Commissioning

Bio Process and Refinery Plant

Irwan
Depok, FTUI
16 Feb 2017
 Feasibility Study

40%
FS

PJ Cost

±30%-
Estimate
Conceptual
Design

PJ Cost
Estimate
±20-30%
Front End
Engineering

±10%
PJ Cost
FEED

Estimate
Estimate
Bidding
E

Engineering

Basic Design
Procurement
P

Detail Design
C

Construction
Typical Flow Scheme of PJ

Operation
&
Maintenance
O&M
 What is Commissioning?
A process of documentation, adjustment, testing,
verification, and training, performed specifically to
ensure that the finished facility operates in
accordance with the owner’s documented project
requirements and the construction documents.

It begins in pre-design and continues through

design, construction, and the life of the facility.
 What is Commissioning?
The commissioning process provides
the framework to verify that a
facility and its systems will function
to meet the design intent and the
owner's needs and to coincide with
the phases of a construction project.
(Applying the PMBOK® Guide Will Enhance the
Commissioning Process and Result in Greater Project Success

- by Aaron Pankonin, CBCP, CAPM)
 Commissioning and Start-Up Process

STAGE INPUTS ACTIVITIES OUTPUTS

• Pre-Mechanical • Design Criteria • Commissioning Procedures
Completion • Test Packages
• Equipment List • Line Cleaning
• Punch Lists
• Discipline Mechanical • Commissioning Strategy • Inspections
• Field Acceptance Tests
Completion • Operation Procedure • Static Test
• Transfer of Authority
• Mechanical Completion • FAT Reports • Mechanical Completion
Commissioning Process

• Design Criteria • No Load Tests

• Commissioning Plan • Function Testing
• Test Sheets
• Commissioning Procedures • Tightness Test
Static Commissioning • Operating Procedures • Energisation
• Punch Lists
• Authority to Energize
• Vendor Coordination/Support • Verification of Control Logic
• Punch Lists • Operator Training

• Chemical Cleaning
• Punch Lists • Handover Packages
• Mechanical Running Test
• Commissioning Procedures • Punch Lists
• Inerting & System Drying
Dynamic • Process Unit Operation
• Refractory Dry-Out
• As Installed Documents
Parameters • Operator Training Docs
Commissioning • Control Logic Review
• Control Logic Verification
• Warranty/Remedial Work
• Steam Blowing
• Vendor Coordination/Support • Statuary Compliance
• Commissioning by System

• Competence Resources
• Operating Procedures • Safe Start-Up Activities • Sustainable Production
• Start-Up • Feed Stock • Performance Testing • Performance Report and
• Stabilize Operation • Final Project Documents
• Vendor Supports
(Equipment/Unit/Overall Plant) Defficiencis Report if any
• Ramp-Up • Product Commissioning by • Target Operation Efficiency for 1st
• Operation Consumables and Contract
• Continuous Operation Supports Operable System year operation (min. 80%)
• Maintenance & Integrity System
What is Commissioning?
(validates the “design”!) “retro” ;
“re”; or
Commissioning “ongoing”
Cx
Commissioning
validates the design!
Design That the design works and
Intent meets the “design intent”

Design Construction O&M

Changing
That the construction is installed “Inspections”
Needs
validate
correctly per the “design”
construction This is not commissioning!
 What Commissioning is NOT?
– Completing Standard Forms
– Contractors’ QA/QC Program
– Verification of the Contractors’ QA/QC
Program
– Construction Inspection
– Construction Management Substitute
 Commissioning Process

What is wrong in this pictures?

What is wrong in this pictures?
 Typical Plant Performance during
Commissioning and Start-Up
Nameplate Trouble free Start-Up and Operation

Expectation:
What performance
should look like
Performance

Historical:
Typical Plant
Performance Curve
over time

CSU & first year of operation

 Elements of Commissioning

 Design Intent Documents (DID or OPR)

 Design Reviews
 Submittal Reviews
 Site Observations and Site Meetings
 Resolution Tracking Forms (RTF’s)
 System Verification Checklists (SVC’s)
 Organized Systems Start-Ups
 Functional Performance Tests (FPT's)
 Operation and Maintenance (O&M) training
 O&M Documentation
 Commissioning Report
 Warranty Review of Plant Operation
 Approaches to Commissioning

– Comprehensive Commissioning

– Construction Phase Commissioning

 Phases of Commissioning
Pre-Design Phase
Design Phase
Construction Phase
Acceptance Phase
Post-Acceptance Phase
Pre-Design Phase is CRITICAL!
 Construction Phase
– Review submittals
– Update commissioning plan
– Coordination including site observation, Cx
Meetings, Resolution Tracking Forms (RTF’s), and
System Verification Checklists (SVC’s)
– Equipment and systems start-ups
– TAB HVAC systems
– Verify Building Automation System (BAS)
installation and start-up
 Acceptance Phase

Review TAB Report

Functional Performance Tests (FPT’s)
O&M Training and Documentation
Commissioning Report
 Post Acceptance Phase

Correct unresolved deficiencies and

conduct required re-tests
Carry out specified off-season testing
Perform specified post-occupancy
monitoring
Review usage changes
Update commissioning documentation
 Why Commission?

Better Plant and Stable Operations

 Plants owners are finding that the energy, water,

and productivity savings achieved by
commissioned the plant can offset the cost of the
commissioning process. Studies indicate 8 to 20
percent savings in plant operating costs over
those in a non-commissioned building.
 Why Commission?
Better People

 Aside from achieving documented cost savings

and cost avoidance, commissioning enhances
customer satisfaction by promoting proper
training of the owner’s Operations & Maintenance
staff, which increases the longevity and efficient
operation of Bio Process and Refinery Plant
systems.
 Typical Commissioning
Instructions
• Pre-energising activities
• Energising the plant
• Conditioning equipment, calibrating instruments and
setting relief valves
• Final check-out and closing up all vessels
• Preparation of start-up
• Start-up
• Lining out
• Performance test runs and guarantee test run
Much of this done by the future operators of the plant
What is cost and value of
commissioning?
What Does Commissioning Cost?
Commissioning (Cx)
(New Construction)
0.5 to 1.5 Percent of Total Construction Cost

Retrocommissioning (RetroCx)
(Existing Construction)
3.0 to 5.0 Percent of Total Operating Cost
 Commissioning Costs

Commissioning New Construction

 Approximately 2%-3% of Mechanical System
Construction Cost
 Approximately 1%-2% of Electrical System
Construction Cost
 Approximately 2%-5% of Comprehensive HVAC
Construction Cost
What Does Commissioning Cost?
The Economics of Commissioning
If planned correctly and implemented early
enough in the design process, commissioning
can be included with little or no cost impact*.

Without Commissioning
First Year Warranty
Design Phase Construction Phase Costs
Period Costs
Costs

With Commissioning
Design Phase Construction Phase Costs First Year Warranty
Costs Period Costs
Commissioning of a project
TITLE SLIDEis a term
that has different interpretations
depending on who is using it.
 Team Effort

Commissioning succeeds when…

Team members understand and carry out
their responsibilities
Team members cooperate and coordinate
with each other and third-party agencies

Communication and accountability essential

for effective teamwork – and they are the
responsibility of the commissioning agent.
 Problems always occur during
• Poor Planning Commissioning
• Ineffective Leadership
• Rushed Installation
• Poor Quality Work
• Too Few Resources
• Inexperienced Resources
• Inadequate training
• Poor design
• Sabotage

• Plant commissioning is the first of many start-ups

• Potentially hazardous: ability to operate not proven
• Many unknown factors
• First start-up & subsequent shutdowns and start-ups
• Excellent experience and expertise building for operators and
maintenance personnel
 Terminologies
PRECOMMISSIONING…Pre-commissioning activities are the non-operating work responsibilities such as adjustments,
cold alignment checks, line cleaning, piping reinstatement, instrument loop check, etc. performed by the contractor prior to
ready for commissioning or mechanical completion.

READY FOR COMMISSIONING…Occurs when the plant or any part of the plant has been erected in accordance
with drawings and specifications and the pre-commissioning activities have been completed to the extent necessary to permit
commissioning activities to begin.

MECHANICAL COMPLETION… Occurs when the plant or any part of the plant has been erected in accordance with drawings,
specifications and applicable codes and the pre-commissioning activities have been completed to the extent necessary to
permit the client to accept the plant and begin commissioning activities. The terms ready for commissioning and mechanical
completion are often synonymous.

COMPLETION OF WORK…Means that the contractor has erected the plant in accordance with drawings and
specifications completed his specified pre-commissioning work and completed his final cleanup, painting and thermal
insulation work.

COMMISSIONING…Commissioning activities are associated with preparing or operating the plant or any part of the plant
prior to the initial start up and some project will be the owner’s work responsibilities. The Commissioning activities such as
tightness test, inerting, system drying, etc.

INITIAL START UP…occurs when feedstocks are introduced to the plant for the express purpose of producing a product
for the first time.
 The clue for Commissioning
Planning
How planning completes commissioning on paper?
As a commissioning team, people learn the
thought, the logic, and approach that led to the
plan.

“Planning has a six-to-one payoff in execution”

for every one hour we spend in planning, we

save six hours in execution.
 Commissioning Activities Terminology (1/2)
LINE CLEANING by water flushing, air blowing, acid cleaning and
steam blowing… To remove dirt, welding slag, etc. Arrange for
cleaning media for carrying out flushing/blowing and disposal of the
cleaning media in accordance with environment regulation. The
minimum velocity of cleaning media to be maintained to achieved good
result for flushing/blowing of piping.

After completion of all pre-commissioning activities, TIGHTNESS

TEST/LEAK TEST of complete process facilities including piping,
equipment, instrument connections etc. with operating pressure condition
is to be carried out in accordance with approved procedure.

INERTING/PURGING… is an industry standard technique for the

replacement of a hazardous or undesirable atmosphere with an inert dry
atmosphere. The two most common methods of purging are
displacement and dilution. The geometry of the process system
determines which method is used. For simple systems, displacement
purging is usually more effective in terms of time and cost but, for more
complex systems, dilution purging is used.
 Commissioning Activities Terminology (2/2)
SYSTEM DRYING….To remove water and moisture from pipes,
instrumentation and equipment that are not normally water filled during
operation, and to avoid hydrate formation. This application can be
applied by dry gas such Instrument Air, Nitrogen or Hydrocarbon Gas
that no water content.

MECHANICAL RUN TEST OF ROTATING EQUIPMENT….To check

the mechanical integrity and condition such as vibration, noise, heat
generation, overload, etc. of rotating equipment including drivers and
auxiliary equipments.

PASSIVATION FOR COOLING WATER AND AMINE SYSTEM….To

protect the inner surface of piping and heat exchangers in a circulation
loop from corrosion. Passivation is carried out to form a corrosion
resistant film on the inner surface of a new and existing circulation loop
system.
Specific Commissioning Activities on Bio Process Plant

• Agitator Dry Run

• Chemical Cleaning for Packed Column and Tower
• Hot Water Circulation for rinsing
• Vacuum Test for insulation or jacket reactor
• Chemical Rinsing
• Filter Pressure Drop Test
• Lube Oil Flushing
Questions, Comments, Discussion