Plant Commissioning Start Up Procedure[1]

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Plant commissioning & start up Plant commissioning & start up procedureprocedure

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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

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The Commissioning Process Detail The Commissioning Process Detail -- 11






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

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

zz Training;Training;

zz Information Compilation;Information Compilation;

zz Safety and Risk Assessment;Safety and Risk Assessment;

zz Commissioning Strategy Commissioning Strategy Development;Development;

zz Procedures and Checklist Procedures and Checklist Development;Development;

zz Detailed Plan and Budget Preparation;Detailed Plan and Budget Preparation;Post Commissioning

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Commissioning StrategyCommissioning Strategy

Equipment Level Activities

System Level Activities

Facility/Plant Level Activities

Commissioning Strategy

Commissioning Master Plan

Individual item commissioning plans, procedures and checklists

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Facility Commissioning IssuesFacility Commissioning Issues

zz Time phasing construction and commissioning activitiesTime phasing construction and commissioning activities

zz Time phasing the commissioning of the various parts of the Time phasing the commissioning of the various parts of the plant relative to each other;plant relative to each other;

zz Relationships and timings determining when various systems Relationships and timings determining when various systems need to be available:need to be available:

zz Electrical, Steam, Water, InstrumentationElectrical, Steam, Water, Instrumentation

zz Sequencing of the overall plant startup and shutdown to Sequencing of the overall plant startup and shutdown to ensure we do not create unsafe conditions;ensure we do not create unsafe conditions;

zz Initial start up;Initial start up;

zz Process Control and Shutdown;Process Control and Shutdown;

zz Performance testing;Performance testing;

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Developing Startup ProceduresDeveloping Startup Procedures

zz Engineering and construction companies generally follow a Engineering and construction companies generally follow a systematic procedure where by their startup engineers systematic procedure where by their startup engineers review the process design several times as it is developed;review the process design several times as it is developed;

zz After the first review, a preliminary startAfter the first review, a preliminary start--up and operations up and operations procedure is written;procedure is written;

zz Decide what must be added to the design to make the Decide what must be added to the design to make the process capable of being started up and operated;process capable of being started up and operated;

zz By the time the final engineering flowBy the time the final engineering flow--sheets have been sheets have been released a complete startup and operating instructions released a complete startup and operating instructions manual should have been completed.manual should have been completed.

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Issues consideredIssues considered

zz Are various part of the process too depend on one Are various part of the process too depend on one another;another;

zz Is there enough surge capacity;Is there enough surge capacity;

zz Are there provisions to prevent abnormal Are there provisions to prevent abnormal pressures, temperatures and rates of reaction;pressures, temperatures and rates of reaction;

zz Where are additional valves and bypass lines Where are additional valves and bypass lines needed;needed;

zz Special lines to allow equipment to be started up Special lines to allow equipment to be started up and rerun product/raw materials.and rerun product/raw materials.

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System Level ActivitiesSystem Level Activities

zz Utilities systems Utilities systems -- steam, instrument air, process steam, instrument air, process water, fire water, drainage, condensate return;water, fire water, drainage, condensate return;

zz Electrical systems;Electrical systems;

zz Instrumentation and instrumentation systems;Instrumentation and instrumentation systems;

zz Cleaning and flushing;Cleaning and flushing;

zz Purging;Purging;

zz Initial start up and shutdowns;Initial start up and shutdowns;

zz Performance testing;Performance testing;

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Equipment Level ActivitiesEquipment Level Activities

zz Pressure testing & mechanical integrity testing of Pressure testing & mechanical integrity testing of vessel, columns and pipe work;vessel, columns and pipe work;

zz Heat Exchangers, condensers, coolers etc. Heat Exchangers, condensers, coolers etc.

zz Mechanical equipment and machinery;Mechanical equipment and machinery;

zz Control Systems and Instrumentation;Control Systems and Instrumentation;

zz Operational testing;Operational testing;

zz Proof testing and acceptance.Proof testing and acceptance.

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What can be done before mechanical What can be done before mechanical completioncompletion

z Utilities commissioning

z Lube and Seal-Oil Systems Cleaned

z Instrumentation and Control Loops Proven

z Piping, Towers and Vessels Cleaned

z Boil-Out, Dry-Out and Acid Cleaning

z Turbine, Motor and Pump Run-Ins

z Nitrogen Purge and Tightness Testing

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Building Building OrganisationalOrganisational LearningLearning

Corporate Knowledge Base

Best Practice Benchmarking

Industry Standards

Legislation

Process Design Specific

Machinery & Equipment

Procedures and Check sheets

Improvement Processes

Experience

Incidents and Near Misses

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ProceduresProcedures

zz Procedures are written routines/instructions that Procedures are written routines/instructions that describe the logical sequence of activities required to describe the logical sequence of activities required to perform a work process and the specific actions perform a work process and the specific actions required to perform each activity;required to perform each activity;

zz If there are no written procedures, there is no basis for If there are no written procedures, there is no basis for monitoring performance, focus for improvement or monitoring performance, focus for improvement or mechanism by which to capture learning;mechanism by which to capture learning;

zz The establishment of procedures and routines allow The establishment of procedures and routines allow more time and mental energy to deal with the more time and mental energy to deal with the unexpected, which always happen during unexpected, which always happen during commissioning.commissioning.

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Commissioning/Startup LogicCommissioning/Startup Logic

zz A Critical Path Network (Plan) with written procedures with A Critical Path Network (Plan) with written procedures with related documents are required. These should define for the related documents are required. These should define for the facility, each plant system:facility, each plant system:

zz The order in which the systems will be started up;The order in which the systems will be started up;

zz Individual activities at each stage;Individual activities at each stage;

zz Operation testing requirements;Operation testing requirements;

zz Durations, waiting times, cooling times;Durations, waiting times, cooling times;

zz Total duration for starting up each system;Total duration for starting up each system;

zz Resources required Resources required -- labourlabour, materials, equipment, , materials, equipment, services;services;

zz Temperatures, pressures, fluid flows used.Temperatures, pressures, fluid flows used.

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Commissioning/Startup and Shutdown IssuesCommissioning/Startup and Shutdown Issues

zz At the facility, system and equipment level, we At the facility, system and equipment level, we want to avoid:want to avoid:

zz Creation/existence of explosive mixtures, usually Creation/existence of explosive mixtures, usually because of the presence of air;because of the presence of air;

zz Water hammer and water based explosion Water hammer and water based explosion effects, due to contact between water and hot effects, due to contact between water and hot substances (steam, oil, etc.);substances (steam, oil, etc.);

zz In particular, during commissioning hot fluids and In particular, during commissioning hot fluids and gases will be coming into contact with cold gases will be coming into contact with cold surfaces in places that would be hot under normal surfaces in places that would be hot under normal operations.operations.

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Mechanical Completion and Integrity Mechanical Completion and Integrity CheckingChecking

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Mechanical Completion and Integrity Mechanical Completion and Integrity InspectionInspection






zz InspectionInspection

zz Pressure testingPressure testing

zz Cleaning and FlushingCleaning and Flushing

zz Machinery checkoutMachinery checkout

Post Commissioning

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Categories of Process EquipmentCategories of Process Equipment

zz Distillation Towers/Fractionation TowersDistillation Towers/Fractionation Towers

zz ReboilersReboilers & Other Shell & Tube Heat Exchangers& Other Shell & Tube Heat Exchangers

zz Boilers and Fired HeatersBoilers and Fired Heaters

zz Pressure Vessels and PipePressure Vessels and Pipe--workwork

zz FinFin--Fan CoolersFan Coolers

zz CondensersCondensers

zz Machinery/Rotating EquipmentMachinery/Rotating Equipment

zz ValvesValves

zz InstrumentationInstrumentation

zz Electrical EquipmentElectrical Equipment

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Machinery/ Rotating EquipmentMachinery/ Rotating Equipment

zz PumpsPumps

zz Steam TurbinesSteam Turbines

zz Gas TurbinesGas Turbines

zz CompressorsCompressors

zz Gas EnginesGas Engines

zz Electric MotorsElectric Motors

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Mechanical Completion and Integrity Mechanical Completion and Integrity InspectionInspection

zz Involves checking that everything has been built and it Involves checking that everything has been built and it there as per specification. Refer:there as per specification. Refer:

zz Piping Plan Drawings;Piping Plan Drawings;

zz Layout and construction drawings;Layout and construction drawings;

zz P & IDP & ID’’ss

zz Electrical systems, Instrumentation and control systems Electrical systems, Instrumentation and control systems checkout down by appropriately qualified personnel checkout down by appropriately qualified personnel (Electricians and Instrumentation technicians). (Electricians and Instrumentation technicians).

zz General commissioning engineers generally do not get General commissioning engineers generally do not get involved in this in a handsinvolved in this in a hands--on manner.on manner.

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Mechanical Completion and Integrity Mechanical Completion and Integrity Inspection ProcedureInspection Procedure

zz Divide plant into manageable areas;Divide plant into manageable areas;

zz In a large plant, assign individuals or teams to In a large plant, assign individuals or teams to specific areas;specific areas;

zz Establish a master set of piping plan drawings and Establish a master set of piping plan drawings and P&IDP&ID’’s, mark up areas:s, mark up areas:

zz Individual commissioning engineers or teams walk Individual commissioning engineers or teams walk every line and mark up every item that can be every line and mark up every item that can be confirmed as present on master set of drawings;confirmed as present on master set of drawings;

zz Use different Use different colouredcoloured ““highlighterhighlighter”” pens to pens to indicate different services.indicate different services.

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Mechanical Completion and Integrity InspectionMechanical Completion and Integrity InspectionEvery line must be walked! Physically sight everything!Every line must be walked! Physically sight everything!

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Mechanical Completion and Integrity Mechanical Completion and Integrity Inspection Procedure Inspection Procedure -- Hints/TipsHints/Tips

zz Ensure pipes, vessels, valves etc. are all in the right Ensure pipes, vessels, valves etc. are all in the right place;place;

zz Valves are correct type Valves are correct type -- globe, gate, control;globe, gate, control;

zz Vents, drains, steam traps etc.Vents, drains, steam traps etc.

zz Flanges, bolts, types of bolts;Flanges, bolts, types of bolts;

zz Blind flanges and Blind flanges and swingableswingable blinds in place, blinds in place, correct rating;correct rating;

zz Check all tag numbers;Check all tag numbers;

zz PunchlistPunchlist any nonany non--conformances.conformances.

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New Plant Piping Tie-ins!

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Pipe StressingPipe Stressing

zz Piping should provide adequately for expansion and Piping should provide adequately for expansion and contraction due to temperature changes, without contraction due to temperature changes, without placing excessive stresses on equipment;placing excessive stresses on equipment;

zz Misalignment between matching flanges on pipeMisalignment between matching flanges on pipe--work work -- particular where there are changes in particular where there are changes in direction (elbows) can cause stressing;direction (elbows) can cause stressing;

zz Misalignments where pipeMisalignments where pipe--work connects to work connects to machinery, vessels and other process equipment;machinery, vessels and other process equipment;

zz Can often be seen visually, or checked with gauges Can often be seen visually, or checked with gauges using the same procedures we use to align rotating using the same procedures we use to align rotating equipment.equipment.

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Piping and Equipment SupportsPiping and Equipment Supports

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Piping and equipment supportsPiping and equipment supports

zz Mobile supports permit and guide the thermal Mobile supports permit and guide the thermal growth of equipment undergoing temperature growth of equipment undergoing temperature change;change;

zz If they do not function correctly, vessels, If they do not function correctly, vessels, equipment, pipe work, nozzles heat exchangers equipment, pipe work, nozzles heat exchangers etc. may be damaged.etc. may be damaged.

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Typical piping support methodsTypical piping support methods

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Piping and equipment supportsPiping and equipment supportszz Inspection prior to start up:Inspection prior to start up:

zz Check that installed according to specification and not jammed;Check that installed according to specification and not jammed;

zz Inspection during warm up:Inspection during warm up:

zz Check thermal growth is occurring and supports are responding Check thermal growth is occurring and supports are responding as per design;as per design;

zz Check that there is no surface buckling or crimping Check that there is no surface buckling or crimping -- this needs this needs to be corrected;to be corrected;

zz Check expansion joints;Check expansion joints;

zz Check long straight runs of piping for bowing or support shoes Check long straight runs of piping for bowing or support shoes that may have slipped;that may have slipped;

zz Rule of thumb Rule of thumb -- bowing is excessive if you can see it.bowing is excessive if you can see it.

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Piping and equipment supportsPiping and equipment supports

zz Inspection after coolInspection after cool--down:down:

zz Check that sliding supports have returned to Check that sliding supports have returned to original positions;original positions;

zz Establish that equipment can expand and Establish that equipment can expand and contract as required.contract as required.

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Inspection of spring supportsInspection of spring supports

zz Before hydroBefore hydro--testing:testing:

zz Check that spring stops are installed. (If not, the Check that spring stops are installed. (If not, the weight of water in pipe will deform the spring).weight of water in pipe will deform the spring).

zz After hydroAfter hydro--testing but before heating:testing but before heating:

zz Check that stops are removed;Check that stops are removed;

zz Check that spring pointer is positioned to cold Check that spring pointer is positioned to cold setting;setting;

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Inspection of spring supportsInspection of spring supports

zz During and at end of heating:During and at end of heating:

zz Check pointer has not exceeded hot setting;Check pointer has not exceeded hot setting;

zz After cool down:After cool down:

zz check to establish piping can expand and check to establish piping can expand and contract as required;contract as required;

zz establish that springs can absorb loads.establish that springs can absorb loads.

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Vessels and ColumnsVessels and Columns

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Inspection of Vessels and ColumnsInspection of Vessels and Columns

zz The inspection of vessels, columns and reactors The inspection of vessels, columns and reactors should be scheduled to be completed before should be scheduled to be completed before construction has closed them up;construction has closed them up;

zz Other inspections Other inspections -- e.g. for completeness or piping, e.g. for completeness or piping, insulation, safety etc. can be scheduled later;insulation, safety etc. can be scheduled later;

zz If a vessel has been sealed up by construction, it is If a vessel has been sealed up by construction, it is your duty to inspect it, even it construction resist.your duty to inspect it, even it construction resist.

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Inspection of Vessels and ColumnsInspection of Vessels and Columns

zz Check that distributors have been installed Check that distributors have been installed correctly;correctly;

zz DeDe--misters installed correctly and of correct misters installed correctly and of correct materials, design, type;materials, design, type;

zz Vortex breakers in place;Vortex breakers in place;

zz Trays Trays -- packed or packed or ““bubblebubble--capcap”” are correct:are correct:

zz Bubble caps not jammed or damaged, down Bubble caps not jammed or damaged, down comers clear, supports all OK.comers clear, supports all OK.

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Pressure TestingPressure Testing

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Pressure Testing Pressure Testing -- ObjectivesObjectives

zz The objective of pressure testing is to confirm the The objective of pressure testing is to confirm the mechanical integrity of the plant;mechanical integrity of the plant;

zz Verifying capability of containing the pressures it has Verifying capability of containing the pressures it has been designed to hold;been designed to hold;

zz Ensure there are no leaks and verify that the plant can Ensure there are no leaks and verify that the plant can be reliably made leak free;be reliably made leak free;

zz Identify any vulnerabilities well before the plant is Identify any vulnerabilities well before the plant is placed into service;placed into service;

zz Meet the requirements of legislation, local, Meet the requirements of legislation, local, international and industry standards.international and industry standards.

Slide 37

Pressure Testing Pressure Testing -- responsibilitiesresponsibilities

zz Pressure tests of tanks, reactors and piping for Pressure tests of tanks, reactors and piping for mechanical strength and tightness of joints is mechanical strength and tightness of joints is usually done by the construction team;usually done by the construction team;

zz Commissioning team representatives should Commissioning team representatives should witness and certify the tests;witness and certify the tests;

zz Need to verify that all necessary safety precautions Need to verify that all necessary safety precautions have been taken;have been taken;

Slide 38

Pressure Testing Pressure Testing -- proceduresprocedures

zz Water for testing and flushing should contain a rust Water for testing and flushing should contain a rust inhibitor inhibitor -- one low in chloride content for stainless one low in chloride content for stainless steel lines;steel lines;

zz After testing, water should be drained completely After testing, water should be drained completely from all lines that do not normally carry water, from all lines that do not normally carry water, steam or steam condensate;steam or steam condensate;

zz All low points should be checked for presence of All low points should be checked for presence of water;water;

zz Lines should be dried by blowing hot air, dry inert Lines should be dried by blowing hot air, dry inert gas or instrument air.gas or instrument air.

Slide 39

Pressure Testing Pressure Testing -- Vacuum SystemsVacuum Systems

zz Final checks of vacuum systems are best Final checks of vacuum systems are best performed by pulling a vacuum and observing the performed by pulling a vacuum and observing the rate of pressure rise in the blocked in system;rate of pressure rise in the blocked in system;

zz Excessive leaks can then be located by applying a Excessive leaks can then be located by applying a mild positive pressure and testing each flange with mild positive pressure and testing each flange with bubble solution.bubble solution.

Slide 40

Pressure Testing Pressure Testing -- Procedures 2Procedures 2

zz Isometric drawings of all systems to be tested should be Isometric drawings of all systems to be tested should be displayed on a board and marked up as each section is displayed on a board and marked up as each section is tested;tested;

zz HydrotestingHydrotesting of piping and equipment according to code of piping and equipment according to code requirements to confirm mechanical strength should be requirements to confirm mechanical strength should be carried out on groups of equipment naturally suggested by carried out on groups of equipment naturally suggested by design pressure and function;design pressure and function;

zz All water, steam, condensate, oil, gas and process steam All water, steam, condensate, oil, gas and process steam piping should be hydrotested;piping should be hydrotested;

zz Major equipment that has already been tested as part of Major equipment that has already been tested as part of manufacturing may be isolated by blanks.manufacturing may be isolated by blanks.

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Cleaning and FlushingCleaning and Flushing

Slide 42


zz Need to ensure no construction debris is left in Need to ensure no construction debris is left in pipes of vessels pipes of vessels -- welding rods, bolts, gloves, rags welding rods, bolts, gloves, rags etc. etc.

zz Large debris (lumber, cable, packaging) should Large debris (lumber, cable, packaging) should have been removed during mechanical integrity have been removed during mechanical integrity inspections;inspections;

zz Small debris (rags, nuts, dirt) must be flushed out Small debris (rags, nuts, dirt) must be flushed out of all pipe and vessels;of all pipe and vessels;

zz Where oil coatings must be removed, chemical Where oil coatings must be removed, chemical cleaning is necessary.cleaning is necessary.

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zz Before flushing is started, check the process Before flushing is started, check the process thoroughly to ensure:thoroughly to ensure:

zz Screens have been installed in front of pump Screens have been installed in front of pump suctions;suctions;

zz Blinds in front of equipment such as Blinds in front of equipment such as compressors and turbines;compressors and turbines;

zz ““JumperJumper”” spool pieces to allow for continuity of spool pieces to allow for continuity of flow.flow.

Slide 44

FlushingFlushing

zz Can be handled by geographic plant area;Can be handled by geographic plant area;

zz Sections too large for water flushing:Sections too large for water flushing:

zz Pipes greater than 30 in diameter (0.75 m), orPipes greater than 30 in diameter (0.75 m), or

zz Pipes that should not be touched with water;Pipes that should not be touched with water;

zz Should all be blown out with air or inert gas.Should all be blown out with air or inert gas.

Slide 45

FlushingFlushing

zz Regardless of whether pipes are cleaned with Regardless of whether pipes are cleaned with water, steam, air or nitrogen, flow velocities water, steam, air or nitrogen, flow velocities should be high enough to ensure that pipes will should be high enough to ensure that pipes will be suitably scoured;be suitably scoured;

zz Need to ensure that the debris from one piece of Need to ensure that the debris from one piece of equipment will not simply be flushed into equipment will not simply be flushed into another;another;

zz Water velocities should be at least 12 ft/sec Water velocities should be at least 12 ft/sec (approx. 3.75 m/sec);(approx. 3.75 m/sec);

zz Air velocities a minimum of 200 ft/sec (approx. Air velocities a minimum of 200 ft/sec (approx. 65 m/sec);65 m/sec);

Slide 46

PrePre--commissioning and Operational commissioning and Operational TestingTesting

Slide 47

The Commissioning Process Detail The Commissioning Process Detail -- 33




zz Steam and other utilities Steam and other utilities commissioned and introduced;commissioned and introduced;

zz Dry running trials;Dry running trials;

zz Hot running trials;Hot running trials;

zz SafeSafe--fluid dynamic testing;fluid dynamic testing;

zz Solvent dynamic testing;Solvent dynamic testing;

zz Process fluid tests.Process fluid tests.



Post Commissioning

Slide 48

Commissioning UtilitiesCommissioning Utilities

Slide 49

Commissioning UtilitiesCommissioning Utilities

zz Utilities commissioning usually represents the first Utilities commissioning usually represents the first phase of commissioning, as these usually need to phase of commissioning, as these usually need to operational first, before the rest of the plant can be operational first, before the rest of the plant can be commissioned;commissioned;

zz The steps for commissioning each utility should be The steps for commissioning each utility should be planned in detail;planned in detail;

zz Provides planning practice for planning the startup Provides planning practice for planning the startup of the main plant.of the main plant.

Slide 50

Commissioning Utilities Commissioning Utilities -- Broad GuidelinesBroad Guidelines

zz Check supply pressures of all services Check supply pressures of all services -- steam, cooling water, steam, cooling water, instrument air, nitrogen etc.instrument air, nitrogen etc.

zz At the most distant points, open drains, vent valves or pipe At the most distant points, open drains, vent valves or pipe flanges and purge until fluids come out clean and rust free;flanges and purge until fluids come out clean and rust free;

zz Purge/blow out lines to each piece of equipment;Purge/blow out lines to each piece of equipment;

zz Check that instrument air is clean and dry, and at correct Check that instrument air is clean and dry, and at correct pressure;pressure;

zz Circulate water to waste water system until water lines clear anCirculate water to waste water system until water lines clear and d clean;clean;

zz Flush waste water and drain systems to ensure no blockages;Flush waste water and drain systems to ensure no blockages;

zz Check operation of steam traps;Check operation of steam traps;

zz Drain condensate to waste water until is is clean.Drain condensate to waste water until is is clean.

Slide 51

Commissioning UtilitiesCommissioning UtilitiesIntroducing SteamIntroducing Steam

zz Steam usually represents the first Steam usually represents the first ““hazardoushazardous”” fluid fluid introduced into the introduced into the ““newnew”” system;system;

zz Admit steam slowly into the distribution system with Admit steam slowly into the distribution system with atmospheric bleeds open:atmospheric bleeds open:

zz Cold pipes will condense steam in places where it Cold pipes will condense steam in places where it would not under normal operation;would not under normal operation;

zz Can lead to Can lead to ““water hammerwater hammer”” -- can distort and rupture can distort and rupture lines;lines;

zz After system has been warmed, slowly raise pressure and After system has been warmed, slowly raise pressure and blow down the system with traps bypassed, until clean;blow down the system with traps bypassed, until clean;

zz Then place steam traps into service and check operation.Then place steam traps into service and check operation.

Slide 52

High Pressure Steam SystemsHigh Pressure Steam SystemsSpecific IssuesSpecific Issues

zz The cleanliness and purity of high pressure steam systems The cleanliness and purity of high pressure steam systems --particularly where the steam is used to drive a steam turbine particularly where the steam is used to drive a steam turbine should be checked by use of a should be checked by use of a ““targettarget””;;

zz For new boilers, or new sections added to steam system For new boilers, or new sections added to steam system --blow down at full pressure;blow down at full pressure;

zz When steam appears clean, fit a target with a When steam appears clean, fit a target with a ““mirroredmirrored””surface (surface (ieie. Small steel plate which has been polished, so that . Small steel plate which has been polished, so that it is in the steam blow down stream;it is in the steam blow down stream;

zz Blow down the boiler or system so that the target is impinged Blow down the boiler or system so that the target is impinged upon for a few minutes;upon for a few minutes;

zz Check target Check target -- ensure there are no small ensure there are no small ““pock markspock marks”” left on left on the target. If pock marked the target. If pock marked -- repeat process.repeat process.

Slide 53

Electrical SystemsElectrical Systems

Slide 54

Commissioning Electrical SystemsCommissioning Electrical SystemsThe following checks are typical of what is requiredThe following checks are typical of what is required

zz Open circuit breakers and switches;Open circuit breakers and switches;

zz Check that all busCheck that all bus--bars are free of dirt and foreign matter;bars are free of dirt and foreign matter;

zz Check grounding systems for continuity and resistance. Check grounding systems for continuity and resistance. Make sure all electrical equipment, vessels, structures are Make sure all electrical equipment, vessels, structures are connected to the grounding system in accordance with connected to the grounding system in accordance with drawings and specifications;drawings and specifications;

zz Check that all sealed fittings are filled with proper sealants, Check that all sealed fittings are filled with proper sealants, all explosion proof, all explosion proof, vapourvapour--tight, dusttight, dust--tight and weather tight and weather tight enclosures are properly closed and secured;tight enclosures are properly closed and secured;

zz Check motor control and power circuitry for correct Check motor control and power circuitry for correct hookup.hookup.

Slide 55

Commissioning Electrical Systems Commissioning Electrical Systems -- 22The following checks are typical of what is requiredThe following checks are typical of what is required

zz Check all nameplates and panel directories to ensure that Check all nameplates and panel directories to ensure that each circuit breaker and switch does control the proper each circuit breaker and switch does control the proper circuit. Label all switches even though their application circuit. Label all switches even though their application may seem obvious;may seem obvious;

zz Close main transformer primary disconnect switch and Close main transformer primary disconnect switch and switchswitch--gear main circuit breaker;gear main circuit breaker;

zz Check voltmeter at switchCheck voltmeter at switch--gear for proper voltage;gear for proper voltage;

zz Close first switchClose first switch--gear circuit breaker, second, third etc.gear circuit breaker, second, third etc.

zz Close first motor control centre main circuit breaker, then Close first motor control centre main circuit breaker, then each motor starter circuit breaker. Repeat for each MCC.each motor starter circuit breaker. Repeat for each MCC.

zz Check overload breakers and heaters to ensure that the Check overload breakers and heaters to ensure that the correct capacity units have been installed.correct capacity units have been installed.

Slide 56

Commissioning Electrical Systems Commissioning Electrical Systems -- 33The following checks are typical of what is requiredThe following checks are typical of what is required

zz Check that all lighting and power circuits are functioning Check that all lighting and power circuits are functioning correctly;correctly;

zz Check motor bearings for proper lubrication;Check motor bearings for proper lubrication;

zz Remove motor power fuses and check main contractor, Remove motor power fuses and check main contractor, interlock and sequencing devices;interlock and sequencing devices;

zz Uncouple each motor, replace fuses and check direction of Uncouple each motor, replace fuses and check direction of rotation by momentarily pressing the start button, then stop;rotation by momentarily pressing the start button, then stop;

zz Check manual, then automatic operation.Check manual, then automatic operation.

zz Replace all couplings, check drive belts and make sure Replace all couplings, check drive belts and make sure guards are installed.guards are installed.

Slide 57

Electric motor driven pumpsElectric motor driven pumps

Slide 58

Operational TestingOperational Testing

Slide 59

Operational TestingOperational Testing

zz Progresses through several stages;Progresses through several stages;

zz Dry runs of individual items of equipmentDry runs of individual items of equipment

zz Hot testing of individual items of equipment and Hot testing of individual items of equipment and systems;systems;

zz Several stages of Dynamic Testing of:Several stages of Dynamic Testing of:

zz Individual items of equipment;Individual items of equipment;

zz Individual Systems/processes in isolation;Individual Systems/processes in isolation;

zz The whole new process plant installation.The whole new process plant installation.

Slide 60

Dry runs and Hot TestsDry runs and Hot Tests

zz Check that motors are connected correctly and turn Check that motors are connected correctly and turn in the right direction;in the right direction;

zz Shafts and impellers move freely;Shafts and impellers move freely;

zz Equipment that is to be operated at temperature, Equipment that is to be operated at temperature, raise to temperature and check;raise to temperature and check;

zz These tests should be performed by the These tests should be performed by the manufacturermanufacturer’’s representative but witnessed by s representative but witnessed by members of the clientmembers of the client’’s operating/commissioning s operating/commissioning personnel.personnel.

Slide 61

Hot testing equipmentHot testing equipment

zz Applies to equipment whose leakApplies to equipment whose leak--tightness must be tested at tightness must be tested at operating temperatures and after temperature reversals;operating temperatures and after temperature reversals;

zz FixedFixed--bed catalytic reactors that in normal conditions are bed catalytic reactors that in normal conditions are heated by heat transfer fluids where leakage would heated by heat transfer fluids where leakage would contaminate the catalyst;contaminate the catalyst;

zz Critical exchangers whose steam or cooling water is at a Critical exchangers whose steam or cooling water is at a high pressure than the process fluid;high pressure than the process fluid;

zz Any equipment having complicated seals through which Any equipment having complicated seals through which leakage could occur;leakage could occur;

zz Rotating machinery which must be able to rotate freely at Rotating machinery which must be able to rotate freely at temperature temperature egeg. Steam turbines, etc.. Steam turbines, etc.

Slide 62

Hot testing proceduresHot testing procedures

zz The thermal shock tolerance of equipment must be The thermal shock tolerance of equipment must be determined beforehand;determined beforehand;

zz To avoid thermal shock, the temperature of the To avoid thermal shock, the temperature of the heating medium may have to be raised gradually;heating medium may have to be raised gradually;

zz Time required for a hot test must be established in Time required for a hot test must be established in advance;advance;

zz Establish a uniform temperature in all parts of Establish a uniform temperature in all parts of equipment that are supposed to be uniformly hot equipment that are supposed to be uniformly hot during operation to avoid setting up stresses;during operation to avoid setting up stresses;

Slide 63

Dynamic TestingDynamic Testing

Slide 64

Dynamic TestingDynamic Testing

zz Involves operating the equipment, before introducing Involves operating the equipment, before introducing ““livelive”” process fluid;process fluid;

zz During dynamic testing, we progress through:During dynamic testing, we progress through:

zz SafeSafe--fluid dynamic testing;fluid dynamic testing;

zz Dynamic testing with solvent;Dynamic testing with solvent;

zz Closed loop testing with process fluid.Closed loop testing with process fluid.

zz Once process fluid is introduced, normal plant safety Once process fluid is introduced, normal plant safety procedures must come into effect as if it were a live procedures must come into effect as if it were a live operating plant.operating plant.

Slide 65

SafeSafe--Fluid Dynamic TestingFluid Dynamic Testing

zz Closed loop dynamic testing with safe fluids consists of Closed loop dynamic testing with safe fluids consists of operating equipment systems with air, water, inert gases operating equipment systems with air, water, inert gases etc.etc.

zz This permits flow testing of equipment;This permits flow testing of equipment;

zz Gives first indication of how control loops work;Gives first indication of how control loops work;

zz Establishes performance while there is still time to modify Establishes performance while there is still time to modify the plant;the plant;

zz FamiliarisesFamiliarises operators with the operation of the equipment operators with the operation of the equipment before hazardous materials are introduced;before hazardous materials are introduced;

zz Gets rid of a lot of dirt which would be more difficult to Gets rid of a lot of dirt which would be more difficult to clear once the process fluid has been introduced.clear once the process fluid has been introduced.

Slide 66

General Principles for TestingGeneral Principles for Testing

zz For most plants, a period of 2For most plants, a period of 2--3 weeks is usually sufficient 3 weeks is usually sufficient for operational testing, after the mechanical dry running of for operational testing, after the mechanical dry running of individual pieces of equipment and hot testing complete;individual pieces of equipment and hot testing complete;

zz Air and water tests should be set up in a closed loop with Air and water tests should be set up in a closed loop with fluids continuously recycled, with loops as large as fluids continuously recycled, with loops as large as possible;possible;

zz The loop should ideally be the same loop that will be The loop should ideally be the same loop that will be subject to solvent testing;subject to solvent testing;

zz Tests should continue for several days in order to give all Tests should continue for several days in order to give all shifts a chance to conduct the same tests;shifts a chance to conduct the same tests;

zz All shifts should be given the opportunity to start up and All shifts should be given the opportunity to start up and shutdown each closed loop test.shutdown each closed loop test.

Slide 67

General Principles for TestingGeneral Principles for Testing

zz A rough flowA rough flow--sheet should be developed for air sheet should be developed for air and water tests, predicting all information that and water tests, predicting all information that normally appears on a process flow sheet normally appears on a process flow sheet -- flow, flow, temperature, pressure, heat transfer, power etc.temperature, pressure, heat transfer, power etc.

zz will assist in alerting commissioning team to will assist in alerting commissioning team to risks from overrisks from over--pressuring, overloading, pressuring, overloading, temperaturetemperature--shocking and stressing equipment;shocking and stressing equipment;

Slide 68

Cautions during TestingCautions during Testing

z Dynamic testing may lead to:

zz Unusual or unforeseen differential expansions;Unusual or unforeseen differential expansions;

zz Corrosion;Corrosion;

zz Excessive weight of liquid into parts of the Excessive weight of liquid into parts of the system;system;

zz Care must be taken not to collapse or burst Care must be taken not to collapse or burst pressure vessels and tanks:pressure vessels and tanks:

zz ensure there is always adequate venting;ensure there is always adequate venting;

zz avoid pulling a vacuum.avoid pulling a vacuum.

Slide 69

Dynamic Testing Dynamic Testing -- Simulated OperationsSimulated OperationsSafe Fluid TestingSafe Fluid Testing

zz Auxiliary services must be brought into operation Auxiliary services must be brought into operation first:first:

zz water cooling, inert gas generators, boiler water cooling, inert gas generators, boiler feedwaterfeedwater, firewater, steam production, etc., firewater, steam production, etc.

zz Water is pumped through the process (except Water is pumped through the process (except where special conditions do not permit it) and where special conditions do not permit it) and boiled up in columns;boiled up in columns;

zz Compressors and blowers should be operated on Compressors and blowers should be operated on air or inert gas.air or inert gas.

Slide 70

The Value of Dynamic Testing The Value of Dynamic Testing --Simulated OperationsSimulated Operations

zz Value of simulated operations will be to allow operator to Value of simulated operations will be to allow operator to become familiar with the operation of the process, before become familiar with the operation of the process, before hazardous fluids are introduced;hazardous fluids are introduced;

zz Equipment deficiencies can become apparent during Equipment deficiencies can become apparent during dynamic testing;dynamic testing;

zz Failures and problems more easily corrected with safe Failures and problems more easily corrected with safe fluids presentfluids present

zz Leaks should be found and tightened;Leaks should be found and tightened;

zz Instruments can be placed into service Instruments can be placed into service -- although selection although selection of setof set--points will have to be deferred;points will have to be deferred;

zz Inspect the plant for evidence of design and construction Inspect the plant for evidence of design and construction errors.errors.

Slide 71

Dynamic Testing Dynamic Testing -- Simulated OperationsSimulated Operations

zz At the end of the simulation, water should be At the end of the simulation, water should be drained drained -- equipment dried and purged;equipment dried and purged;

zz Depending on the process Depending on the process -- drying may not be drying may not be necessary necessary -- but purging will always be required;but purging will always be required;

Slide 72

Dynamic testing with a solventDynamic testing with a solvent

zz After safe fluid testing and subsequent repairs and After safe fluid testing and subsequent repairs and modifications, we are ready for dynamic closed modifications, we are ready for dynamic closed loop testing with a solvent;loop testing with a solvent;

zz The The ““solventsolvent”” is a relatively safe fluid whose is a relatively safe fluid whose properties are close to that of the process fluid, or properties are close to that of the process fluid, or the process fluid itself;the process fluid itself;

zz In order to allow for continuous reIn order to allow for continuous re--circulation of circulation of the solvent and the use of different solvents in the solvent and the use of different solvents in different parts of the plant, temporary lines will different parts of the plant, temporary lines will need to be installed.need to be installed.

Slide 73

Dynamic Testing with Process SolventDynamic Testing with Process Solvent

zz Introduce the process solvent. (if there is more than Introduce the process solvent. (if there is more than one, introduce only one at this stage);one, introduce only one at this stage);

zz The dynamic testing procedure used for the safe The dynamic testing procedure used for the safe fluid test is repeated for the process solvent dynamic fluid test is repeated for the process solvent dynamic testing;testing;

zz After operations with the first solvent have been After operations with the first solvent have been brought completely under control, should the second brought completely under control, should the second solvent be introduced (if there is one).solvent be introduced (if there is one).

Slide 74

Dynamic testing with a solventDynamic testing with a solvent

zz The purpose of dynamic testing with a solvent is to The purpose of dynamic testing with a solvent is to check out equipment and instrument loops at, or check out equipment and instrument loops at, or near design conditions prior to the introduction of near design conditions prior to the introduction of more hazardous process fluid;more hazardous process fluid;

zz No reactions should be allowed to occur during No reactions should be allowed to occur during these tests, so as to ensure that test fluids remain these tests, so as to ensure that test fluids remain predictable in composition and properties;predictable in composition and properties;

zz Guidelines used for safeGuidelines used for safe--testing apply;testing apply;

zz Need to plan how solvent will be fed into the Need to plan how solvent will be fed into the system and later removed.system and later removed.

Slide 75

Stages of dynamic testing with a Stages of dynamic testing with a ““solventsolvent””

zz Drain safe fluid and purge air used in the previous test from Drain safe fluid and purge air used in the previous test from the system;the system;

zz Dry out equipment where safe fluid was water. Check flow Dry out equipment where safe fluid was water. Check flow sheets for where water is likely to accumulate.sheets for where water is likely to accumulate.

zz Fill systems with the solvent. Ensure provisions made for Fill systems with the solvent. Ensure provisions made for venting and drains closed;venting and drains closed;

zz When adequate levels established, place pumps and When adequate levels established, place pumps and compressors online to complete filling;compressors online to complete filling;

zz Start closed loop circulation;Start closed loop circulation;

zz Heat up the systems to simulate operating conditions by Heat up the systems to simulate operating conditions by placing reflux, placing reflux, reboilerreboiler and condensation systems into and condensation systems into operationoperation

Slide 76


zz Systematically check out instrumentation and control loops;Systematically check out instrumentation and control loops;

zz After instruments have checked out, place as many as After instruments have checked out, place as many as possible on automatic control;possible on automatic control;

zz All shifts should go through starting and stopping All shifts should go through starting and stopping equipment, heating and cooling closed loop systems;equipment, heating and cooling closed loop systems;

zz Dynamic Dynamic ““solventsolvent”” testing offers the best opportunity for testing offers the best opportunity for operator training before the operator training before the ““real thingreal thing””;;

zz Operate equipment as near as possible to design capacities;Operate equipment as near as possible to design capacities;

zz Reliability of emergency shutdown systems and alarms Reliability of emergency shutdown systems and alarms must be proven;must be proven;

zz Critical instruments must be calibrated over their full range.Critical instruments must be calibrated over their full range.

Slide 77


zz Deliberately operate equipment near its limits:Deliberately operate equipment near its limits:

zz Flood columns;Flood columns;

zz Ease compressors into mild surges and plot surge curves;Ease compressors into mild surges and plot surge curves;

zz Overload condensers;Overload condensers;

zz Do not fear blowing a relief valve or two!Do not fear blowing a relief valve or two!

zz After tests have been completed, plant should be ready for After tests have been completed, plant should be ready for initial operation.initial operation.

Slide 78

Closed Loop Dynamic Testing with Closed Loop Dynamic Testing with Process FluidProcess Fluid

zz Finally, introduce process fluid;Finally, introduce process fluid;

zz During this step, instruments should be calibrated During this step, instruments should be calibrated to cover their full range of flow, temperature and to cover their full range of flow, temperature and pressure;pressure;

zz Ensure that instruments, process Ensure that instruments, process analysersanalysers and and safety devices are kept work properly during these safety devices are kept work properly during these processes;processes;

zz After operations with process fluid are brought After operations with process fluid are brought completely under control should the final stage of completely under control should the final stage of startstart--up be attempted.up be attempted.

Slide 79

Preparing to introduce process fluidsPreparing to introduce process fluids

zz Before introducing hazardous liquids into the Before introducing hazardous liquids into the plant, we complete additional pressure testing and plant, we complete additional pressure testing and purging;purging;

zz Need to check that the stresses and strains of Need to check that the stresses and strains of dynamic testing has not caused any leaks dynamic testing has not caused any leaks -- these these must be found and fixed;must be found and fixed;

Slide 80

Pressure testing and purgingPressure testing and purging

zz Consists of pressuring and deConsists of pressuring and de--pressuring with pressuring with nitrogen several times, until at least <3% oxygen is nitrogen several times, until at least <3% oxygen is reached;reached;

zz Vacuum systems should be evacuated and then reVacuum systems should be evacuated and then re--pressured with nitrogen;pressured with nitrogen;

zz Long runs of piping are swept with nitrogen;Long runs of piping are swept with nitrogen;

zz While under pressure, rate of pressure loss of the While under pressure, rate of pressure loss of the ““blocked inblocked in”” system is monitored as a check for system is monitored as a check for leaks and that no vents or drains have been left leaks and that no vents or drains have been left open.open.

Slide 81

Dehydrating by CirculationDehydrating by Circulation

zz It is usually not possible to waterIt is usually not possible to water--free equipment free equipment simply by draining;simply by draining;

zz Only positive method to waterOnly positive method to water--free process free process equipment is oil circulation followed by repeated equipment is oil circulation followed by repeated draining of low points;draining of low points;

zz Ensure sufficient low point drains are provided on Ensure sufficient low point drains are provided on piping, control valve loops, vessels and process piping, control valve loops, vessels and process machinery;machinery;

zz Startup lines Startup lines -- deliver oil to upper part (trays) of deliver oil to upper part (trays) of distillation towers (size for 20% of net distillate distillation towers (size for 20% of net distillate product rate);product rate);

Slide 82

Start Up and Initial OperationStart Up and Initial Operation

Slide 83

Start Up and Initial OperationStart Up and Initial Operation



Post Commissioning

zz Introduction of process fluidIntroduction of process fluid

zz StartStart--up and initial operationup and initial operation

zz TroubleTrouble--shooting and shooting and problem correction. problem correction.

zz Plant taken to full operations. Plant taken to full operations.




Slide 84

Starting Up the PlantStarting Up the Plant

Product refining

RecoveryReactionFeed

Preparation

zz Most plants in petrochemical/chemical industry Most plants in petrochemical/chemical industry have the following have the following ““generalgeneral”” form.form.

zz Start Up from the Start Up from the End of the Process End of the Process and Work backand Work back

Slide 85

Start Up LogicStart Up Logic

zz It is common practice to buy in product and start It is common practice to buy in product and start up the last past of the process first and work up the last past of the process first and work backwards to the front. E.g.backwards to the front. E.g.

zz Start up refining, get this working and in Start up refining, get this working and in control;control;

zz Then possibly start up reaction and recovery;Then possibly start up reaction and recovery;

zz Finally, feed preparation.Finally, feed preparation.

Slide 86

Into the initial operationInto the initial operation

zz Once raw materials are fed into the plant Once raw materials are fed into the plant -- usually usually at reduced rate until reaction conditions have been at reduced rate until reaction conditions have been established;established;

zz As each section is started up, establish as quickly As each section is started up, establish as quickly as possible that process conditions are as expected;as possible that process conditions are as expected;

zz If potentially serious problems develop, there If potentially serious problems develop, there should be no hesitation on going into an should be no hesitation on going into an emergency shutdown.emergency shutdown.

Slide 87

Ramping up the plantRamping up the plant

zz Plant is brought slowly to design feedPlant is brought slowly to design feed--rates and rates and operating conditions;operating conditions;

zz Usually done in steps with operating data Usually done in steps with operating data evaluated and verified as OK at each step;evaluated and verified as OK at each step;

zz Plant and laboratory data are now being collected Plant and laboratory data are now being collected and should be being evaluated promptly;and should be being evaluated promptly;

Slide 88

Coordination and Supervision during Coordination and Supervision during start upstart up

zz Additional personnel, both supervisory and Additional personnel, both supervisory and ““onon--thethe--groundground”” are required at this stage;are required at this stage;

zz Cooperation between startup personnel and plant Cooperation between startup personnel and plant supervisory personnel is critical at this stage:supervisory personnel is critical at this stage:

zz Need a daily meeting at least;Need a daily meeting at least;

zz Often, a briefing each shift.Often, a briefing each shift.

Slide 89

Trouble ShootingTrouble Shooting

zz At this stage, many problem with equipment of the At this stage, many problem with equipment of the process itself may become apparent;process itself may become apparent;

zz The commissioning process goes through what is The commissioning process goes through what is often an intense (and hopefully short) period of often an intense (and hopefully short) period of problem trouble shooting, problem solving, problem trouble shooting, problem solving, engineering correction and plant modification;engineering correction and plant modification;

Slide 90

Performance and Acceptance TrailsPerformance and Acceptance Trails

Slide 91

Performance and Acceptance TestingPerformance and Acceptance Testing



Post Commissioning

zz Performance trails;Performance trails;

zz Formal Acceptance testFormal Acceptance test




Slide 92

The Performance TrailsThe Performance Trails

zz Once the plant is fully operational, the final Once the plant is fully operational, the final ““proving trailproving trail”” or performance run is performed in or performance run is performed in order to prove the plant can do what it is supposed order to prove the plant can do what it is supposed to do;to do;

zz The values or range of values for each independent The values or range of values for each independent variable variable -- flow, temperature, pressure, level, flow, temperature, pressure, level, concentrations, etc. to which the plant must be concentrations, etc. to which the plant must be operated to are determined;operated to are determined;

zz The plant is brought up to those conditions and the The plant is brought up to those conditions and the prepre--agreed trial period begins.agreed trial period begins.

Slide 93

Before the trail or performance run need Before the trail or performance run need to ensure thatto ensure that……

zz Control of plant operating conditions has been Control of plant operating conditions has been achieved. I.e. temperature, pressures, levels and achieved. I.e. temperature, pressures, levels and analyses are reasonably constant or in the case of a analyses are reasonably constant or in the case of a batch process, there is repeatability;batch process, there is repeatability;

zz Daily material and energy balanced can be Daily material and energy balanced can be performed and that these agree with performed and that these agree with ““officialofficial””production figures;production figures;

zz Product specifications are being achieved Product specifications are being achieved consistently.consistently.

Slide 94

Need to verify Need to verify …… ..

zz Physical operation, capability and capacity of plant Physical operation, capability and capacity of plant and equipment;and equipment;

zz Energy and mass balance;Energy and mass balance;

zz Process chemistry;Process chemistry;

zz Efficiencies, yields and quality;Efficiencies, yields and quality;

zz All to specification.All to specification.

Slide 95

AcceptanceAcceptance

zz When the plant has met the Performance and When the plant has met the Performance and Acceptance test requirements designed by the Acceptance test requirements designed by the commissioning team there is usually a formal commissioning team there is usually a formal acceptance process involving signing of acceptance acceptance process involving signing of acceptance certificates;certificates;

zz Once the plant is accepted it is officially part of the Once the plant is accepted it is officially part of the normal operations normal operations -- the responsibility of operations the responsibility of operations and maintenance;and maintenance;

zz Commissioning is officially over;Commissioning is officially over;

zz The may still be outstanding The may still be outstanding punchlistpunchlist itemsitems

Slide 96

Acceptance TestingAcceptance Testing

zz It is common practice to prove performance It is common practice to prove performance repeatability and plant integrity as part of the repeatability and plant integrity as part of the performance test. That is:performance test. That is:

zz Shutdown and Start Up the plant on several Shutdown and Start Up the plant on several occasions and bring it up to test conditions to occasions and bring it up to test conditions to prove repeatability. Also ramp down and ramp up prove repeatability. Also ramp down and ramp up while online;while online;

zz ReRe--inspection of critical process equipment inspection of critical process equipment --particularly columns to ensure they have not been particularly columns to ensure they have not been damaged by the performance run.damaged by the performance run.

Slide 97

Commercial Significant of AcceptanceCommercial Significant of Acceptance

zz Formal Acceptance represents formal acknowledgment Formal Acceptance represents formal acknowledgment that the that the

zz Contractor has fullContractor has full--filled their contractual filled their contractual obligations;obligations;

zz Commissioning team have fullCommissioning team have full--filled their filled their obligations;obligations;

zz Completion of the Capital Project and transfer to Completion of the Capital Project and transfer to Operations;Operations;

zz Expenses and costs from acceptance onwards are now Expenses and costs from acceptance onwards are now operating expenses not capital project costs;operating expenses not capital project costs;

zz All subject to agreed punchAll subject to agreed punch--list items.list items.

Slide 98

PostPost--CommissioningCommissioning

Slide 99

Post CommissioningPost Commissioning






Post Commissioning

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

zz Adjustments, modifications and Adjustments, modifications and fault correction;fault correction;

zz Completion of outstanding Completion of outstanding punchlistpunchlist itemsitems

Slide 100

Post CommissioningPost Commissioning

zz Covers the period immediately after Acceptance;Covers the period immediately after Acceptance;

zz Outstanding punchOutstanding punch--list items are completed;list items are completed;

zz The first routine maintenance checks are performed, The first routine maintenance checks are performed, findings evaluated and reported;findings evaluated and reported;

zz Process equipment and items covered by warranty Process equipment and items covered by warranty are scrutinized for signs of premature wearare scrutinized for signs of premature wear--out or out or problems;problems;

zz Operating data is collected and evaluated to ensure Operating data is collected and evaluated to ensure consistent plant operations are maintained and consistent plant operations are maintained and sustainable.sustainable.

Documents

Plant Commissioning Start Up Procedure[1]