Process commissioning services are provided by Process Technical Services (PTS). Process commissioning occurs between the time construction is complete and plant startup commences. During this period process commissioning managers are occupied with the task of ensuring the facilities have been constructed and assembled according to the engineering design and the equipment manufacturer’s directions.
Before any process commissioning activities can be undertaken, procedures that describe in detail how the various tests will be conducted and evaluated must be written. The process commissioning procedures must also describe safety precautions that must be taken before, during, and after the commissioning process. PTS provides
qualified and experienced
commissioning engineers and specialists in process commissioning to specify the tests to be conducted and to then follow the progress of this work in the field.
Process commissioning begins with a detailed plan to synchronize construction turnover of process units with the commissioning effort
as described in the PTS seminars on plant start-up. When construction on each process unit is declared as complete, process commission activities can then begin. Project planning software, such as Primavera, can be used to organize and control the commissioning process, so that resources can be scheduled and deployed in the most effective way to ensure that all elements are eventually
Just as with the actual construction of the process facility, process commissioning is a complex activity covering all aspects of the newly constructed facilities. The objective is to ensure that the equipment has been properly installed and is ready to receive
and operate as originally conceived.
Each element of the process unit is examined and tested. Process control valves must be stroked, sensors and analyzers must be calibrated, relief valve settings must be checked, and controller tuning coefficients must be checked.
Piping and equipment must be either hydrostatically tested or tested with inert gas to find and eliminate any leaks that might occur. Tramp metal collectors must be installed at critical locations in the piping system to prevent damage to pumps and control valves. Insulation must be inspected and steam tracing tested.
Electrical connections must be checked and electrical equipment tested where and when it can be done safely. Rotating equipment must be checked for alignment and manually rotated to ensure there are no interferences. Electrical motors need to be run to ensure the connections are correctly installed and that the motor rotates in the right direction.
Any defects found during he commissioning process must be corrected by the contractor before the process unit commissioning can be declared as complete. Troubleshooting guides should be prepared for mechanical equipment to help identify and correct any mechanical malfunctions that might occur.
A major part of process commissioning is in preparing the operating instructions for the startup of the process. The procedures for a newly constructed plant often differ from the procedures that would be placed in service after a successful production campaign. In the case of a newly constructed plant, the procedure may call for each upstream unit to be brought up to operating temperatures and pressure and held for a period of time to validate the integrity of the unit before process material is allowed to flow to the next downstream unit. PTS can provide experienced and skilled operators to undertake this initial startup, and can maintain the operation until the process stabilizes and the regular operators are prepared to take over.
Should problems develop during the startup phase, written plans and procedures should be in place to empty each process unit in a safe and environmentally compliant manner so that whatever problems occurred can be fixed.
Process Technical Services has the management expertise and the skilled and experienced engineers and specialists to handle all aspects of process commissioning and plant startup. PTS operates as the project owner’s representative in all respects.