Start-up and Commissioning Written

by John Lozinski
Published on October 21, 2016
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John Lozinski
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E&I C&I Turbine & Commissioning Consultant Veteran LNG & Refinery jlozinsk@yahoo.com
508-536-3109
Start-up and commissioning is part of the overall design verification, validation and
operational readiness process. Prior to Commissioning and Start-up the following two
actions take place.

PSUA abbreviated for Pre-Start Up Audit.

This is a walk down to find any defunct items and have them corrected ASAP.

PSSR abbreviated for Pre-Startup Safety Review.

This is a final checklist which includes each step to Commissioning and Startup of
equipment.In order to keep a correct sequence some of the list below is construction*
and thus marked. It is commonly agreed that 68% of all equipment failures can be
traced to design, installation or startup deficiencies. Startup ensures that all systems
meet specifications so that the clients process gets a safe and efficient operating
system that meets all specifications and safety requirements. Validation and
verification not only insure quality they insure people do not get hurt at a later time.
Construction issues me a Certificate of Mechanical Completion then it starts. I have
worked in Pharmaceutical validation of processes also and if a bottle needs 10 pills
and a machine puts in 8 it is always possible that a remote patient dies because of this.
In Oil and Gas my mentor almost died because of an SO2 failure and he was alone.
Hydrofluoric Acid Mercury Silica also Radon and Formaldehyde in Natural gas and
other such chemicals have endangered human lives also. This is why you need a
TEAM of experienced old hands like I can provide. Flow chart at the end of
article.The scope of this article is to present preparation and execution of
commissioning and related activities for all types of developments such as oil, gas or
power generation projects, Greenfield or brownfield. "the on-time submission of
correctly prepared as-built documentation may play an important role at the final
commissioning stage when you deal with government body for variety of
permissions." * see comments

Commissioning & start-up preparation

The Commissioning Process verifies that equipment and systems that have not been
operated before, or if they have been modified are brought into operation safely and in
the correct sequence. The objectives of the process are:

1. To show and document that equipment and systems that have

been modified or newly installed are able to perform in
accordance with specified requirements.

2. To bring the equipment or system safely into service and hand

it over to the asset owner.

For re-commissioning, to show and document that repairs, overhaul or routine

maintenance of equipment or systems that have previously been operational are able
to perform to current specified requirements. Facility and/or project may vary but
regardless of whether Greenfield or Brownfield, the objectives remain the same.

* Talk to your client and obtain all information from the client to determine specific
needs & concerns. Review it carefully to correct any immediately visible errors.*

The Commissioning Startup (CSU) Team will start up and operate the non-
hydrocarbon systems during commissioning activities until these systems are fully
proven and handed over to Operations provisionally.

Prepare planning and execution.

Manage safety and your team organization during the commissioning.

Prepare Documentation and databases correctly.

Insure that all parts are ordered to arrive in time and spares and second sourcing
exist.

Run a schedule for measuring progress.

 Insure all operators are trained and assessed to be able to
perform their duties.

Insure all regulatory requirements are met.

The following do not belong to C&SU but need to be checked that construction has
done them. I mark them with * it is good practice to know that all prep has been done.

Evaluate size of all control systems control systems valve and loop tuning.*

Create a checklist based on the client's needs and your years of experience.*

Make sure everyone on your TEAM is aware of and familiar with all
the information collected during the project's planning, design, & construction*

*Sort project data from the P&ID design database into the appropriate areas also
insure that they have all been ordered and delivery is scheduled on time. Make sure
they are to correct specifications sometimes cheaper instruments were selected to
replace original designs which ultimately could cost project safety accuracy and
duration:

1. Equipment*

2. Piping*

3. Valves*

4. Instrumentation*

Piping Verification and Validation

Perform a walk-down and do functionally testing of the entire piping system. *the
first 4 items are construction items not Comissioning and start up responsibility!

1. Confirm complete installation of all required parts*

2. Perform hydro test*

3. Perform pressure test*

4. Solve all issues and problems with gaskets, welds, & valves*

5. Cleanout the system and Caustic wash/surfactant to remove oil, grease, & other
contaminants.

6. Flush the system with detergents.

7. Complete the cleaning process with an Acid wash & remove iron from stainless
steel surface.

8. Visually inspect tanks & piping to verify that Clean in Place systems are
adequate

9. If needed and applicable to the process use of a light coat of a protective

material, such as metal oxide, to create a shell against corrosion.*

10. Chemical wash to protect cleaned stainless steel from chloride attack.

11. Commissioning requires the introduction of fluids (process or non-process) and

operation of the system. This needs to be documented.

Piping System sterilization

System are sterilized by direct injection of low-pressure steam. Piping,

Equipment and sterile barrier surface temperatures are checked with
calibrated instruments and documented.

On occasions when needed a system can have some sort of sterile media inserted and
bacterial growth monitored for several days to insure the system is sterile. Even
systems tested sterile can later show contamination and the source needs to be
identified so as to prevent this recurring. A number of possible causes exist.
1. Equipment design or maintenance

2. Operators and workers procedures or practices

3. Stainless steel quality and integrity.

4. Failure of sterilizing equipment.*

5. Clean-in-place equipment failure*

6. Area and structure contaminants including airborne particulates and organisms.

Mechanical completion audits and walk downs

1. Validate correct equipment installed

2. Validate and verify correct installation procedure for each piece of equipment

3. Check the type and amount of lubrication

4. Check rotation and couplings.

Electrical and instrumentation calibration and check-out

Commissioning and start-up include:

1. Check hardware, including wiring, to ensure that each motor starts from the
correct motor control center (MCC)

2. Check all PLC wiring and electrical controls wiring along with junction box
connections.

3. Check software addressing by actually engaging equipment to insure proper

operation and direction of each motor and response of each instrument to the correct
signal from the display.

4. Start all motors drives and individual pieces of equipment.

5. Verify and validate power supply transformer switchgear functionality and
validate operation.

6. Verify and validate safety & software interlocks operation.

7. Verify and validate all written documentation.

8. Perform system trial runs with water and other disposable products.

9. Tune process control loops and validate and verify temperature, pressure, flow

10. Train operators.

11. Inform every one of safety procedures. Preform all functional safety tests.

12. Turn-over the area and closed out Punch list.