Ing. Luis E. Penuela V.

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.

Ing. Luis E. Penuela V.

 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

Ing. Luis E. Penuela V.

 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

Ing. Luis E. Penuela V.

 prepare, plan and execute startup
commissioning management
Preparation of specific plant procedures
Management of risks
Safety & environmental compliance

Ing. Luis E. Penuela V.

 Mechanical completion
Provisional acceptance
Acceptance

Construction Production

Ing. Luis E. Penuela V.

 Mechanical completion
Progressive provisional acceptance
Progressive acceptance
0 Construction O&M
1
2

1 Pre-commissioning,
2 Start up and 3 Post commissioning
Equipment Inspection,
Commissioning and Performance
Equipment Operational testing
Tests Ing. Luis E. Penuela V.
 Progressive mechanical completion and
concurrent commissioning creates challenges:
Coordination and planning
Safety and risk
Isolation
Testing
Integration into operating plant

Ing. Luis E. Penuela V.

 what constitutes mechanical completion?
on completion, start-up can officially commence
problems when part of a plant are commissioned
while construction not yet finished.

Ing. Luis E. Penuela V.

Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

Start Up & Initial

Operation

Performance and
Acceptance testing

Post Commissioning

Ing. Luis E. Penuela V.

 Appointment of Commissioning
Preparation and planning
Manager or Lead Commissioning
Engineer;
Mechanical Completion
and Integrity checking Appointment of Commissioning
Team Members and Support Staff;
Pre-commissioning & Training;
Operational Testing
Information Compilation;
Start Up & Initial Safety and Risk Assessment;
Operation
Commissioning Strategy
Performance and
Development;
Acceptance testing Procedures and Checklist
Development;
Post Commissioning
Detailed Plan and Budget
Preparation;
Ing. Luis E. Penuela V.
Preparation and planning

Inspection
Mechanical Completion
and Integrity checking Pressure testing
Cleaning and Flushing
Pre-commissioning &
Operational Testing Machinery checkout
Start Up & Initial
Operation

Performance and
Acceptance testing

Post Commissioning

Ing. Luis E. Penuela V.

Preparation and planning

Mechanical Completion
and Integrity checking
Steam and other utilities
Pre-commissioning &
Operational Testing
introduced;
Dry running trials;
Start Up & Initial
Operation Hot running trials;
Purge, Air evacuation and
Performance and
Acceptance testing
inertization of circuits;
Safe-fluid dynamic testing;
Post Commissioning
Solvent dynamic testing;
Process fluid tests.
Ing. Luis E. Penuela V.
Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

Start Up & Initial Introduction of process fluids

Operation
Start-up and initial operation
Performance and Trouble-shooting and problem
Acceptance testing correction.
Plant taken to full operations.
Post Commissioning

Ing. Luis E. Penuela V.

Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

Start Up & Initial

Operation

Performance and Performance trails;

Acceptance testing
Formal Acceptance test
Post Commissioning

Ing. Luis E. Penuela V.

Preparation and planning

Mechanical Completion
and Integrity checking

Pre-commissioning &
Operational Testing

From plant on-stream to settled down

Start Up & Initial
and in regular production;
Operation
Adjustments, modifications and fault
Performance and correction;
Acceptance testing Completion of outstanding punchlist
items
Post Commissioning Learned lessons practice

Ing. Luis E. Penuela V.

 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.

Ing. Luis E. Penuela V.

 Management Issues Preparation and planning Technical Issues
Organisation and roles; Plant preparation and
isolation;
Information Mechanical Completion
Management; and Integrity checking Utilities and Electrical
System Commissioning
Procedure development
Pre-commissioning & Equipment Specific
Safety and risk Commissioning Issues
management; Operational Testing
Machinery/ Rotating
Permit systems
Start Up & Initial Equipment
Job safety analysis
Operation Vessels, Towers and
Planning and control; pipe work etc.
Budgeting and cost Performance and Removal of hazardous
control; Acceptance testing substances and purging
Commissioning strategy. Instrumentation
Post Commissioning commissioning

Ing. Luis E. Penuela V.

 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.

Ing. Luis E. Penuela V.

 The Process
Process conditions
Special Equipment
HSEQ aspects
Starting Procedures
Shutdown Procedures

Ing. Luis E. Penuela V.

 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.

Ing. Luis E. Penuela V.

 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.

Ing. Luis E. Penuela V.

 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

Ing. Luis E. Penuela V.

 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

Ing. Luis E. Penuela V.

 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.

Ing. Luis E. Penuela V.

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

Ing. Luis E. Penuela V.

 Project design file
Process file
Engineering data file
Plant layout file
Operating instructions
Analytical procedures
Log sheets and calculation procedures.

Ing. Luis E. Penuela V.

 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

Ing. Luis E. Penuela V.

Ing. Luis E. Penuela V.
 Three categories of cost;
Costs for normal startup equipment, materials and
personnel;
Costs for unexpected changes and additions;
Costs for mechanical equipment breakdowns.

Ing. Luis E. Penuela V.

 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

Ing. Luis E. Penuela V.

 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.
Ing. Luis E. Penuela V.
 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.
Ing. Luis E. Penuela V.
 A Crude Stabilization Plant 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.

Ing. Luis E. Penuela V.

 Startup Costs^
Cost = 100 (0.10 -0.02 -0.03 + 0.04 +1*0.02)
= 100 * 0.11 = $11 Million
^ Cost = A(0.10 + B + C + D +NE)

Startup Time^^
Time = 8(0.15 -0.01-0.01+ 0.15+1*0.1)
= 8 * 0.38 = 3 Months

^^Time = a(0.15 + b + c + d +Ne)

Ing. Luis E. Penuela V.

Thanks by your attention

Ing. Luis E. Penuela V.