Commissioning of Combined Heat and Power Plants: Lessons Learned

July 1, 2008 Presented by Abbe Bjorklund, PE, LEED AP Sebesta Blomberg & Associates and Bruce Nicholson Cooperative Consulting Services, Inc.

Topics Covered

Beneficial commissioning processes Roles and responsibilities Benefits, costs and challenges of a formal startup/commissioning process Coordination and conflict between construction startup/commissioning OEM coordination issues and how to address

Beneficial Commissioning Processes from Construction through Systems Testing, Performance Testing, Environmental Testing, and Reliability Testing

Beneficial Commissioning Processes Design Purchase Install Construct Turnover to startup/commissioning Equipment checkout System testing/initial operation and system functional testing Integrated system/plant functional testing Performance testing Environmental/compliance testing Reliability/acceptance testing Turnover to the Owners/plant final acceptance

Roles and Responsibilities

Roles and Responsibilities

Clearly define roles and responsibilities through design, construction, startup/commissioning

Designer Constructor Independent Commissioning Authority/Agent Startup Engineer Owner

Roles and Responsibilities

Construction and Startup

Where does construction end? Where does startup begin? Need to define formally for each project Construction testing vs. Startup testing

Roles and Responsibilities

Startup and Commissioning

Where does startup end? Where does commissioning begin? Need to define formally for each project

Roles and Responsibilities

Examples from typical projects

Project Organization Chart Roles & Responsibilities by Major Phase Responsibility Matrix Construction Phase Responsibility Matrix Startup & Commissioning Phase

Example: Project Organization Chart

Design Phase Construction Phase Design Engineering Commissioning Agent Construction Manager GTG Vendor HRSG Vendor General Contractor Inst & Controls Electrical Contractor Mechanical Contractor Piping Contractor Construction Management Procure Install Construction Completion Construction Testing

Example Roles & Responsibilities Major Phases

Turnover Package Turnover to SU&C Startup & Commissioning Phase Component System Plant Testing Testing Testing Turnover to Owners

Engineer of record Startup & Commissioning Management

Construction Construction Construction

Startup & Commissioning Support Startup & Commissioning Support Startup & Commissioning Support

Construction Construction

Startup & Commissioning Support

Startup & Commissioning Support Startup & Commissioning Support Startup & Commissioning Support

Construction

Construction

Example Responsibility Matrix Construction Phase

Activity Startup and Commissioning Program Development
Typically 50 to 75 items such as: Review systems turnover package list Review scoped turnover package documents Review Project Punchlist procedure

SU&C
CXing Agent

CONSTRUCTION ORGANIZATION
CM Mech Piping Elec I&C HRSG GTG

OWNER
Representative

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

Construction Completion
Typically 20 to 30 items such as: Complete Required Data Sheets and Test Records Prepare System Completion punchlists Perform System As-Built

X X X

X X X

X X X

X X X

X X X

X X X

X X X

Construction Testing
Typically 25 to 50 items such as: Perform Nondestructive Testing Perform Pressure Testing Verify Installation of Instruments and Controls Schedule Vendors Required for Construction Testing Alignment of Rotating Equipment Megger Cables and Equipment Verify Installation is in accordance with Design Required Equipment Maintenance Interface with Startup on Systems Ready for Turnover Assemble Initial Turnover Packages and records Perform Turnover Walkdown and Exception Lists Initial System Turnover (to SU&C)

X X X

X X X X X X X X X X X

X X

X X

X X X X X X X X X X X

X X X X X X X

X X X X X

X X X X X X

X X X X X X

X X

Example: Responsibility Matrix Startup & Commissioning Phase

SU&C Activity Component Testing
Typically 40 to 50 items such as: Administer Startup Safety Tagging Program Inspect, Test, and Calibrate Instruments and Loops Test major Electrical Equipment Megger Testing, Motor Rotation
CXing Agent Startup & Commissioning Support Team CM Owner Mech Piping Elec I&C HRSG GTG Operations

X X X X

X X X X X

System Testing
Typically 10 to 20 items such as: Interface with local Utilities Lineup System for Operation Initial Energization of Power Supply Systems, Rotating Equipment Initial Run In Functional checks of Controls, Equipment & Systems
X

X X X X

X X

X X X

X X

Plant Testing
Typically 40 to 50 items such as: Perform Final HVAC Balancing Fine Tune Combustion Controls Final Tuning of Instruments, Controls, and Valves Finalize controls & tuning settings, software Execute System Functional Test Procedures Performance, Emissions, Reliability Testing

X X X X X X

X X X X X X X X X X X X X X

Project Completion
Typically 20 to 40 items such as: Finalize System Turnover Packages Finalize Project Punchlist Perform Turnover Walkdowns with Owners

X X X

X X

Benefits, costs and challenges of a formal startup and commissioning process

Benefits

A formal program ensures that an organization with commissioning experience is put in place Formal program includes
Formal turnover process Well-documented functional performance criteria O&M documentation Operator training program

Benefits

Track deliverables
Identified early in the project Are a part of the Contract Specifications Are formally tracked

Benefits Track progress of construction and commissioning with tools developed and implemented which allow for easily tracking the overall process
Master Tracking Matrix Notification schedule Deliverables list Integrated Construction and Startup/Commissioning schedule Project punchlist System turnover exceptions lists

Costs

Turnover process may require an additional person to manage Formal documentation of testing activities
Time to develop formal test procedures, checklists and datasheets Staff hours for testing are relatively the same Additional time to formally document test data and results

Startup & Commissioning Program is typically 2 to 5% of the overall project.

Costs Any cost increase should be offset at the end of the project
System turnover packages and documentation streamlines the review and acceptance Documentation can be reviewed on a system by system basis
System boundaries are defined Each organization has same understanding of the scope of each system. Owner's representatives spot checks the progress and results

Warranty claims can be handled smoothly both during the startup/commissioning phase and after acceptance by the owners
Typically vendors will ask for test data such as:
vibration analysis, meggar records, system cleaning records, lubrication records

Troubleshooting performed more quickly and accurately

The controls system historian and test data used to help identify root cause

Challenges Proper planning early in the project with the right people
Cxing plan that clearly defines roles and responsibilities Detailed commissioning specifications which are included in the RFP All parties embrace a formal startup and commissioning program and fulfill specified roles and responsibilities

Need an Owner that fully supports a formal startup and commissioning program General Contractor develops purchase orders and equipment specifications that include requirements for startup & commissioning

Challenges Involvement of Owners operators in the startup/cxing process Initial operation of equipment and testing on a campus
Some activities are loud, some are sudden and may appear unusual. Campus events can impact the activities of the project Communicate a well thought out startup/commissioning plan and schedule to the general campus population

Coordination and conflicts between construction and startup/commissioning organizations

Coordination and Conflict

Startup Engineer/Cxing entity should report directly to the Project Manager

The Startup & Commissioning team should be a peer of the Construction team Each group has a direct line to the Project Manager

Detailed specifications issued with the RFP help minimize conflicts later
Detailed lists of deliverables and tracking mechanisms

OEM coordination issues and how to address

OEM Coordination Issues

From pre-purchase through construction and startup/commissioning:

Need to coordinate vendors for startup/commissioning Must work as a team Startup Manager must be able to coordinate and direct the OEMs

Beneficial Commissioning Processes Design Purchase Install Construct Turnover to startup/commissioning Equipment checkout System testing/initial operation and system functional testing Integrated system/plant functional testing Performance testing Environmental/compliance testing Reliability/acceptance testing Turnover to the Owners/plant final acceptance

Thank you!
Questions???