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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.xls7/29/2019 Commissioning Procedure for System Engineer power plant
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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.doc7/29/2019 Commissioning Procedure for System Engineer power plant
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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.xlsx7/29/2019 Commissioning Procedure for System Engineer power plant
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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