Procedure for Pre-Commissioning

& Commissioning of ETP

Project

Client

TPIA

Contractor
 INDEX
• Introduction
• Systems & Equipments of ETP at Lingala
• Checklist
• Pre-Commissioning
• Pre Start Checks
• Start Up Procedure
• Shut Down Procedure
• Commissioning
• Performance Guarantee Test Run
INTRODUCTION
 Introduction

GGSs
ETP (Produced
Oil Wells Heater Treater
Produced Water Water from GGSs
Separators ( Crude
(Effluent) (free for treatment i.e.,
(Crude Oil + (Separates Emulsion is
oil, emulsified
removal of
oil + dissolved&
Associated Gas) Liquid and treated to
suspended Oil/Suspended
Gas) separate water
from crude oil)
solids + Solids)
impurities)
SYSTEMS & EQUIPMENTS OF
ETP
 Systems & Equipments of ETP

Raw Effluent Treated

CPI Unit IGF Unit NSF Units
tanks Water Tanks

Treated
Effluent Feed Treated Water
Effluent Nutshell Filters
Pumps Transfer Pumps
Booster Pumps

Nutshell Filter
Skim Oil pumps Backwash
pumps
 Systems & Equipments of ETP
Instrument Air
Chemical Dosing Sludge Handling Gas Generator
Compressor Slop Oil System
System System Set
Package

Deoiler-I Storage Vessels Instrument Air Slop Oil Sump Wet Sludge Pit
Compressors

Deoiler-I Injection Pumps Slop Oil Pumps Sludge Pumps

Air Pre-Filters

Scale Inhibitor Storage Thickner

Vessels Slop Oil Tank

Instrument Air Dryers

Scale Inhibitor Injection Sludge Collection Sump
Pumps
Slop Oil Transfer Pumps

Air After-Filters Sludge Feed Pumps

Deoiler-II Storage Vessels

Raw Water Transfer Centrifuge

Deoiler-II Injection Pumps Pumps
Instrument Air Receivers

Dewatering Chemical Sludge Drying Bed

Storage Vessels

Dewatering Chemical
Injection Pumps
CHECKLIST
 Checklist
• Location, Orientation, Elevation of nozzles as per drawing
• Internal Installations as per drawing
• Tanks Internally for cleanliness
Vessels & • All platforms and ladders provided for easy access
Storage Tanks • Man way inspection

• Internal Installations
• Internal pipes installation with correct bolts and gaskets
• Instrument nozzles, Vessel Nozzles in right location, clear and no obstruction
CPI, IGF & • Inspection of Vessels internally for cleanliness
NSF • Inlet pipes and distribution pipes installation as per design Intent

• Base Plate properly grouted to foundation

• Operation of suction and discharge valves
• Pump and Driver checks for freedom of movement
• Motor bearing lubrication
Pumps • Instrument alarms/shutdown settings
 Checklist
• Equipment Installation as per drawing
• Equipment cleanliness
• Free rotation of shaft in correct direction that rotor does not foul with tank internals
Agitators • Bolting lubrication

• Installation damages
• Suction and discharge piping is clean and supported
• Motor rotation
Dosing Pumps • Coupling and coupling guard installation

• Compressor Lubrication
• All electrical connections are tight
Instrument air • Rotation in the correct direction
compressors
PRE-COMMISSIONING
 Pre-Commissioning
• Mechanical Completion of systems All Installation works of the system
have been completed and hydro-tested.
• Pre-commissioning Activities: Activities to be performed after
Completion/Installation, Inspection, Hydro-testing, etc. of an
equipment/system. These include but not limited to,
 Installation of Seals and Packing
 Removal of temporary bracing
 Checking of Rotating machinery for correct direction of rotation and for
freedom of moving parts before connecting Driver
 Checking of all lubricants and their quality, fill etc., before operating the
equipment
 Installing all safety devices on the equipment
 Protecting equipment from normal weather conditions or damage before
commissioning
 Pre-Commissioning
Pre-Commissioning Procedure:
 Tanks, Vessels, CPI, IGF Units and NSF Units
• Equipments after erection and put in place have internals requiring field
installations/inspections. These internals shall be inspected before and
after installation.
 Pumps, Compressors, Fans and Drivers
• Check alignment and ensure that levels of supports, etc are in order.
• Charge the lube oil, seal oil and cooling systems with flushing oil and
circulate for cleaning purposes. Dispose of any flushing oil in accordance
with the Company’s approved procedure.
• Charge the lube oil, grease, seal oil and oil cooling system as
recommended by the manufacturer.
• Ensure that all fittings supplied by vendor are installed in proper condition.
• Ensure that there is no unacceptable vibration after equipment is put on
rotation.
 Pre-Commissioning
Pre-Commissioning Procedure:
 Piping System
• Orifice Plates, Control Valves and any other online instruments should not
be installed before testing and flushing.
• Piping System shall be thoroughly flushed and cleaned to the satisfaction
of the company.
• Hydrostatically and pneumatically test all piping as required by the
drawings or specifications.
• Vents shall be provided at high points of loops and shall be plugged after
testing.
 Instrumentation System
• Functional Check of all instrument and controllers
• Checking positions of all valves as per drawings
• Checking of all electrical signals and alarm wiring fro continuity, correct
source of power and polarity
• Check all Shut down Systems before commissioning.
 Pre-Commissioning
Pre-Commissioning Procedure:
 Electrical System
• To perform continuity test and Insulation Resistance Test for power and
control circuits.
• Earth continuity test for all circuits.
• Verification of phase sequence.
• Checking of Safety features for correctness of operation etc.
• Checking of all wired interface contacts for PLC at panel and equipment
terminal chambers as applicable.
• A close visual inspection of electrical equipment in hazardous areas shall be
made to ensure that equipment is suitable for the classified zone and gas
group and correctly installed, with all covers, bolts, nuts and hardware
intact and there is no physical damage mark seen on the enclosure.
PRE START CHECKS
 Pre-Start Checks
• Ensure safety systems are in place.

• Ensure all the Utilities are available.

• Sufficient copies of Log Books should be ready.

• Required Quantity of Chemicals for one day should have to be shifted from Chemical store
room.

• Check the spare parts and Tools that are availability at site.

• Prepare the chemical in the dosing tanks as per the procedure laid down.

• Required parameters will be analyzed as per standard method of ASTM/IS code, check
availability of Lab instruments and chemicals accordingly.
START UP PROCEDURE
 Start Up Procedure
• Intake the effluent from the nearby existing GGS to stabilize the plant.
• The effluent is collected from the Existing Heater Treater to Raw Effluent Tank
(005-TK-001 A/B).
• Inlet samples are taken to analyze the pH, TSS and Oil and grease.
• Deoiler-I dosing pumps (005-P-011 A/B), Scale Inhibitor pumps (005-P-014 A/B)
and agitator will be started when the effluent received in the Raw Effluent Tank.
• The Effluent water will enter into the Raw Effluent Tank after the addition of
Deoiler from Deoiler-I Injection Skid (005-A-004) by Deoiler-I dosing pumps and
Scale Inhibitor from Scale Inhibitor Injection Skid (005-A-007).
• The free oil that is separated by gravity will float on the upper layer of Effluent
Water and will be collected by oil skimming pumps (005-P-002 A/B) that is
routed to Slop Oil Sump (005-A-001).
• And the Treated Raw Effluent Water enters the CPI separator (005-Z-001)
through Low Shear Centrifugal Effluent Feed Pumps (005-P-001 A/B).
• In the CPI the Free floating oil will be removed by the corrugated plate and
suspended solids will be separated.
 Start Up Procedure
•The separated oil from CPI flows to the Slop Oil Sump and the suspended solids will get
deposited in Wet Sludge Pit (005-A-002).
•Maintain the flow rate as per the requirement.
•The Treated Raw Effluent from CPI is collected by IGF (005-Z-002) through gravity.
•Deoiler from Deoiler-II Dosing Tanks (005-V-004 A/B) will be pumped to IGF at Inlet by
Deoiler-II Injection Pumps (005-P-012 A/B).
•The gas will be introduced in IGF for the removal of Emulsified Oil.
•Sample will be collected at the IGF Inlet and Outlet.
•The outlet water from IGF will be pumped to the Nutshell filters (005-P-003 A/B) through
Treated Effluent Booster Pumps (005-P-003 A/B) for further treatment.
•The outlet water from NSF will be transferred to CPI through NSF Backwash Pumps (005-P-
004).
•Treated water from NSF shall be collected by Treated Water Tank.
•From wet sludge pit, the sludge is pumped to Thickner (005-A-011) for removing free
water.
•The free water from the Thickner flows to the water compartment of Slop oil Sump.
•Then the sludge after removal of free water is collected by sludge collection sump (005-A-
012).
 Start Up Procedure
• Dewatering Chemicals will be added in Sludge Collection Sump to by
Dewatering Chemical Injection pumps (005-P-013 A/B).
• The sludge from the Sludge Collection Sump will be pumped to centrifuge
(005-A-013) by Sludge Feed pumps (005-P-017 A/B).
• The residual sludge from centrifuge will be collected by sludge Drying bed
where the water evaporates and the dry sludge will be sent for disposal and
the free water from centrifuge goes to the water compartment of the Slop Oil
Sump by Gravity.
• Samples will be collected at the Outlet of NSF system and required parameters
will be analyzed.
SHUT DOWN PROCEDURE
 Shutdown Procedure
• Close the main inlet valves to the ETP at Inlet Header (4”-PW-001-G1).
• Close the Effluent inlet valve in the Raw effluent Tanks (005-TK-001 A/B).
• Stop the Deoiler-I Dosing pumps (005-P-011 A/B), Agitator and Close the suction
and discharge valves.
• Stop the Scale Inhibitor pumps (005-P-014 A/B), Agitator and Close the suction
and discharge valves.
• Stop the Effluent Feed pumps (005-P-001 A/B) and Close the suction and
discharge valves.
• Close the effluent inlet valve for the CPI Separator (005-Z-001).
• Close the effluent inlet valve in the IGF (005-P-002).
• Stop the Deoiler-II Dosing pumps (005-P-011 A/B), Agitator and Close the
suction and discharge valves.
• Close the fuel gas inlet control valve in IGF.
• Stop the Skim Oil Pumps (005-P-002 A/B) from the IGF to the Slop Oil Sump and
close the suction and Discharge valves.
 Shutdown Procedure
• Stop the Treated Effluent Booster pumps (005-P-003 A/B) and close the suction and
discharge valves.
• Stop the Nutshell filter Back Wash pumps (005-P-004 A/B) and close the suction and
discharge valves.
• Close the treated effluent inlet valve in the Nutshell filters (005-F-001 A/B).
• Close the inlet valves for the Treated Water Tanks (005-TK-003 A/B).
• Stop the Treated Water Transfer Pumps (005-P-009 A/B) and close the suction and discharge
valves.
• Stop the slop oil pumps (005-P-005 A/B) and close the suction and discharge valves.
• Close the inlet valves for the Slop Oil Tank (005-TK-002).
• Stop the slop oil transfer pumps (005-P-007 A/B) and close the suction and discharge valves.
• Stop the sludge pumps (005-P-006 A/B) and close the suction and discharge valves.
• Stop the Thickener (005-A-011).
• Stop the Dewatering Chemical Injection Pumps (005-P-013 A/B) and close the suction and
discharge valves.
• Stop the sludge feed pumps (005-P-017 A/B) and close the suction and discharge valves.
• Stop the Centrifuge (005-A-013).
• Stop the Instrument Air Compressor (005-K-001 A/B) and close the discharge valves.
COMMISSIONING
 Commissioning
• The ETP shall be considered `Ready for Commissioning' when all the facilities
have been completed along with their auxiliaries and support facilities in every
respect including charging of lubes, chemicals, preparation of solution, any last
minute modifications, if any, as recommended by the Company/Vendors. All
temporary structures, scaffolding etc. used for carrying out the pre-
commissioning works shall be removed.
• Commissioning shall mean taking the feed, passing it through the normal route;
establishing the process control parameters first at turn down & then at design
value.
• The plant/facility shall be considered to be commissioned successfully when the
plant/facility, with instrumentation / control systems, process, utilities and
support systems have been on uninterrupted stable operation for not less than
72 hours. Whether the 72 hours operation has been successful or not, shall be
decided by the COMPANY based on observations recorded during 72 hours. The
countdown for 72 hours operation shall start only after plant/facility has been
on stable operation with all controls and safety system in normal operation for a
period of not less than 48 hours.
PERFORMANCE GUARANTEE
TEST RUN (PGTR)
 PGTR
• After the plant/facility have been completed, put into operation and steady
state operation is established, performance test of units shall be conducted
before carrying out the performance test of facilities.
• M/s. Owner intends to install an ETP facility for treating the Produced Water i.e.
removal of free/emulsified oil, dissolved & suspended solids, to meet the
requirements for sub surface disposal under given parameter.
• The pre-commissioning checks, commissioning procedure and performance
guarantee test run (PGTR) to be carried out for 72 Hrs at ETP facility
• As per the Bid document the unit must be operated for 72 hours with specified
inlet and outlet parameters both quantity and quality wise including power and
utility consumption without any interruption. The outlet parameters shall be
required to meet contractual requirements.