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Plant Construction, Startup and Commissioning

The document discusses the key stages of plant construction, commissioning, and startup. It outlines the planning, operations, and sequencing involved in construction activities like site preparation, equipment erection, and facility installation. Commissioning stages include mechanical completion, pre-commissioning of utilities and controls, and gradual process commissioning. Startup involves mobilizing personnel and materials, charging systems, section-wise startup, and trial runs to meet performance guarantees before handover.

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Harisankar A R ch23m010
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72 views

Plant Construction, Startup and Commissioning

The document discusses the key stages of plant construction, commissioning, and startup. It outlines the planning, operations, and sequencing involved in construction activities like site preparation, equipment erection, and facility installation. Commissioning stages include mechanical completion, pre-commissioning of utilities and controls, and gradual process commissioning. Startup involves mobilizing personnel and materials, charging systems, section-wise startup, and trial runs to meet performance guarantees before handover.

Uploaded by

Harisankar A R ch23m010
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Plant Construction, Startup and Commissioning

Athul Unnikrishnan
TCR18CH023
Plant Construction

The plant engineer must have an understanding of the following aspects of construction:
• Construction planning
• Labour and labour relations
• Actual construction operation

The stages of construction planning include:


● Design drawing and Specification give the detailed information to construction department.
● Construction engineers should study the preliminary engineering data and scale models of plants to
be erected.
● Selection of derricks and hoisting equipments.
● Positioning of construction equipments
● Planning of erection
Construction Operations

● Site Preparation
● Driving Of Pile
● Temporary Buildings
● Temporary Water Supply
● Roadways and Rail
● Excavation
● Installation of underground facilities
● Electrical conduit and underground piping
● Foundation construction
● Erection of derricks / cranes
Construction Operations

● Erection of elevated reinforced concrete structure and structural steel.


● Erection of major equipments
● Installation of piping
● Pipe identification
● insulation
● Buildings:- office buildings, warehouses, change houses, canteens, M/C shop, lab etc.
● Final stages of construction :-
Instruments, electrical apparatus, small piping for instrumentation,
Cleaning of site and Installation of safety equipments
Commissioning of Process Plants

● Mechanical completion: It is the phase between installation and pre commissioning. The components are proven to be
mechanically fit in this phase. The main contractor/ equipment supplier is responsible for this phase.
● Pre Commissioning: refers to preparing the plant for the introduction of process materials and its main object is to eliminate
any problems which might arise at later and more critical stages of plant operation. The availability of manuals, emergency
protocols and SOPs must be ensured.
● Commissioning of control systems: The control system including instrumentation, sensors and field wiring, transmitters,
switches, relays etc are included in this phase. The computer hardware and system software is also tested.
● Commissioning of utilities, offsite
● Process Commissioning: It begins after the pre commission process is completed. Temporary screens to protect valves and
pumps are removed. Before this all final check of safety equipments like fire extinguisher, first aid kit etc are tested and
emergency vehicles are prepared.
● Guarantee run- performance and acceptance test: Parameters like Plant capacity, consumption of raw materials,
utilities,Effluent and product quantity are monitored. If the design output and efficiency are matching the operational
values, the operation is continued. If a mismatch occurs due to design error the contractor is held liable.
● Handed over to the owner
● Post commissioning documentation: Includes the P & ID, audits, maintenance records, log sheets, accident reports etc.
Process Commissioning Sequence

● Utilities:-
● Electricity
● Water and its treatment
● Compressed air
● DM water
● Fire water
● Cooling water
● Boiler
● Condensate
● Nitrogen
● Refrigeration
● ETP
Process Commissioning Sequence

● Tank farm
● Ancillary equipments
● Ventilation and fume extraction system
● Scrubber and absorber
● Vacuum system
● Intermediate storage tank
● Flare stack
● Reaction
● Raw Materials fed at correct temperature
● Catalyst Activation
● Controlling reaction parameters
Startup and Commissioning

The important steps involved in the startup and commissioning process are as follows:
● Mobilization of commissioning crew involving engineers of various disciplines,
chemists and their training.
● Clearing up the plant and site
● Inspection and testing: involves testing if all parts are fitted correctly. Other tests
include mechanical integrity test, pressure test, leak test and test for electrical
machinery.
● Mobilization of Materials: The materials that are to be mobilized are; Raw materials,
Steam, cooling water, Power, Boiler Feed Water, Lubricant Oil, Grease etc.
● Charging and Catalyst Activation: Various items like lubricant oil and catalysts are
charged and catalyst is activated.
Startup and Commissioning

● Section-wise startup
● Performance testing
● Quality check of intermediate and final products
● Gradual increase in plant capacity
● Consumption of raw materials and utilities are brought down to guarantee level
● Commissioning
● Trial Run
● Handover to owner

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