Project design file● Process file● Engineering data file● Plant layout file● Operating instructions● Analytical procedures● Log sheets and calculation procedures.

Commissioning DocumentationCommissioning Documentation

● Technical manual giving process technology and equipment● Standard operating procedures giving details of each system● Safety valve and rupture disk manual, listing the design basis

for each safety device, and giving the procedure for taking it out of service

● Training manual detailing the program for new personnel● Safety manual setting policies and procedures● Emergency response manual, tabulating emergency

procedures and responses to adverse conditions (e.g. weather)● Maintenance procedures specific to the new plant

Commissioning and Start Up Budget Commissioning and Start Up Budget Cost EstimationCost Estimation

Startup BudgetsStartup Budgets

● Three categories of cost;● Costs for normal startup equipment, materials

and personnel;● Costs for unexpected changes and additions;● Costs for mechanical equipment breakdowns.

Estimating plant startup & commissioningEstimating plant startup & commissioning

● Allow from 5-15% of overall capital cost of the project for startup and commissioning

● Empirical rules for estimating both startup time and startup costs, suitable for initial project budget

Estimate Startup CostsEstimate Startup CostsCost = A(0.10 + B + C + D +NE)Cost = A(0.10 + B + C + D +NE)

● A = Direct fixed capital cost of project;

● B = Process factor● 0.05 for radically new process● 0.02 for relatively new● -0.02 for familiar process

● C = Equipment factor● 0.07 for radically new● 0.03 for relatively new● -0.03 for familiar equipment

● D = Labour factorD = Labour factor● 0.04 for labour in very short supply0.04 for labour in very short supply● 0.02 for labour somewhat scarce0.02 for labour somewhat scarce● -0.01 for surplus labour-0.01 for surplus labour

● N = Number of process units N = Number of process units involvedinvolved

● E = Dependency factorE = Dependency factor● 0.04 for interdependent process 0.04 for interdependent process

unitsunits● 0.02 for moderately dependent0.02 for moderately dependent● -0.02 for independent plants.-0.02 for independent plants.

Estimate Startup TimeEstimate Startup TimeTime = a(0.15 + b + c + d +Ne)Time = a(0.15 + b + c + d +Ne)

● a = Construction Time● b = Process factor

● 0.15 for radically new process● 0.05 for relatively new● -0.01 for familiar process

● c = Equipment factor● 0.15 for radically new● 0.08 for very new● 0.05 for relatively new● -0.01 for familiar equipment

● D = Labour factorD = Labour factor● 0.15 for labour in very short supply0.15 for labour in very short supply● 0.05 for labour somewhat scarce0.05 for labour somewhat scarce● -0.01 for surplus labour-0.01 for surplus labour

● N = Number of process units N = Number of process units involvedinvolved

● E = Dependency factorE = Dependency factor● 0.25 for interdependent process 0.25 for interdependent process

unitsunits● 0.10 for moderately dependent0.10 for moderately dependent● -0.02 for independent plants.-0.02 for independent plants.

Startup Costs and Time ExampleStartup Costs and Time Example● A Crude Stabilisation Plan is currently under construction.● Its capital cost is $100 Million and it is expected to take 8

months to complete;● Because of its remote location it will be difficult to attract

skilled labour for the commissioning;● The technology is all familiar and proven technology;● Once operational the plant will be dependent on the existing

Gas Processing facility for smooth operation, but it has been designed to allow it to be isolated from the gas side given that it is a single operating unit;

● Estimate the cost and time to commission this unit.

Estimate Startup Costs & TimeEstimate Startup Costs & Time

● Startup Costs● Cost = 100 (0.10 -0.02 -0.03 + 0.04 +1*0.02)

= 100 * 0.11 = $11 Million● Startup Time

● Time = 8(0.15 -0.01-0.01+ 0.15+1*0.1)

= 8 * 0.38 = 3 Months

Documents

PLANT Commissioning Bases