SAFETY IN COMMISSIONING

AND
START UP OPERATIONS
S.K. Ghosh, IOCL
S.M. Vaidya, IOCL
12th August, 2010

PLANT START-UP AND

COMMISSIONING

Plant commissioning is the first of many start-ups;

Potential hazardous : Ability to operate not proven;

Many unknown factors.

Expensive;

ROI severely affected;

Financial viability under question.

ELEMENTS OF SUCCESSFUL
COMMISSIONING

MANPOWER DEPLOYMENT
9

Multi-disciplinary core team

years prior to commissioning;

including team leader 2

Balance team deployment at least 1 year prior to

commissioning;

Blend of experienced and new in the ratio of 3:1;

Deploying few senior members of project team for

maintenance jobs;

Team leader should able to command the resources;

Top management support to the team.

TRAINING
9

Extensive theoretical and field training on similar plants;

Training at critical equipment vendors workshop;

Training simulator
commissioning;

Structured training on emergency responses, handling of

hazardous chemicals;

Licensor training;

Inducting commissioning group for HAZOP;

Mock operational drills.

must

be

placed

year

before

The Process;
9

Conditioning and Special Equipment;

9

Starting Procedures;
9

Limits Of Operation;
9

Shutdown Procedures;

Develop work and safety procedures;

9

Specify typical maintenance activities;

9

Select and purchase maintenance supplies and spare parts;

9

Negotiate with vendors and contractors;

9

Keep maintenance records;

9

Make detailed designs of any changes and additions made

9
9

9
9

Technical manual for process technology and equipment

SOPs;
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
depicting
emergency response etc.;

policies,

Maintenance procedures specific to the new plant;

Change Management .

procedures

PRE-COMMISSIONING
9

Pre-commissioning
completion;

activities

overlap

mechanical

Plant is segregated into manageable systems / subsystems / flushing loops;

Checking of design conformity;

Checking status of Electrical, Mechanical & Instrument

Installations;

No Load / Load run of rotary equipment;

Flushing, Cleaning, Drying etc.;

Loop checking should also start after flushing.

CHECK LISTING
9 Why to do?
9 When to do?
9 Who is to do?
9 How to do?
9 What to do?

WHAT TO DO IN CHECK LISTING?

To be done as per system/sub-systems;

System is as per P&ID;

Identifying skewness of Flanges;

Short/Long Bolting;

Use of proper gasket color codes;

Support systems.

Contd..

WHAT TO DO IN CHECK LISTING?

Location of drains/vents;

Column/Vessels internals as per drawing;

Positioning of instruments;

Valve / CVs installations;

SEQUENTIAL PRE-START UP SAFETY CHECKS

MULTI LAYER APPROACH
9

Safety checks by Licensors compliance;

In-house multidisciplinary
compliance;

OISD Audit - compliance;

In-house multidisciplinary audit before feed-in;

Adherence to Plant/Equipment check list;

*External audit is done e.g. Shell Global did for PNC.

audit as per OISD Format

OBJECTIVE OF PRE-START UP SAFETY REVIEW

9

Construction as per design specification;

P&IDs are complete;

System Protection Interlocks/ ESDs;

O&M & Safety system / Procedures /Documentation;

Training & its effectiveness;

Statutory compliances are met;

MINIMUM FACILITIES BEFORE START UP

Implementation of Work permit system;

Fire
fighting
facilities
extinguishers etc.;

Clearly defined emergency exits , with display boards;

Removal of debris /
connections;

Tested Paging systems & availability of Walkie talkies;

Readiness of OWS /CRWS system with ETP in operation;

including

positioning

of

temporary structures and power

contd..

MINIMUM FACILITIES BEFORE START UP

9

Availability of adequate PPEs /First Aid boxes;

Judicious implementation of isolation scheme;

Properly stenciled Utility points with connecting hoses /

lancers;

Unlocking of springs/ supports of all headers;

All gas / hydrocarbon detectors are tested and kept on;

ESD s are tested , documented and kept activated etc.;

Flare system is in position.

OTHER START UP SAFETY ISSUES

9

Multidisciplinary group accountability for flange box-up/RTJ

Joints;

Best leak test is at operating severity;

Hydrogen
leakage
depressurization ;

O2 content in N2 must be checked before inertisation;

Furnace lit up with pilot only; keeping main valve blinded,

purge fire box min. for 15mnts after each attempt;

Water /Condensate draining from all low points after gas

backing up;

Condensate draining before charging steam headers;

should

only

be

attended

after

contd..

OTHER START UP SAFETY ISSUES

9

Catalyst injection lines of petrochemical plants to be flushed

with mineral oils;

In Naphtha Cracker Units important headers to be dried up

to (-)65/70oC to avoid hydrate formation;

White oil tanks to be commissioned with at least 5 cm of

water level;

Black oil tank should be commissioned dry, top M/H cover

may be kept open if required;

Blind Lists are ready;

All safety valves, including TSVs are in line;

contd..

OTHER START UP SAFETY ISSUES

LPD/HPV

valves closed and capped;

All supports are un-locked;

Fine mesh strainer on rotary equipment;

ESD/De-pressurisation systems check;

Flare area to be cordoned chances of

during start up.

fire balls