The document discusses the process of commissioning a chemical plant. It defines commissioning as a series of checks to confirm that a newly constructed plant is fit for purpose. Commissioning involves three main stages - pre-commissioning during construction, commissioning when systems are first operated, and start-up when the plant is brought into actual production. The document outlines various commissioning terminologies and provides details about safety and environmental considerations during the commissioning process.
The document discusses the process of commissioning a chemical plant. It defines commissioning as a series of checks to confirm that a newly constructed plant is fit for purpose. Commissioning involves three main stages - pre-commissioning during construction, commissioning when systems are first operated, and start-up when the plant is brought into actual production. The document outlines various commissioning terminologies and provides details about safety and environmental considerations during the commissioning process.
The document discusses the process of commissioning a chemical plant. It defines commissioning as a series of checks to confirm that a newly constructed plant is fit for purpose. Commissioning involves three main stages - pre-commissioning during construction, commissioning when systems are first operated, and start-up when the plant is brought into actual production. The document outlines various commissioning terminologies and provides details about safety and environmental considerations during the commissioning process.
The document discusses the process of commissioning a chemical plant. It defines commissioning as a series of checks to confirm that a newly constructed plant is fit for purpose. Commissioning involves three main stages - pre-commissioning during construction, commissioning when systems are first operated, and start-up when the plant is brought into actual production. The document outlines various commissioning terminologies and provides details about safety and environmental considerations during the commissioning process.
Commissioning ➢Commissioning is NOT just turning up the day after construction is complete and pressing the BIG GREEN BUTTON !
➢Commissioning is a series of checks that confirm newly
constructed chemical plant is fit for purpose, these checks being made at all stages of a project's life, not just after construction is complete. Commissioning ➢Commissioning is the use of a disciplined, systematic and professional methodology: 1-To convert newly constructed process plant into a fully integrated and operational unit in the most safe, efficient, cost effective and timely of manners. 2-To achieve start up and production targets “right first time". Commissioning Terminologies Dry Commissioning: Tests and procedures that are conducted where there is no process or safe chemicals yet introduced to the plant.
Examples of these activities would be:
• Interlock and emergency shutdown tests • Control system sequence checks. • Potentially initial running of major motors of such as Compressor, Oil lubrications systems, uncoupled from the turning mechanism. Wet Commissioning:
➢ Water or some other relatively safe medium has been
introduced to the process and initial commissioning of the system and its major plant items can be undertaken.
➢ Putting the process through its operating scenarios to
replicate in the most suitable manner possible the normal operation of the unit Commissioning • Commissioning is usually the phase in a project when design process fluids are introduced to the systems.
• Sometimes commissioning means running the systems with a safe fluid
only.
PSSR= Pre Start-Up Safety Review
Start-Up: • The phase in a project where the entire plant (all systems and sub- systems) are taken into operation. • Process fluids are introduced and process conditions are established with the intent of making products.
Initial Operation: • The phase in a project after start-up of the complete plant in order to adjust and optimize and prepare the plant for the performance testing phase. Hot Commissioning / Live Commissioning: • Design process fluids are introduced in the systems and sub- systems. Performance Testing: • Check if the plant meets the specifications under normal operating condition. Post Commissioning: • Solving of outstanding punch points after the plant has been handed over to the client. De-Commissioning: • Means taking out of active use and dismantling of an industrial plant. Safety and Environmental Considerations During Commissioning stages there are hazard that could cause damage to the Newly installed equipment, Injury People , Impact Environment .
These Hazards could be caused and initiated by :
• People: Lack of experience. • Pre-commissioning & Commissioning activities: Hydrostatic Pressure testing. • Environment: Hot weather. Safety & Environmental Consideration- • The safe and environmentally friendly commissioning of any new asset should always be of highest priority and integral with every check-sheet and procedure written during the preparation and execution of the commissioning process. • The safety of personnel plus the environmental implication must always be the first consideration of any commissioning activity . • Schedules must be considered and constructed in a way that sufficient time is allocated to each and every commissioning activity. • Safety implication can be neglected during intensity and critical time of the commissioning and start up phases Safety & Environmental Consideration During commissioning and whilst introduction of energy to the plant : • The various process area must be clearly identified , barricaded or fenced off and tagged appropriately. • Clearly identifying the nature of the activities before commence in the area. • All electrical items at field; devices and motor control centers MCC must be clearly labeled, locked out. • The commissioning team must undergo all relevant training required by the site to which the project is being worked. • The commissioning organization should establish safe system of work at work location ;These safe systems include permit to work systems , confined space entry permits, and hot permits. Safety & Environmental Consideration • The commissioning personnel must make themselves familiar with all site regulatory procedures and works instructions such as ;Environment impact assessments , job safety analysis , major job review , job method statement , pre-task planning , safe and unsafe acts audits. • Discussion must takes place between the contracting and site client personnel to ensure no transgression or site violation takes place within the initially commissioning the new facility; examples: • Opening process valves potentially from an existing operation area. • Starting electrical equipment. • The finding from the discussion must be fully documented within the commissioning manual and subsequent commissioning procedure and strictly adhered to during the actual commissioning activities Control Measures to Eliminate Risk & Incidents: ➢ Training programme should be available and conducted to all commission team members (Operation, Maintenance , Contractor , and vendors). ➢Hazop Study must be conduct for pre-commissioning and commissioning activities ➢Sufficient time is allocated to each and every commissioning activity ➢Process areas must be clearly identified ➢Areas must be taped, barricaded or fenced off and tagged appropriately. ➢ The nature of the activities MUST clearly identifying . Control Measures to Eliminate Risk & Incidents: ➢Performing audit during construction and commissioning phases. ➢Sufficient commissioning staff must be made available on site ➢All electrical items at field devices and motor control centers (MCC) must be clearly labeled, locked out and tracked in a safe-and-sound manner. ➢The commissioning personnel must make themselves familiar with: ✓the procedures and works instructions ✓environmental impact assessments, job safety analysis, job method statements, pre task planning, ✓safe and unsafe acts audits etc… Commissioning Successful Commissioning of a chemical plant is divided into three main Categories: Commissioning Commissioning: Pre-commissioning: Activities 1-various systems and items of equipment carried out during construction that are first put into initial operation. prepare and enable the unit to move to to gain the confidence that when process Start-up, the main commissioning phase. chemicals are introduced the plant will operate as designed and intended.
Pre-commissioning activities include:
• Installation of filters, • Utility systems, instrument air, cooling The plant is • Packing of distillation columns, water and general purpose water are brought into • Filling a reactor with catalyst, made live. actual • Cleaning pipes and equipment, • The unit is leak tested, started up, shut operation. • Vendor and factory acceptance down, distillation columns and testing, Punch listing and scrubbing columns put into use, instrument, • Electrical and motor loop testing. Most commissioning activities fall into the following key headings: • System configuration check. • Instrumentation system check verification of alarms and trips. • Flushing and cleaning of lines and vessels with water. • Assessment of ancillary equipment. • Calibration of vessels and instrumentation. • Start-up protocol. • Shut-down protocol. • Chemical trials. • Handover. Commissioning Process: Commissioning Process is delivered in three distinguished Stages
Prepare Implement Close Out
All the steps within each stage should be considered for any project, of any size, to ensure all of the commissioning activities required are included in the management system to get successful plant start-up. The Commissioning Phases Prepare: Activities to be taken to set commissioning up, gather information, select the commissioning team, develop the schedule and create documentation. Implement: This phase, is “commissioning”, examines the facets that address the installation, checking and start-up of the new equipment.
Close out: The final stage of the commissioning process: ensuring that all paperwork systems and trials are complete, and that the plant or equipment has met its acceptance criteria, enabling the plant to be handed to the ongoing operations group.
The commissioning team will then be closed down.
Overview of Commissioning Stages Prepare Stage: • Appoint the Commissioning Manager. • Define the commissioning scope. • Systemize the plant utilizing the project Piping and Instrument Diagrams (P&lD) and other relevant documents Including layout drawings and mechanical flow diagrams, into commissioning system Integrate commissioning systems into the engineering documents, line tables, Instrument index, P&IDs, equipment lists and procurement plans. • Input to design
• The commissioning team upon agreement With the Project Manager and Commissioning Managers Will attend the following reviews: P&ID, Piping isometric, Plant Layout, Constructability, 3-D model, Schedule, SIL, LOPA and action upon alarm • Compile the Commissioning Schedule
• Compile the Commissioning Estimate/Budget
Prepare Stage: • Agree interface/handover procedure With project, client and construction groups • Obtain pertinent and relevant documents and establish electronic libraries • Attend Hazard Study • Compile Initial Commissioning Plan • Set up Site base and compile commissioning consumables list • Determine initial fill chemicals, Simulants and procure • Create Commissioning Manual • Compile Standard Operating Procedures (SOPs) • Compile training packages • Agree Safe Systems of Work With all interested parties • Compile Commissioning Procedures • Give input as required to the User Requirement Specification (URS) for a Distributed Control System (DCS) • Compile Decontamination Procedures Thank You
