Process engineer in Precommissioning & Commissioning 1

[WiseNow]

helloo to all process eng's,

We are in the process of Precommissioning & commissioning activities. My question is how can I be ready from the engineering point of view in this stage? and how can I be helpful during Precommissioning & commissioning, is there any technical support I can provide or any kind of certain calculations I can provide?..I know those questions might be really strange, but because it's my first time that I am involved in such activity for my company. I know what I should do during run and maintain phase of existing process plants, but I don't know what should I do in starting up new plants as i described above,,,sorry for making it so lengthy question.

 

[JLSeagull]

Prepare a list with all normal operating setpoints and all alarm setpoints.

Provide the first fill volumes. Assure that the initial fills are on site and clearly labeled in letters so large that you could identify the material from outside the gate. First fill errors can be very embarassing.

Prepare a set of P&ID's with a number assigned to EVERY valve including level bridles, etc. As you move from commissioning to startup you will use this list to open and close the various valves and tag for the status during that phase of the commissioning / startup. Plastic tags and wireties work well for this.

Prepare procedures for cleaning, inerting, first fills, pressuring, etc. Especially identify safety related stuff like the percentage O2 permitted in the flare header before startup, etc.

 

[owg]

Good points from JLS - Just being an extra body and willing to anything legal is a real help. A few things I recall:
- Check carefully for blinds left in, learn the difference among, spacers, blinds, and orifice plates.
- Look around for combustibles like wood left lying around next to things that are going to get hot.
- Things are going to stretch as they warm up, look for interferences which will block the proper expansion.
- Be able to get a quick answer to questions like "I am losing 30 psi in that line section, is that normal or is the line partially plugged?
- In addition to set points it is very useful to have a process flow diagram with intermediate temperatures and pressures, i.e. between controllers.

HAZOP at

http://www.curryhydrocarbons.ca

 

[786392]

Dears An Excellent discussion may be of some use

http://www.cheresources.com/invision/index.php?showtopic=7257

Best Regards
Qalander(Chem)

 

[BenThayer]

other things to watch for is the order that you need systems.

for example, you need instrument air to check the valves before you put fluids through them.

we had a major argument on our site because i was planning to check out the waste tanks prior to the process tanks. i had to endure some shouting from a red-faced supervisor about how stupid i was since that was the last tank in the process stream.

i waited and asked where he proposed to move the solvents from the processing tanks if they had a leak, etc.

now he was red-faced from embarassment but he was not shouting.

you will have many things to start that can be parallel and some in series but it will not necessarily follow the normal proces flow of the equipment.

 

[WiseNow]

Thank you all for this nice and valuable replies. I agree with you all, that a lot of things have to be done. I've read the link

http://www.cheresources.com/invision/index.php?showtopic=7257

,,and what it's there does make a sense, that there are many different ways and tools depending the process facility we are commissioning..

thanks again..

 

[Unotec]

Use common sense.
Walk around and trip or bump your head. Make sure that these hazards are pointed out and documented so that they will not show up in the next design.
Reach for valves to open and close and look where your coveralls get caught.
Look at the instrument displays and that they can be easily read.
Look for overhead motors and whether they have a switch right next to them so that they can be locally de-energized when serviced.
Basically, make sure that what's in the drawing is in place and picture yourself as if you were operating it.
And the most important part if this is your first time: Keep your ears open and absorb the information of what the experienced guys are doing. Do not be afraid to ask questions

<<A good friend will bail you out of jail, but a true friend
will be sitting beside you saying ” Damn that was fun!” - Unknown>>

 

[786392]

Well Said;
From practical stand point physical extra ordinary level of alertness and responsive attitude of whole team performing this activity is extremely important.

Best Regards
Qalander(Chem)

 

[HamishMcTavish]

Other things that you might consider are permits to work / tag-outs if you are commissioning a system in parts. Ensure that everyone knows what bits of kit are live/pressurised!

Also - and i know it's not the most thrilling aspect - document things properly. Specify how the testing of requirements is to be carried out, document the results and make sure you get someone who's SQEP to sign them off or accept deviations.

Regards, HM

sorry SQEP = Suitably Qualified and Experienced Person!

No more things should be presumed to exist than are absolutely necessary - William of Occam

 

[JLSeagull]

The contract dictates some issues mentioned in some of our posts. Some commissioning responsibilities depend upon whether employed by a contractor, the operating company engineering division or by the plant.

During construction and checkout, CONSTRUCTION is in charge. Some in construction are not very receptive of the 'HOME OFFICE ENGINEERS' at their job site. This may be true into pre-commissioning stage.

Once things are powered, air compressors running etc. the operating company may begin running the show especially once process fluids are loaded for startup. Things change during the transfer from engineering to construction toward startup.

Some groups want to flex their muscle when in charge. Plan to participate as a hand to provide technical services. Don't arrive at the site with an attitude, expect a Gold Hard Hat or whatever symbol suggests being the boss. Regardless, lots of experience gained during the commissioning phase will be helpful for future design projects. Enjoy the opportunity. Try to get some sleep.

Good luck.

 

[BigInch]

See attached

**********************
"Pumping accounts for 20% of the world’s energy used by electric motors and 25-50% of the total electrical energy usage in certain industrial facilities."-DOE statistic (Note: Make that 99% for pipeline companies)

http://virtualpipeline.spaces.live.com/

 

[BRT549]

Bring extra food, because you may not go home when you usually do. Be prepared to sleep in your office or car.

 

[owg]

You probably have temporary strainers(TS)protecting pumps. Have a plan for removing them. Too early and you damage pumps, too late and they gradually foul up and may cause an unnecessary shut down.

HAZOP at

http://www.curryhydrocarbons.ca