Commissioning of Instrumentation

MRPL, Phase-III Refinery Project, Mangalore, India

S-01838/KSIN & ASDO

1 Electrical and Instrument Engineering Department

Commissioning of Instrumentation

MRPL, Phase-III Refinery Project

Mangalore, India
97,293 Nm3/h Hydrogen unit

Speaker:

Kuldeep Singh & Ashish Dogra

Electrical & Instrument Engineering Department

2 Electrical and Instrument Engineering Department

Kuldeep singh & Ashish Dogra

Kuldeep Singh

Education: B.Tech in Instrumentation (2001)

Employed with Topsoe: Since Jan 2009
Engineering: Ammonia, Hydrogen, Methanol,

Ashish Dogra

Education: B.Tech in Electronics (2004)

Employed with Topsoe: Since Sep. 2010
Engineering: Refinery, Hydrogen

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 Participants background

Operators?

Instrument Maintenance?

Mechanical Engineers?

Instrument Engineers?

Process engineers?

Other?

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Topics

Planning

Documentation for erection and commissioning

Checks during mechanical erection

Calibration

DCS, ESD & subsystems

Critical loops and 2oo3 philosophy

Test of electrical system and cables

Pressure & leak tests

Tools required at site

Precommissioning

Commissioning (loop check)

Assemble all erection and check documentation

Hand over to operation

Initial controller settings to use at plant start-up

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The key to a successful start-up is Planning

Develop a detailed work plan

Fix responsibilities within the instrument “team”

Agree on work rules with other disciplines

Resources:
- staff
- equipment
- vendor specialists
- documentation

Time schedule
- instrument tests and loop checks make up 20-25 %
of the total instrument work at site

Let start-up team make priorities for loop check

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 Documentation for erection and commissioning

Piping and Instrument diagrams

Instrument lists, I/O List, data sheets & detail specifications

Installation drawings (hook-ups, JB’s, cable dwgs. etc.)

Instrument location drawings

Loop diagrams

Vendor documentation

Setpoint list for alarms & trips (maintained by process)

Erection and commissioning schedule
………………….

Forms for check, calibration, loop check etc

Access to documentation from other disciplines

Adequate facilities for copying and distribution

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Checks during mechanical erection

Flow elements:
- check and measure pipe ID and circularity
- check grinding of flange welds
- tapping orientation
- flow direction and straight lengths
- check and measure flow element bore
- check flow element calculations
- store orifices in a safe place until installation

Nozzle allocation

Check control elements that later will be boxed up

Check accessibility of instrument tappings, valves etc.

Solve conflicts (fouling) with other disciplines
- it is not always the one that came first that is right !

Co-ordinate cable runs with electrical

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Flow
Orifice

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 Flow
Nozzle

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Calibration

Be sure that your calibration equipment is calibrated
and certified by an approved and renowned authority

Be sure that you have the necessary and adequate
calibration equipment

Allow electronic calibration equipment to warm up

Record calibration results on dedicated forms, that
later can be used as maintenance files

Set up the calibration system:
- who will do what
- procedures for calibration
- procedure for witnessing
- clearly mark instruments that have been calibrated
- check ranges and settings against the engineering
documents

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Calibration ...

All instruments should be calibrated or checked:
- dp cells
- pressure transmitters
- displacement level transmitters
- pressure gauges
- filled temperature elements
- thermocouples and RTD’s
- control valves
- safety relief valves
- analysers
- switches (process and electrical)
- speed and vibration probes
- flame detectors
- Combustible & Toxic gas and fire alarms
- etc

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 Calibration Record Sheets

Transmitters, indicators, recorders

Switches

Temperature elements

pH transmitters

Control valves and accessories

Safety relief valves

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Transmitters
Indicators
Recorders

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Switches

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 Temperature
elements

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pH
transmitters

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Control valves
and accessories

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 Safety relief
valves

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DCS, ESD & subsystems

After installation and power up and before connecting
field cables the systems shall be thoroughly tested (SAT)

A thorough FAT shall be done at the vendor before the system
arrives at site

The tests should preferably be done together with vendor
specialists.

Take care of proper grounding (electrical and signal)

Keep software back up copies in a safe place

Set up procedures for software and hardware changes

Limit access to systems (both operator area and marshalling area)

Test function of UPS

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Critical loops and 2oo3 philosophy

Steam/ Carbon ratio, feed MW and IS-1 actuation

MOV interlocks

DCS close loops

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 Test of electrical system and cables

Cabling:
- signal wiring (4-20 mA, thermocouple, RTD etc.)
- power
- control wiring (signal exchange with electrical)
- grounding

Execute and record tests:
- insulation test (to be done after stripping and
glanding but before termination of cable)
- visual inspection of workmanship, ferrulling,
shielding, grounding, cable laying, segregation etc.
- continuity test (including shields and drain wires)
- be aware of ground loops

Avoid repair of damaged cables, pull new ones

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Pressure and leak tests

Hydrostatic test of hook-ups and impulse lines shall take place after
full assembly and verification of correct material choice.

Co-ordinate test pressures with mechanical.

Set up procedures for tests, witnessing and records.

Remember to test vessel mounted instruments and instrument air
distribution systems.

Clearly mark tested installations.

Set up a procedure with mechanical to handle leaking root valves.

Tube installations to be checked with manufacturer’s gap inspection
gauge

Remove test medium after test

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Pressure and leak tests ...

Check that instruments can withstand the test pressure.
- many differential pressure instruments cannot
withstand full test pressure on one side only.

Dry out instrument air piping after test.

Pneumatic tubing shall be checked for leaks using
instrument air. Bubbler test is recommended.

Remember to blow out pneumatic tubing.

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 Tools required at site

Hand held pressure caliberator

HART calibrator

Multimeter

Stop watch to record opening and closing time of valves

Measuring tape for checking Orifice Meter run

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Precommissioning

Precommissioning is the work done after the erection is completed
but before the instruments are energised.

Check that the erection is made in accordance with the engineering
drawings: hook-ups, P&I diagrams, JB drawings etc.

Check that the required tests and calibrations as described before
have been done.

Precommissioning includes check of wiring, cabling, junction boxes,
air supply and painting.

Set up procedures and records.

Precommissioning is the final check for single instruments as
pressure, level and temperature gauges.

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Installation
check sheet

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 Commissioning (loop check)

Commissioning (loop check) is the work done after
precommissioning with the instruments energised (electrical and
pneumatic).

Definition:
“A loop consists of two or more instrument components that
interchange common intelligence”

The loop check brings together all the previous work of checking
and testing and shall ensure that nothing is overlooked.

In a loop check the complete transmission line from the process side
of the measuring instruments to/via the indicator/display/controller to
the final control element is checked.

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Commissioning (loop check) ….

The loop check includes connections to other loops.

Loop check may involve other disciplines like electrical.

Set up procedures and records for loop check.

Set up procedures to involve process or operating staff in the loop
checks.

Keep lists of and clearly mark (where possible) which loops that
have passed the test.

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Loop
check sheet

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 Assemble all erection and check documentation

Often this topic is “forgotten”.

The erection and check documentation is of high value during plant
running and trouble shooting.

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Hand over to operation

Set up a formal procedure for handing over the instrument system to
operation.

The procedure should
- allow for part hand over
- define who takes instruments on-line
- define who makes the tuning of controllers

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Initial controller settings to use at plant start-up

(none-critical loops)

Reasonable initial controller settings give the start-up team time to

concentrate on critical loops

.. and minimise the risk to switch controllers to manual mode (and
leave it there forever)

The main practical objective during start-up is to limit the amplitude
of oscillation.

The ideal objective: Stability can be taken care of later.

Assumptions for recommended settings:
Proper sizing of valves, vessels, instrument ranges, minimum
process dead time etc.

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 Initial controller settings….
Primary influences:

The process transfer function -

- how sensitive
- how fast

The sensor (transmitter) -
- input span
- transient response

The controller itself -
- proportional action
- reset action
- rate action

The final controlling element

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Initial controller settings…

Liquid level

Proportional action is all that is needed; however reset action is
often added to keep the level at set point after a load change. With
reset action the loop can never be ideally stabilised (two
integrators).

Recommended settings (displacer or dp-cell sensor):
Proportional band - 20 %
Reset - 5 repeats/min
Rate - 0 min (for dp-cells the rate can
be set to cancel out the transmitter dampning)

Surge tank: reset - 1 repeat/min and
time-const. x max. flow x 100%
Prop. band = ------------------------------------------------
tank area x span of sensor

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Initial controller settings …

Pressure

Slow systems (e.g. gas and large volume):

Proportional band - 200 % x overshoot / span
Reset - 2 repeats/min
Rate - 0 min

Fast systems (e.g. gas and small volume or liquid):

Proportional band - 200 %
Reset - 20 repeats/min
Rate - 0 min

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 Initial controller settings …
Temperature

Thermal systems (e.g. heat transfer):
Typical large time constants and negligible dead
time.
Proportional band - 200 % x overshoot / span
Reset - 0.2 repeats/min
Rate - 0.5 min

Mixing systems (e.g. steam or water injection):

Typical dead time.
Proportional band - 200 % x overshoot / span
Reset - 0.2 repeats/min
Rate - 0 min

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Initial controller settings …

Flow

Flow loops are most often fast and behave like fast pressure loops:

Proportional band - 200 %

Reset - 20 repeats/min
Rate - 0 min

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Graph

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 Graph

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Reformer furnace Pressure Transmitters

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Magnetic level gauge

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 Cable ducts

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Analyser shelter

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Rack room

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 Questions

?
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