Introduction to Process Plant Startup & Commissioning.ppt

Introduction to Process Plant Start-up and Commissioning,Plant Start-up and Commissioning,Plant commissioning is the first of many start-upsPotentially hazardous:ability to operate not provenMany unknown factorsFirst startup&subsequent shutdowns and startupsExcellent experience and expertise building for operators and maintenance personnel.,Start-up and Commissioning apply to,Entire facilities in Greenfield projectsMajor expansions or additions to existing plantsRe-commissioning of plants and equipment;Individual items of plant,egBoilersInstrument air compressors etc,Delays in Startup&Commissioning expensive!,slow start-ups reduce the Return on Investmentdelayed revenue streamIncreased cost of deliveryFinancial viability20-25%of construction time(good planning)Causes of delays:75%due to equipment failure20%from inadequate equipment5%from process failure,Details vary depending on plant butprocedure remains the same,prepare,plan and execute startup commissioning managementPreparation of specific plant proceduresManagement of risks Safety&environmental compliance,Construction&CommissioningHow we would like it.,Construction,Pre-commissioning,Inspection and Operational Testing,Start up and Performance testing,Post commissioning,Mechanical completion,Provisional acceptance,Acceptance,Construction and CommissioningHow it happens.,Construction,Pre-commissioning,Inspection and Operational Testing,Start up and Performance testing,Post commissioning,Mechanical completion,Progressive provisional acceptance,Progressive acceptance,Commissioning in practice,Progressive mechanical completion and concurrent commissioning creates challenges:Coordination and planningSafety and riskIsolationTestingIntegration into operating plant,From construction to commissioning,what constitutes mechanical completion?on completion,start-up can officially commenceproblems when part of a plant are commissioned while construction not yet finished.,The Commissioning ProcessKey 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-1,Preparation and planning,Mechanical Completion and Integrity checking,Performance and Acceptance testing,Start Up&Initial Operation,Pre-commissioning&Operational Testing,Appointment of Commissioning Manager or Lead Commissioning Engineer;Appointment of Commissioning Team Members and Support Staff;Training;Information Compilation;Safety and Risk Assessment;Commissioning Strategy Development;Procedures and Checklist Development;Detailed Plan and Budget Preparation;,Post Commissioning,The Commissioning Process Detail-2,Preparation and planning,Mechanical Completion and Integrity checking,Performance and Acceptance testing,Start Up&Initial Operation,Pre-commissioning&Operational Testing,InspectionPressure testingCleaning and FlushingMachinery checkout,Post Commissioning,The Commissioning Process Detail-3,Preparation and planning,Performance and Acceptance testing,Start Up&Initial Operation,Steam and other utilities introduced;Dry running trials;Hot running trials;Safe-fluid dynamic testing;Solvent dynamic testing;Process fluid tests.,Mechanical Completion and Integrity checking,Pre-commissioning&Operational Testing,Post Commissioning,The Commissioning Process Detail-4,Preparation and planning,Performance and Acceptance testing,Post Commissioning,Introduction of process fluidStart-up and initial operationTrouble-shooting and problem correction.Plant taken to full operations.,Mechanical Completion and Integrity checking,Pre-commissioning&Operational Testing,Start Up&Initial Operation,The Commissioning Process Detail-5,Preparation and planning,Performance and Acceptance testing,Post Commissioning,Performance trails;Formal Acceptance test,Mechanical Completion and Integrity checking,Pre-commissioning&Operational Testing,Start Up&Initial Operation,The Commissioning Process Detail-6,Preparation and planning,Mechanical Completion and Integrity checking,Pre-commissioning&Operational Testing,Start Up&Initial Operation,Performance and Acceptance testing,Post Commissioning,From plant on-stream to settled down and in regular production;Adjustments,modifications and fault correction;Completion of outstanding punchlist items,What makes commissioning&start-up 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 Process,Preparation and planning,Mechanical Completion and Integrity checking,Performance and Acceptance testing,Start Up&Initial Operation,Post Commissioning,Pre-commissioning&Operational Testing,Organisation and roles;Information Management;Procedure developmentSafety and risk management;Permit systemsJob safety analysisPlanning and control;Budgeting and cost control;Commissioning strategy.,Management Issues,Technical Issues,Plant preparation and isolation;Utilities and Electrical System CommissioningEquipment Specific Commissioning IssuesMachinery/Rotating EquipmentVessels,Towers and pipe work etc.Removal of hazardous substances and purgingInstrumentation commissioning,Task force responsibilitiesDuring design stage,Review design for safety and operabilityCarry out HAZOP and other safety studiesoperating procedures Arrange modifications requiredRecruitment,training of operations&maintenance personnel.,Typical Operating Instruction Manual,The ProcessConditioning and Special EquipmentStarting ProceduresShutdown Procedures,Maintenance Responsibilities,Publish work and safety procedures;Specify maintenance activitiesSelect 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-1,Detailed procedures for maintenance work and work to be done when executing the commissioning procedure Need to cover each major piece of equipment Locking out electrical systemsInstructions covering atmospheric testing,type of test and permissible limits of contaminants.,Safety in Maintenance-2,Definition of type of permit required to carry out workType of equipment required for maintenanceDescription of personal protection equipment requiredInstructions regarding emergency equipment Instructions on potential hazardsEmergency procedures,Spare Parts and Maintenance Minimum Inventories for Commissioning and Start-up,manufacturers recommended spare parts for motive equipment-avoid duplicationgaskets 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-2Minimum Inventories for Commissioning and Start-up,Pressure gauges of appropriate rangesThermometers and any special instrument partsRupture disksPipe insulation materials including jacketingLubrication oils and greasesSpare parts for electronic&analytical equipment.,Process Plant Machinery Commissioning Failure Problems in decreasing order of problem frequency,1.Centrifugal compressors2.Steam turbines3.Large gear speed increaser units4.Electric motors in size categories above 1000 HP5.Reciprocating compressors6.Gas turbines7.Gas expanders,Commissioning Team Information Requirements,Project design fileProcess fileEngineering data filePlant layout fileOperating instructionsAnalytical proceduresLog sheets and calculation procedures.,Commissioning Documentation,Technical manual giving process technology and equipmentStandard operating procedures giving details of each systemSafety valve and rupture disk manual,listing the design basis for each safety device,and giving the procedure for taking it out of serviceTraining manual detailing the program for new personnelSafety manual setting policies and proceduresEmergency 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 Cost Estimation,Startup 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&commissioning,Allow from 5-15%of overall capital cost of the project for startup and commissioningEmpirical rules for estimating both startup time and startup costs,suitable for initial project budget,Estimate Startup CostsCost=A(0.10+B+C+D+NE),A=Direct fixed capital cost of project;B=Process factor0.05 for radically new process0.02 for relatively new-0.02 for familiar processC=Equipment factor0.07 for radically new0.03 for relatively new-0.03 for familiar equipment,D=Labour factor0.04 for labour in very short supply0.02 for labour somewhat scarce-0.01 for surplus labourN=Number of process units involvedE=Dependency factor0.04 for interdependent process units0.02 for moderately dependent-0.02 for independent plants.,Estimate Startup TimeTime=a(0.15+b+c+d+Ne),a=Construction Timeb=Process factor0.15 for radically new process0.05 for relatively new-0.01 for familiar processc=Equipment factor0.15 for radically new0.08 for very new0.05 for relatively new-0.01 for familiar equipment,D=Labour factor0.15 for labour in very short supply0.05 for labour somewhat scarce-0.01 for surplus labourN=Number of process units involvedE=Dependency factor0.25 for interdependent process units0.10 for moderately dependent-0.02 for independent plants.,Startup 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&Time,Startup CostsCost=100(0.10-0.02-0.03+0.04+1*0.02)=100*0.11=$11 MillionStartup TimeTime=8(0.15-0.01-0.01+0.15+1*0.1)=8*0.38=3 Months,