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 & subsequent shutdowns and startups

● Excellent experience and expertise building for

operators and maintenance personnel.
 Start-up and Commissioning apply to

● Entire facilities in Greenfield projects

● Major expansions or additions to existing plants

● Re-commissioning of plants and equipment;

● Individual items of plant, eg

● Boilers

● Instrument air compressors etc

 Delays in Startup & Commissioning
expensive!
● slow start-ups reduce the Return on Investment
● delayed revenue stream

● Increased cost of delivery

● Financial viability

● ~20-25% of construction time (good planning)

● Causes of delays:
● 75% due to equipment failure

● 20% from inadequate equipment

● 5% from process failure

 Details vary depending on plant but
procedure remains the same
● prepare, plan and execute startup
● commissioning management

● Preparation of specific plant procedures

● Management of risks

● Safety & environmental compliance

 Construction & Commissioning
How we would like it …..
Mechanical
completion
Provisional
acceptance Acceptanc
Constructio
n e

Pre-
commissioning,
Inspection and Start up and
Operational Performance Post
Testing testing commissioning
 Construction and Commissioning
How it happens …..
Mechanical
completion
Progressive provisional
acceptance Progressive
Constructio
n acceptance

Pre-commissioning,
Inspection and
Start up and
Operational Testing Performance Post commissioning
testing
 Commissioning in practice

● Progressive mechanical completion and concurrent

commissioning creates challenges:
● Coordination and planning

● Safety and risk

● Isolation

● Testing

● Integration into operating plant

 From construction to commissioning

● what constitutes mechanical completion?

● on completion, start-up can officially commence

● problems when part of a plant are commissioned

while construction not yet finished.
The Commissioning Process
Key Stages
Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

Start Up & Initial

Operation

Performance and
Acceptance testing

Post Commissioning
 The Commissioning Process Detail - 1
● Appointment of Commissioning
Preparation and planning
Manager or Lead Commissioning
Engineer;
Mechanical Completion ● Appointment of Commissioning Team
and Integrity checking
Members and Support Staff;
Pre-commissioning &
● Training;
Operational Testing ● Information Compilation;
● Safety and Risk Assessment;
Start Up & Initial
Operation

Performance and
Acceptance testing

Post Commissioning
 The Commissioning Process Detail - 2
Preparation and planning
● Inspection
Mechanical Completion
and Integrity checking ● Pressure testing
● Cleaning and Flushing
Pre-commissioning &
Operational Testing
● Machinery checkout

Start Up & Initial

Operation

Performance and
Acceptance testing

Post Commissioning
 The Commissioning Process Detail - 3
Preparation and planning

Mechanical Completion
and Integrity checking
● Steam and other utilities
Pre-commissioning & introduced;
Operational Testing
● Dry running trials;
Start Up & Initial ● Hot running trials;
Operation

Performance and
Acceptance testing

Post Commissioning
 The Commissioning Process Detail - 4
Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

Start Up & Initial ● Introduction of process fluid

Operation
● Start-up and initial operation
Performance and ● Trouble-shooting and
Acceptance testing

Post Commissioning
 The Commissioning Process Detail - 5
Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

Start Up & Initial

Operation

Performance and ● Performance trails;

Acceptance testing
● Formal Acceptance test
Post Commissioning
 The Commissioning Process Detail - 6
Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

Start Up & Initial

● From plant on-stream to settled
Operation down and in regular production;
● Adjustments, modifications and
Performance and
Acceptance testing

Post Commissioning
 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
Management Issues
● Organisation and roles;
● Information
Management;
● Procedure development
● Safety and risk
management;
● Permit systems
● Job safety analysis
● Planning and control;
● Budgeting and cost
control;
● Commissioning strategy.
Preparation and planning Technical Issues
● Plant preparation and
isolation;
Mechanical Completion
and Integrity checking ● Utilities and Electrical
System Commissioning
Pre-commissioning & ● Equipment Specific
Operational Testing Commissioning Issues
● Machinery/ Rotating
Start Up & Initial Equipment
Operation ● Vessels, Towers and
pipe work etc.
Performance and ● Removal of hazardous
Acceptance testing substances and purging
● Instrumentation
Post Commissioning commissioning
 Task force responsibilities
During design stage
● Review design for safety and operability
● Carry out HAZOP and other safety studies
● operating procedures & maintenance manuals
● Familiarization with the plant
● Check compliance with design, intent and standards
● Documentation for commissioning, operation & training;
● Arrange modifications required
● Recruitment, training of operations & maintenance personnel.
 Typical Operating Instruction Manual

● The Process
● Conditioning and Special Equipment

● Starting Procedures

● Shutdown Procedures
 Maintenance Responsibilities
● Publish work and safety procedures;
● 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 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 & system
● take into account all possible hazards
● Include:
● Instructions for isolating (blinding, draining, venting,
purging) process and utility systems;
● 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 protection equipment required
● Instructions regarding emergency equipment
● Instructions on potential hazards
● Emergency procedures
 Spare Parts and Maintenance
Minimum Inventories for Commissioning and Start-up
● manufacturer’s recommended spare parts for
motive equipment - avoid duplication
● gaskets 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 - 2
Minimum Inventories for Commissioning and Start-up
● Pressure gauges of appropriate ranges
● Thermometers and any special instrument parts

● Rupture disks

● Pipe insulation materials including jacketing

● Lubrication oils and greases

● Spare parts for electronic & analytical equipment.

 Process Plant Machinery Commissioning
Failure Problems
in decreasing order of problem frequency

1. Centrifugal compressors
2. Steam turbines
3. Large gear speed increaser units
4. Electric motors in size categories above 1000 HP
5. Reciprocating compressors
6. Gas turbines
7. Gas expanders
Commissioning Team Information Requirements
● Project design file
● Process file

● Engineering data file

● Plant layout file

● Operating instructions

● Analytical procedures

● Log sheets and calculation procedures.

 Commissioning Documentation
● Technical manual giving process technology and equipment
● Standard operating procedures giving details of each system
● Safety valve and rupture disk manual, listing the design basis
for each safety device, and giving the procedure for taking it
out of service
● Training manual detailing the program for new personnel
● Safety manual setting policies and procedures
● Emergency 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 commissioning
● Empirical rules for estimating both startup time
and startup costs, suitable for initial project budget
 Estimate Startup Costs
Cost = A(0.10 + B + C + D +NE)
● A = Direct fixed capital cost
of project;
● 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 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 Time
Time = a(0.15 + b + c + d +Ne)
● a = Construction Time
● b = Process factor
● 0.15 for radically 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 = Number 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 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 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