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 ..

Constructio
n

Mechanical
completion
Provisional
acceptance Acceptanc
e
Precommissioning,
Inspection and Start up and
Operational
Performance Post
Testing
testing
commissioning

Construction and Commissioning

How it happens ..

Constructio
n
Pre-commissioning,
Inspection and
Operational Testing

Mechanical
completion
Progressive provisional
acceptance Progressive
acceptance

Start up and
Performance
testing

Post commissioning

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

Preparation and planning
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning

Appointment of Commissioning
Manager or Lead Commissioning
Engineer;
Appointment of Commissioning Team
Members and Support Staff;
Training;
Information Compilation;
Safety and Risk Assessment;

The Commissioning Process Detail - 2

Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning

Inspection
Pressure testing
Cleaning and Flushing
Machinery checkout

The Commissioning Process Detail - 3

Preparation and planning
Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning

Steam and other utilities

introduced;
Dry running trials;
Hot running trials;

The Commissioning Process Detail - 4

Preparation and planning
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation

Performance and
Acceptance testing
Post Commissioning

Introduction of process fluid

Start-up and initial operation
Trouble-shooting and

The Commissioning Process Detail - 5

Preparation and planning
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation
Performance and
Acceptance testing
Post Commissioning

Performance trails;
Formal Acceptance test

The Commissioning Process Detail - 6

Preparation and planning
Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing
Start Up & Initial
Operation

Performance and
Acceptance testing
Post Commissioning

From plant on-stream to settled

down and in regular production;
Adjustments, modifications and

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.

Technical Issues

Preparation and planning

Mechanical Completion
and Integrity checking
Pre-commissioning &
Operational Testing

Start Up & Initial

Operation
Performance and
Acceptance testing
Post Commissioning

Plant preparation and

isolation;
Utilities and Electrical
System Commissioning
Equipment Specific
Commissioning Issues
Machinery/ Rotating
Equipment
Vessels, Towers and
pipe work etc.
Removal of hazardous
substances and purging
Instrumentation
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

manufacturers 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