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Commissioning Approach Integrated Service Solutions.

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Presentation on theme: "Commissioning Approach Integrated Service Solutions."— Presentation transcript:

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2 Commissioning Approach Integrated Service Solutions

3 optimising maintenance costs maximising plant productivity preserving asset integrity Conduct Plant operation Technical assistance for O&M Engineering Commissioning O&M Procurement Construction Plant Life Cycle - Dynamic simulation support - Process data reconciliation - etc. - Turnover Management Methodology - Pre-commissioning - Commissioning / start-up - High Tech. Support - technical assistance - Spare Parts - M.M. (Material Management) - I.P.O.S. (Integrated Procurement outsourcing services) Training Integrated operation & maintenance IOP Simplant® ClassroomHands-on Training Side by Side

4 Engineering Commissioning O&M Procurement Construction Plant Life Cycle - Dynamic simulation support - Process data reconciliation - etc. - Turnover Management Methodology - Pre-commissioning - Commissioning / start-up - High Tech. Support - High tech. personnel - Spare Parts - I.P.O.S. (Integrated Procurement outsourcing services) Training optimising maintenance costs maximising plant productivity preserving asset integrity Integrated operation & maintenance IOP Simplant® ClassroomHands-on

5 Turnover Management Methodology Preparatory works (Home office activities) Mechanical Completion verification Precommissioning Commissioning End Main RootMain ActivitiesCertificates/Issues Tool for Mesurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc) Field inspections, documentation inspection (outstanding Item verification) Inspections, Punch-list issueing, utilities comm, cleaning, flushing, blowing, chemical cleaning, non operating adjustment, motor run-in, catalyst, internal inspection,... Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, …….. Turnover management system operating manual check and preparation Interim Handover Certificate verification (P/L outstanding) Ready for Commissioning Certificate Ready for Start-up Certificate Performance Tests Conduct performance tests Provisional Acceptance Certificate Start-Up Oil-In Ready for performance test

6 Home Office Phase (Preparatory work) The Turnover Management System will allow to: Manage QA/QC certificates Manage Construction piping activities Manage Construction electrical activities Manage Construction instrument activities Manage Construction machinery activities Manage Construction punch lists Have Construction progress per area Have Construction overview progress Have day by day reports Manage the transaction between construction and commissioning activities Manage pre-commissioning activities based on construction progress Manage punch list outstanding items Manage pre-commissioning and commissioning punch list Manage Turnover progress and certificates Manage mechanical completion progress, certificates and activities Manage reinstatement progress, certificates and activities Manage ready for pre-commissioning turnover progress, certificates and activities Manage ready for commissioning turnover progress, certificates and activities Manage performance test turnover progress, certificates and activities Manage provisional acceptance turnover progress, certificates and activities Dossiers management Preparatory works (Home office activities) Tool for Measurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc) Turnover management system operating manual check and preparation

7 SYSTEM START-UP PASSWORD ADMINISTRATOR'S AREA Construction Reports & Progress Commissioning PipingElectricalInstrumentMachninery Punch List Management Mechanical Completion Flushing Tighteness Test Performance Test Provisional Test Acceptance Test Loop Check Dossier Filling Handover Management Outstanding Item management Preinst. Installat. Operation Type 1 Type 2 Type 3 Type 4 Type 1 Type 2 Type 3 Type 4 Welding Piping Hydrotest Reinstat. Turnover Management System System layout USER'S AREA

8 Turnover Management System System detail pictures 1) Main password 2) Main Menu 3) Instrument management system 4) Piping Menu 5) Punch List management system 6) Punch List Out standing Item 7) Piping Construction management system8) Equipment Management system 9) Hydrotest Progress

9 Pre-commissioning and Commissioning Manual will be supplied as a collection of precommissioning procedures; these procedures are operating instructions for the activities to be carried out during the performing of precommissioning. The list of the procedures of the pre-commissioning manual is the following: Mechanical Preparation Chemical Cleaning Instructions Physical Cleaning Instructions Mechanical Restoration Machinery Run in Tightness test Electrical testing/functional tests/energising Instruments calibration and functional test Loading of chemicals Loading of catalyst Heaters drying Chemicals boil out of steam generation facilities Verification of Mechanical Completion Performance Test Operating Manual with the following contents: Introduction General Basis of design Duty of plant Environmental conditions Feedstocks and products specifications Battery limit conditions Specifications and consumption of utilities, chemicals catalysts Process Description Description of flow Process Variables Process Theory Preparation for Initial Start-up General Plant Inspection Cleaning of Piping and equipment Specific pre-start-up operations Start-up procedure Normal Operation Normal Shutdown Procedure Emergency Shutdown Analytical requirements Attachments (P&IDs, Class Specifications and other Project documents) Pre-commissioning and Commissioning ManualOperating Manual Pre-commissioning & Commissioning manuals preparation & check

10 Mechanical Completion verification Field inspections, documentation inspection (outstanding Item verification) Interim Handover Certificate verification (P/L outstanding) In order to optimize time and costs we will: Verify the mechanical completion Punch list outstanding items via field inspections and certificates control and registration; Plan the pre-commissioning and commissioning activities based on the real situation

11 Precommissioning Inspections, Punch-list issueing, utilities comm, cleaning, flushing, blowing, chemical cleaning, non operating adjustment, motor run-in, catalyst, internal inspection,... Ready for Commissioning Certificate inspection punch-listing utilities commissioning cleaning flushing blowing chemical cleaning non operating adjustment motor run in vessel loading internals catalyst desiccant resins packing drying machinery alignment instrument calibration loopchecking orifice plates installation safety valves bench test tightness test

12 Commissioning Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, …….. Ready for Start-up certificate Check all spring hangers Start up cooling water system,which may include Chlorinator Run in pumps on water,where possible, and establish Circulation Start up compressors,where possible,on nitrogen and air Activate the inert gas system Light flare pilots, if used, and activate flare purges at the extremity of lines in the unit Turn on the fuel gas system to process burners Start up the fuel oil system to process burners Boil out the steam generator (if it has not been chemically cleaned during pre-commissioning) Commission water treating facilities Implement steam system andsteam trcing before insulation is checked Activate condensate systems Purge equipment, where required Perform operational pressure test Run required vcuum tests Dry out refractories and heaters and special lines Reactor system dry out Check waste-treatment area for operation Circulate chemical solutions where required Activate catalysts where required Prepare for and circulate test oil Recheck all trip circuits and their bypasses Practice normal and emergency shutdowns. If time allows, practice restarts

13 Performance Tests Conduct performance tests Provisional Acceptance Certificate Performance Tests Procedures preparation and validation Systems preparation for performance tests Conduct performance test in order to meet process guaranteed figures Start-up Oil-in Ready for Performance test Introduce feed at low flow rate Adjust temperatures, pressures, levels and flows Route off-specifications material to the designated areas When the product reaches the specifications route it to storage Increase slowly the feed rate to the Unit until the designed value.

14 Pre-commissioning & Commissioning typical organization chart Comerint Main Contractor

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19 Comerint Organisation Chart

20 EPC CONTRACTORSOWNERS OPERATIONS MAINTENANCE CONSULTANCY SERVICES TRAINING AND HRD (CTS) ENGINEERING AND TECHNICAL DEPT. SUPPORT SERVICES (SIMULATION) ENGINEERING AND TECHNICAL DEPT. SUPPORT SERVICES (SIMULATION) COMMISSIONING START-UP Comerint services during Plant Life Cycle


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