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1、Introduction to Process Plant Start-up and Commissioning,Plant Start-up and Commissioning,Plant commissioning is the first of many start-ups Potentially hazardous: ability to operate not proven Many unknown factors First startup Individual items of plant, eg Boilers Instrument air compressors etc,De
2、lays in Startup 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 Det
3、ail - 2,Preparation and planning,Mechanical Completion and Integrity checking,Performance and Acceptance testing,Start Up Dry running trials; Hot running trials; Safe-fluid dynamic testing; Solvent dynamic testing; Process fluid tests.,Mechanical Completion and Integrity checking,Pre-commissioning F
4、ormal Acceptance test,Mechanical Completion and Integrity checking,Pre-commissioning Adjustments, modifications and fault correction; Completion of outstanding punchlist items,What makes commissioning massive coordination of construction, contractors, vendors, commissioning team, operations and main
5、tenance 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 Accepta
6、nce testing,Start Up Information Management; Procedure development Safety and risk management; Permit systems Job safety analysis Planning and control; Budgeting and cost control; Commissioning strategy.,Management Issues,Technical Issues,Plant preparation and isolation; Utilities and Electrical Sys
7、tem Commissioning Equipment Specific Commissioning Issues Machinery/ Rotating Equipment Vessels, Towers and pipe work etc. Removal of hazardous substances and purging Instrumentation commissioning,Task force responsibilitiesDuring design stage,Review design for safety and operability Carry out HAZOP
8、 and other safety studies operating procedures Arrange modifications required Recruitment, training of operations Specify maintenance activities Select and purchase maintenance supplies and spare parts; Negotiate with vendors and contractors; Keep up maintenance records; Make detailed designs of any
9、 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 majo
10、r piece of equipment Locking out electrical systems Instructions covering atmospheric testing, type of test and permissible limits of contaminants.,Safety in Maintenance - 2,Definition of type of permit required to carry out work Type of equipment required for maintenance Description of personal pro
11、tection equipment required Instructions regarding emergency equipment Instructions on potential hazards Emergency procedures,Spare Parts and Maintenance Minimum Inventories for Commissioning and Start-up,manufacturers recommended spare parts for motive equipment - avoid duplication gaskets for vesse
12、ls 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 ranges Thermometers
13、 and any special instrument parts Rupture disks Pipe insulation materials including jacketing Lubrication oils and greases Spare parts for electronic Costs for normal startup equipment, materials and personnel; Costs for unexpected changes and additions; Costs for mechanical equipment breakdowns.,Es
14、timating plant startup B = Process factor 0.05 for radically new process 0.02 for relatively new -0.02 for familiar process C = Equipment factor 0.07 for radically new 0.03 for relatively new -0.03 for familiar equipment,D = Labour factor 0.04 for labour in very short supply 0.02 for labour somewhat
15、 scarce -0.01 for surplus labour N = Number of process units involved E = Dependency factor 0.04 for interdependent process units 0.02 for moderately dependent -0.02 for independent plants.,Estimate Startup TimeTime = a(0.15 + b + c + d +Ne),a = Construction Time b = Process factor 0.15 for radicall
16、y new process 0.05 for relatively new -0.01 for familiar process c = Equipment factor 0.15 for radically new 0.08 for very new 0.05 for relatively new -0.01 for familiar equipment,D = Labour factor 0.15 for labour in very short supply 0.05 for labour somewhat scarce -0.01 for surplus labour N = Numb
17、er of process units involved E = Dependency factor 0.25 for interdependent process units 0.10 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
18、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
19、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 Costs Cost = 100 (0.10 -0.02 -0.03 + 0.04 +1*0.02) = 100 * 0.11 = $11 Million Startup Time Time = 8(0.15 -0.01-0.01+ 0.15+1*0.1) = 8 * 0.38 = 3 Months,