plant installation and commissioning pdf

Plant Installation And Commissioning Pdf

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Pre-commissioning or Commissioning Activities

The commissioning phase is a period of intense activity where many previously unrelated activities start to merge or interact with one another forming a complex sequence of events, with the advent of large generating units, the increased complexity of the plant and the closer limits available on the operating parameters, it is essential to ensure that the plant has been thoroughly tested prior to the normal operation so that initial performance can established and defects and omissions clear.

The system described in the document is discussed hereunder,. To established the reasons for any failure to achieve the design performance or any other limitation. The role of each part of the organization must be clear both within its own boundaries and in relation to each other.

The initiative for the setting up the detailed system on the site lies clearly with the Erection Department but in must be emphasized that all activities should be considered jointly by all the above departments. It is a fundamental requirements that staff from all the above department including the contractor must be made available, full time of placing contracts the contractor is made aware of the significant workload that will be placed on him by the introduction of an organized commissioning procedure.

Steering Committee The purpose of this committee is to provide policy and priorities to the activities of the plant erection and commissioning, ensure that adequate resource are available both in material and manpower, to demand and approve programme of work to approve documentation, The committee would normally be chaired by the site General Manager and consists of the senior officers from the Corporate Centre, Site and also senior responsibilities contractors.

The Working Parties are formed for the major plant areas, The objectives of the working party are:. To be aware of target dates and Contractual requirements to effectively assist Erection Department in putting the plant to work. To establish responsibilities and communications with inter plant related Working parties.

To implement the policies and priorities decided by the steering Committee and Commissioning panel. To report to the commissioning panel or Steering Committee as necessary, progress, shortage and delays due to staff shortage, safety requirements, plant access, incorrect test procedures, equipments delivery incorrect programmer or the planning.

To define operational practices so that, when plant is commissioned, the operation of its correct. To Define maintenance information required. At the point when NTPC takes over the protection and maintenance clear instructions must be available. To define drawings and manuals that must be handed over prior to the protection and servicing of the plant.

To define, agree and provide the number the type and content of the Commissioning documents required to fulfill the objectives laid out in the paper of the principle. To define, and issue the necessary certificates which record the stage of the completion of the erection and commissioning, in accordance with agreed procedure. To the established Testing Terms whose members are the working engineer drawn from the various departments and contractors involved in a particular plant area.

To monitor the performance and effectiveness of the Testing Team and to ensure that to ensure that the instructions, policy and procedure set out in the approved commissioning documents are being adhered to.

The Test Team Leader plays a very important role in commissioning. He provides a dynamic communication link between the engineers in the field and the day-to-day commissioning coordinator, He is responsible for the carrying out the agreed procedures and reporting deviations to the Working party and finally for the preparation of the Test Report and results.

Papers of Principle The papers of the principles are prepared jointly by the erection Department and Corporate Center. The Paper of Principle is the first and most vital documents to be produced as it is the base upon which other documents are compiled. Site staff must be made available full time at Corporate Centre to enable the documents to be provided.

The objectives of papers of the principles can be briefly summarized as: i. Testing and Commissioning Schedules Testing and Commissioning Schedules are prepared by nominated members of the Working Party to meet the requirements of the Paper of Principle. It should be recognised that there is a fundamental requirement for contractor to be involved in the production of the documents.

The documents define the plant to be tested or commissioned and cover aspects such as detailed test method, safety, emergencies, detailed programme, individual responsibility and results.

Standard Check Lists, Test Producers and Instruments Proving Schedules Standard Check Lists are intended for use at the completion of the erection to ensure correct erection, testing and to a limited extent, operation, Where items of a similar nature are to be checked, for instance mm parallel slide valves, a simple standard check list issued.

Test procedures are used to ensure that all tests are carried out in a consistent manner, the test producer may procedure maybe referred to as one step on the standard Check List. Instrument Proving Schedules are used where a number of instruments interact to from a minor control system which is to be checked, A second use is to hold together the standard Check Lists for a Major plant Auxiliary.

Design Change Notification With the increased complexity and diverse nature of the modern plant, it is necessary to device, as early as possible during construction, a system of managing and controlling design changes so that all necessary departments are informed.

Where commissioning activates are carried out to fulfill objective and to make objective assessment, it imperative that the results of these activities are properly record from and method and of the presenting results will depend on the nature of the activity and may very from a simple calibration with design specification. The from of the Test reports will decided by the networking by for the plant area concerned.

SAFETY The procedure requires that be tore an item of the plant item of the plant is energized it must come within the scope of the safety Rules and once within that scope be done on that plant item once the requirements of the safety Rules have been met. It a mandatory that a system of the Safety Rules is established.

No plant item may be energized or pressurized until such a Safety Rules systems is an operation, these are statements deigned not to plant, the first being irreplaceable and the second representing a massive capital investment.

In the order to the mark events to the ensure that satisfactory procedures are established, certain technical requirement have been met and safety measure have been taken, certificates are issued at different stage e.

When the plant is fully commissioned up to the design intent, a final completion Commissioning report is to be prepared for the plant. It will include plant details, programmer and schedule and achieved, major deviations, etc.

The name plate legend agrees with the approved NTPC plant Nomenclature is clearly visible securely fixed, durable and correlates with remote labels. The installation is complete and correct in accordance with the latest drawing and specification and support attachments to building Steel work and pipework are secure and satisfactory. Check Marinate rings are correctly fitted and undamaged where appropriate 7.

Check hanger adjusted to cold setting according to manufactures figures. Position when hot. Activity Remarks Portable Dead Weight Tester, Comparator. Or other similar sure of the vacuum source. Standard Test gauge if not using a dead weight tester, other standard pressure vacuum gauge, dependent on the range of the instrument being tested.

The commissioning procedure may be broadly divided into the following stages right from the pre-commissioning checks to the reliability run of the boiler with its auxiliaries. Precommissioning check up the pre commissioning checks are envisaged to the identify the points so that corrective actions can be taken in time so that the commissioning programme can be carried out without unnecessary delays and possible consequent quality deterioration.

Safe running the equipment for 8 hours period with all the interlocks and protections, indications etc. In the case of the items like dampers, gates, valves, etc, freeness of movements, full travel, full closure are checked individually and along with drives.

Pre commissioning Tests: Gas tightness and air boiler pressure tests are carried out identify and rectify leakage points in the systems,. Thermal flow tests: In the order to detect possible chocking in the boiler tubes thermal flow test is carried out.

The water wall tubes, economisers and superheaters tubes are normally checked by means of this test. Steam Boling: Steam purging of super heaters and critical steam pipe lines is carried out by puffing method to remove mill scales weld beads etc.

This is achieved in a number of the stage planned to suit the layout of the system, Re heater safety valves are floated at this stage. Safety Valve Setting: After steam blowing operations, the safety valves drum super heater are required to be set to operate at the desired pressure. Commissioning of the Boiler: After completion of the pre commissioning activities as briefly outlined above, the unit is made ready for rolling of the turbine and synchronizing.

Normally this is followed by bearing inspection of turbine and subsequent loading of the unit. Reliability run of the boiler: After the Boiler has been commissioned and various automatic put in the operation the boiler is taken for the reliability run. The boiler is operated for a predetermined period as agreed upon by the customer and supplier. The commissioning team will organise their activities in such a manner that the following jobs are completed to meet the boiler light up requirements: a.

Many of the above mentioned activities are parallel and with various inputs given in time it may take nearly two months to complete the above jobs. Listed below are the various steps along with tentative time needed to the achieve them from first light up to Reliability run of the boiler.

Preparation for Acid cleaning Removal of Internals, Blanking Flow test comers for the thermal Flow test, putting temporary Piping connection etc,. In the case unit it to be loaded further by coal firing after synchronization before going for the bearing inspection then the following systems are also to be made ready before synchronizing which otherwise needed after bearing inspection.

For both drainable and non drainable portions, normally usages of DM water only is recommended. All non- drainable parts can be filled with DM water or condensate containing 10 ppm Ammonia as NH3 and ppm of the hydrazene with a solution ph value of approximately Economizer, water walls and all drainable portions can be filled with DM water or condensate containing 10ppm Ammonia as NH3 and ppm of the hydrazine with a solution pH Value of a approximately Prior to usage, filtered water quality should be ascertained.

The required quantity of the ammonia and hydrazine should be added into the water of recommended quality and a homogenous mixture should be ensured prior to filling. All the drainable parts, economizer, water walls and the drum should be filled through their respective bottom drains with vents open.

Filling may be stopped vent drum is filled half this can be ensured by keeping level gauge tapings opened. The tank containing clear to the filtered water be drainable and flushed. All the no drainable parts includes drainable super heater should be filled through their bottom drains with the recommended quality of the water containing 10 ppm of the ammonia as NH3 and ppm of hydrazine with a solution pH of approximately Prior to filling a homogeneous mixture of the chemicals and water be ensured.

All the respective vents should be kept opened during filling operation. When water gushes out ensuring free flow from all the air vents including drum, close the air vents.

Now pressurise the system up to the working capacity of the filling pump. Water used should be only DM water containing 10 ppm ammonia and ppm hydrazene with a solution pH of Pressure reading during the tests will be taken from the pressure gauge at the high point of the boiler.

Hydrostatic test pressure shall be as per IBR and contract agreement. The rate of the pressure rise and rate of the pressure drop for the inspection and draining be as per IBR. After successful complain of the hydraulic test, the system may be drained to the as per requirement and kept under wet preservation immediately as per recommended procedure.

In the actual practice, it is found that after first to the hydraulic test, closing weld joints are to be made. Ensure to the as a last of to the water kept to the in the boiler used for to the hydraulic test is having a solution pH of not less than Even during cases of the isolated hydraulic test of drainable portion alone, wet preservation under nitrogen blanket should be practiced for the portion tested.

Periodical tests are for to the pH and hydrazene content should be done for the samples collected from superheater, As and when the pH goes less. The smoke generators are used for the easier direction of the air leak and ingress points. The smoke-generator is a sealed cylindrical container having to the chemical in it which produce huge quantity of the smoke when ignited.

This is being to the produced from the defense stores. Generally to the ignite a smokeGenerator, the seal should to the punctured or removed and it should be ignited with to the help a burning swab, when the chemicals are ignited, they are burnt completely within 10 or 15 minutes and a huge quantity of a smoke is liberated out.

Now the smoke will try to escape into the atmosphere from all known on unknown leakage points Air ingress points these points are noted and later on repaired. If necessary the FD or PA fan can be run to slightly pressurise the furnace. The number of the smoke generators required for the test depends on the volume of the space to the tested. The furnace zone covers up to goose neck and penthouse 4 Nos of gas generators can be used for this zone.

Installation, commissioning and start-up

By Martin Killcross. The Chemical and Process Plant Commissioning Handbook , winner of the Basil Brennan Medal from the Institution of Chemical Engineers, is a guide to converting a newly constructed plant or equipment into a fully integrated and operational process unit. Good commissioning is based on a disciplined, systematic and proven methodology and approach that achieve results in the safest, most efficient, cost effective and timely manner. The book is supported by detailed, proven and effective commission templates, plus extensive commissioning scenarios that enable the reader to learn the context of good commissioning practice from an experienced commissioning manager. It focuses on the critical safety assessment and inspection regimes necessary to ensure that new plants are compliant with OSHA and environmental requirements.

Pre-commissioning or Commissioning Activities

This plant commissioning checklist is used for the commissioning of wastewater projects or treatment plants. Toggle navigation. Features Use cases Pricing Contact us Blog.

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They liaise closely with your construction manager, safety officer, and mechanical contractor to ensure a safe and trouble-free installation.

Power Plant Commissioning.pdf

What are the things to be checked carefully during pre-commissioning or commissioning activities for instrument engineer? Before a plant or facility is handed over for normal operation, it should be inspected, checked, cleaned, flushed, verified and tested. This process is called commissioning and involves both the contractor and operator of a facility. The transition from construction to operation is the commissioning and startup. Processing plant commissioning embraces activities such as cleaning, flushing, verifications, leak tests, performance evaluation and functional tests essential for bringing a newly installed plant or facility into routine operation. Correct commissioning is vital to the satisfactory operation of any plant or facility.

The commissioning phase is a period of intense activity where many previously unrelated activities start to merge or interact with one another forming a complex sequence of events, with the advent of large generating units, the increased complexity of the plant and the closer limits available on the operating parameters, it is essential to ensure that the plant has been thoroughly tested prior to the normal operation so that initial performance can established and defects and omissions clear. The system described in the document is discussed hereunder,. To established the reasons for any failure to achieve the design performance or any other limitation. The role of each part of the organization must be clear both within its own boundaries and in relation to each other. The initiative for the setting up the detailed system on the site lies clearly with the Erection Department but in must be emphasized that all activities should be considered jointly by all the above departments. It is a fundamental requirements that staff from all the above department including the contractor must be made available, full time of placing contracts the contractor is made aware of the significant workload that will be placed on him by the introduction of an organized commissioning procedure. Steering Committee The purpose of this committee is to provide policy and priorities to the activities of the plant erection and commissioning, ensure that adequate resource are available both in material and manpower, to demand and approve programme of work to approve documentation, The committee would normally be chaired by the site General Manager and consists of the senior officers from the Corporate Centre, Site and also senior responsibilities contractors.

In addition, most of the findings are also applicable to The California Energy Commission is leading the state to a percent clean energy future. As the state's primary energy policy and planning agency, the Energy Commission is committed to reducing energy costs and environmental impacts of energy use while ensuring a safe, resilient, and reliable supply of energy. Design, Construction, and Commissioning of the Nos. This paper outlines the operational issues arising from this situation along with establishing a biological process. Next, qualification refers to the activities undertaken to demonstrate that facilities, building systems, and process equipment are suitable and perform as specified in project design documents. Recordation of the quality control data via the check lists may include entering deficiency information. The initiation project may include commissioning of the process plant, and the project history information in the database may be made available for subsequent preventative maintenance or other work during operation of the process plant.


Commissioning of a building or plant is used to ensure that all process systems have been Ensure that applicable equipment and systems are installed properly and graceandknowledgechurch.org​_graceandknowledgechurch.org


Pre-commissioning or Commissioning Activities

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Pre Commissioning Procedure Pdf Pre-start, and start-up procedures 3. Subsea Umbilical and Cable Pre-commissioning. Pre-commissioning work. Chemical cleaning covers a wide range of services from new construction to ongoing maintenance activities.

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Commissioning and start-up is the final step before production runs in a processing plant.

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5 Comments

  1. Salvador M.

    What are the things to be checked carefully during pre-commissioning or commissioning activities for instrument engineer?

    28.05.2021 at 08:34 Reply
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    28.05.2021 at 16:34 Reply
  3. Vaniria V.

    Project commissioning is the process of assuring that all systems and components of a building or industrial plant are designed, installed, tested, operated, and maintained according to the operational requirements of the owner or final client.

    29.05.2021 at 11:49 Reply
  4. Daryl A.

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    29.05.2021 at 13:00 Reply
  5. Rucmotytim

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    02.06.2021 at 15:46 Reply

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