Commissioning of Gas Terminal 5

[GazPlumer]

Hello all,

I am assigned to the commissioning team of a gas terminal with no previous commissioning experience. Is there any general tip for safe and successful commission / start up a gas plant? Is there any useful literature available on this topic.

Thanks very much for your help!

 

[GregLamberson]

GazPlumer

What stage are you at? Are you responsible for putting together the Hook Up & Commissioning Plan or executing it?

Greg Lamberson, BS, MBA
Consultant - Upstream Energy
Website:

http://www.oil-gas-consulting.com

 

[GazPlumer]

Thanks, Greg, for your attention.

We are close to mechanical completion at the moment. In terms of planning, there's a generic company commissioning procedure but this requires fine tune to be project specific. I will be starting with the planning and followed on to execution.

 

[GregLamberson]

GazPlumer

Not to criticize your company, because it is a common oversight. I prefer to have operations involved early in the project, say during FEED and they develop the comminssioning plan & procedures as the project unfolds.

That being said. Commissioning is basically the transition between construciton & start up. There are a few htings you need to do rather quickly:
- detemrine what the commissioning process looks like.
- determine the systems required to be commissioned, this may happen in a module yard for some systems or at the site, where the turnover and commissioning procedures are executed. For example, reinstatement test and commission of utility systems (air, firewater, HVAC, safety systems, etc.), as well as process support systems (vent, flare, drains, cooling, produce water, chemical injection system, etc.) and process systems (dehydration, water injection, gas compression, metering system, etc.).
- you will need to do a risk assessment (HAZOP, HAZID, or whatever you want to call it). The key to this is to assemble a group of very knowledgable experts to go through the systems
- you'll want to develop a matrix that lists all equipment and the quantities of first fill items required for the equipment flush, test, run-in and operations for a required period of time.
- you must have detailed commissioning procedures developed - again, the key is utilizing knowledgable folks.
- you'll need to work closely with operations for sequencing
- if it is within an existing facility, a detailed SIMOPS will need to be developed with operations

Those are a few ideas, sounds like you have been thrown quite unfairly into a difficult situation.

Greg Lamberson, BS, MBA
Consultant - Upstream Energy
Website:

http://www.oil-gas-consulting.com

 

[BigInch]

Good stuff Greg.

As far as detailed procedures go, you may have more luck looking for commissioning procedures for each individual type of equipment than for a whole plant, then assemble those into a unit package. Detailed commissioning procedures may have already been submitted to the project documentation system. If this information is not available for a major piece of equipment, appropriate procedures should be developed. If necessary, get direct advice from the manufacturer.

In addition to making and checking ...and checking again all the endless punch lists...

Generally what you must do is,

Develop a fool-proff lock-out system.

Be sure all systems are clean and free from construction debris and other contamination. Clean and flush and dry as necessary all piping systems.

Ensure that all auxiliary equipment has been supplied and filters, etc. installed, check valves in the proper direction, moving items free and especially that all safety protection devices are installed and operable.

When installing mechanized equipment and motors, check the belts and drive couplings for fit. Belts, fitting and couplings should be tight.

Inspect for recent construction damage or other happenings since original installation or during clean-up.

Fill all cylinders and tanks and vent or bleed any air from lines, etc.

Motors - fill the case of piston-type motors with clean hydraulic fluid through the highest case-drain port and connect the case-drain line.

Bump starts,

Check that all pipe and hose connections are tight.

Confirm reservoir fluid level is above the minimum.

Confirm all controls are in neutral to ensure the system will start unloaded. Take safety precautions to prevent machine movement in the event that the system is activated during initial startup.

If a driver is electric, momentarily start and then stop the electric motor to visually confirm the direction of motor rotation is correct for the pump. Rotating the pump in the wrong direction can damage the pump.

Start a motor to run at the lowest possible rpm.

Monitor pressure gauges. If the manufacturer’s specified charge pressure, established within 20 to 30 seconds, shut down the prime mover and investigate the problem. Do not operate a system without adequate charge pres
sure.

Allow the system to run at idle and unloaded for ten minutes. Monitor pump(s) for unusual noise or vibration, inspect system for leaks and observe reservoir fluid level.

Operate the system without load. Stroke cylinders slowly.

With the system at operating temperature, check and adjust settings of circuit protection devices according to manufacturers’ specifications.

Cycle the system under load to verify correct operation.

Inspect the system for leaks.

Shut down the prime mover, remove all gauges fitted during commissioning, check reservoir fluid level and, if necessary, refill to the correct level.

Hope its enough to get you started.

http://virtualpipeline.spaces.msn.com

 

[JLSeagull]

Involve the equipment manufacturers early if the process includes complex equipment such as major rotating machinery or fired heaters. Turbo compressors require lubricating systems to be "really clean" with specific criteria.

The field commissioning activities are where people gain experience; often reflected in strong positions regarding assorted issues during your next design project.

 

[davefitz]

I would like to suggest a few other items prior to commissioning for this situation:

1. read and understand the O+M manuals form each equipment vendor, and if the O+M precautions or requirements are not consistent with the plant layout or implied commisioning procedure, discuss this with the EPC contractor and vendor.

2. read the incident reports for the recent accidents that occured in the last 3 yrs at regas and liquifaction facilities

Now I'm beginning to get a little nervous that such a terminal is being commissioned with someone with little experience.

 

[hahor]

GazPlumer,

try to get a copy of "How to facilitate StartUp", Chemical Engineering Magazine, June 1993. It is a good starter to get an overview.

Kind Regards,
hahor

 

[GazPlumer]

Thanks a million, guys!

They've all been good stuff that you suggested. Now I start to get my head round what information is available and what is still needed in due course. Really appreciated your advices.