58683165 machinery comhhfghgfmissioning rotating and reciprocating equipment
DESCRIPTION
fghfghfghfhhhhsTRANSCRIPT
© Max Zornada (2002)Slide 1
Process Plant Equipment and Machinery Process Plant Equipment and Machinery CommissioningCommissioning
© Max Zornada (2002)Slide 2
Objectives of this ModuleObjectives of this Module
Process Equipment & Machinery is usually designed by process technology organisations or manufactured by specialist manufacturers e.g. rotating equipment. Every designer and
manufacturer will have there own unique and often proprietary approaches to commissioning and start up depending on the design and configuration features included in their processes
and equipment. All commissioning procedures for process designs, machinery and equipment should be developed in cooperation with manufacturers’ and vendors’ representatives in order
to be able to take such issues into account during commissioning and development of commissioning procedures.
The material presented in this section is therefore of a general nature and will in all cases be superseded by any specific manufacturer and vendor
recommendations where ever these are in conflict with what is presented here.
This section provides participants with an introduction to some of the key issues which must be considered when commissioning specific types of process equipment and machinery typically found in chemical and petrochemical
processing plants.
DisclaimerDisclaimer
© Max Zornada (2002)Slide 3
Types of Process EquipmentTypes of Process Equipment Distillation Towers/ Fractionation Distillation Towers/ Fractionation
TowersTowers Reboilers & Other Shell & Tube Reboilers & Other Shell & Tube
Heat ExchangersHeat Exchangers Boilers and Fired HeatersBoilers and Fired Heaters Pressure Vessels & PipeworkPressure Vessels & Pipework Fin-Fan CoolersFin-Fan Coolers CondensersCondensers ValvesValves InstrumentationInstrumentation Electrical EquipmentElectrical Equipment
Machinery and Rotating Machinery and Rotating EquipmentEquipment
PumpsPumps Steam TurbinesSteam Turbines Gas TurbinesGas Turbines CompressorsCompressors Gas EnginesGas Engines Electric MotorsElectric Motors
© Max Zornada (2002)Slide 4
Types of Process EquipmentTypes of Process Equipment
Pressure Vessels and Heat Pressure Vessels and Heat ExchangersExchangers
Reboilers & Other Shell & Tube Reboilers & Other Shell & Tube Heat ExchangersHeat Exchangers
Pressure Vessels & PipeworkPressure Vessels & Pipework Fin-Fan CoolersFin-Fan Coolers CondensersCondensers ValvesValves TanksTanks
Fired Heaters and BoilersFired Heaters and Boilers
Machinery & Rotating EquipmentMachinery & Rotating Equipment PumpsPumps Steam TurbinesSteam Turbines Gas TurbinesGas Turbines CompressorsCompressors Gas EnginesGas Engines Electric MotorsElectric Motors
Towers and ColumnsTowers and Columns Distillation Towers/ Fractionation TowersDistillation Towers/ Fractionation Towers Packed ColumnsPacked Columns
For commissioning purposes, we can cluster the different types For commissioning purposes, we can cluster the different types of process equipment into broad categories, based on the of process equipment into broad categories, based on the
degree of similarity in commissioning procedures.degree of similarity in commissioning procedures.
© Max Zornada (2002)Slide 5
Causes of Startup DelaysCauses of Startup Delays
75% due to equipment failure;75% due to equipment failure; 20% from inadequate equipment;20% from inadequate equipment; 5% from process failure.5% from process failure.
© Max Zornada (2002)Slide 6
Machinery Commissioning FailuresMachinery Commissioning FailuresIn decreasing order of problem frequencyIn decreasing order of problem frequency
1. Centrifugal compressors1. Centrifugal compressors
2. Steam turbines2. Steam turbines
3. Large gear speed increaser units3. Large gear speed increaser units
4. Electric motors in size categories above 1000 HP4. Electric motors in size categories above 1000 HP
5. Reciprocating compressors5. Reciprocating compressors
6. Gas Turbines6. Gas Turbines
7. Gas Expanders7. Gas Expanders
© Max Zornada (2002)Slide 7
Machinery CommissioningMachinery CommissioningRotating and Reciprocating EquipmentRotating and Reciprocating Equipment
© Max Zornada (2002)Slide 8
Key Steps in Machinery CommissioningKey Steps in Machinery Commissioning(% of total resources used)(% of total resources used)
Review Completeness of Installation (21%)Review Completeness of Installation (21%) Review maintainability of equipment (7%)Review maintainability of equipment (7%) Checks to ensure long-term, trouble free operation (4%)Checks to ensure long-term, trouble free operation (4%) Driver solo runs and rotation checks (9%)Driver solo runs and rotation checks (9%) Cleanliness checks (5%)Cleanliness checks (5%) Autostart simulations (joint mechanical/instrument technician Autostart simulations (joint mechanical/instrument technician
effort 1.5%)effort 1.5%) Documentation assembly (3.5%)Documentation assembly (3.5%) Machinery repairs, strip-down, dissassemle/reassemble (39%)Machinery repairs, strip-down, dissassemle/reassemble (39%) Miscellaneous (11%)Miscellaneous (11%)
© Max Zornada (2002)Slide 9
Process Plant Machinery CommissioningProcess Plant Machinery Commissioning
Executing the review tasks is facilitated by the use Executing the review tasks is facilitated by the use of checklists;of checklists;
The first and most important checklist is a The first and most important checklist is a checklist restating every construction and checklist restating every construction and installation related item contained in the job installation related item contained in the job specification documents;specification documents;
Checklist used to ensure the installation complies Checklist used to ensure the installation complies with the original specification;with the original specification;
See examples attached.See examples attached.
© Max Zornada (2002)Slide 10
Pre-commissioning Mechanical EquipmentPre-commissioning Mechanical Equipment
Field disassemble and reassemble;Field disassemble and reassemble; Clean out of the lubrication system, including chemical cleaning and Clean out of the lubrication system, including chemical cleaning and
passivation where required;passivation where required; Check circulation of lubricant to - check flow and temperature;Check circulation of lubricant to - check flow and temperature; Clean out, check and activate cooling water system;Clean out, check and activate cooling water system; Check out and commission of instruments;Check out and commission of instruments; Check for free and unhindered rotation of rotating elements;Check for free and unhindered rotation of rotating elements; Check tightening of anchor bolts and flange bolts;Check tightening of anchor bolts and flange bolts; Check for stresses on and due to connecting piping - disconnect and Check for stresses on and due to connecting piping - disconnect and
reconnect piping;reconnect piping; Check using dial gauges, set on one flange, measure movement in Check using dial gauges, set on one flange, measure movement in
connecting flange when bolts undone.connecting flange when bolts undone.
© Max Zornada (2002)Slide 11
Pre-commissioning Mechanical Equipment (Cont.)Pre-commissioning Mechanical Equipment (Cont.) Install temporary suction filters;Install temporary suction filters; Set system for no load running;Set system for no load running; Operate driver uncoupled;Operate driver uncoupled; Recoupling, with driver and verification of alignment;Recoupling, with driver and verification of alignment; Check out vent system;Check out vent system; Check out seal system;Check out seal system; Operation empty to check for vibration and heating of bearings (not always)Operation empty to check for vibration and heating of bearings (not always) Operation under load;Operation under load; Dry-run equipment and check for vibration and bearing overheat;Dry-run equipment and check for vibration and bearing overheat; Run with load;Run with load; Execute performance run and shutdown.Execute performance run and shutdown.
© Max Zornada (2002)Slide 12
PumpsPumps
© Max Zornada (2002)Slide 13
Pre-commissioning pumpsPre-commissioning pumpsInspection by mechanicsInspection by mechanics
Check for no unusual piping loads or temperature stresses Check for no unusual piping loads or temperature stresses are being imposed on pump flanges;are being imposed on pump flanges;
Check using an alignment indicator and loosed bolted at Check using an alignment indicator and loosed bolted at suction and discharge;suction and discharge;
Check clearances;Check clearances; Mechanical seals for proper installation an suitability;Mechanical seals for proper installation an suitability;
Check seal flushes for correct piping;Check seal flushes for correct piping; Check bearing chambers in pump and driver/motor:Check bearing chambers in pump and driver/motor:
Ensure free of flushing compounds or shipping grease Ensure free of flushing compounds or shipping grease and packing.and packing.
© Max Zornada (2002)Slide 14
Pre-commissioning pumpsPre-commissioning pumpsInspection by operatorsInspection by operators
Check pump pedestals, stuffing boxes, seal flush coolers, Check pump pedestals, stuffing boxes, seal flush coolers, cooling water connections to bearing jackets, process cooling water connections to bearing jackets, process piping connections;piping connections;
Check for installation of bleeds, drains, suction strainers;Check for installation of bleeds, drains, suction strainers; Instrumentation;Instrumentation; Lubrication of drivers and couplings;Lubrication of drivers and couplings; Working order block valves, check valves, plug cocks.Working order block valves, check valves, plug cocks.
© Max Zornada (2002)Slide 15
Running in PumpsRunning in Pumps
Motor loads of pumps started on water should be checked Motor loads of pumps started on water should be checked with an ammeter;with an ammeter;
Flow in pump should be restricted to limit motor load to Flow in pump should be restricted to limit motor load to nameplate value;nameplate value;
Open suction valve wide and close discharge valve of a Open suction valve wide and close discharge valve of a centrifugal pump;centrifugal pump;
For positive displacement pump, discharge must be For positive displacement pump, discharge must be slightly opened to limit excessive pressure buildup.slightly opened to limit excessive pressure buildup.
Bleed (prime) pump until it is full of liquid;Bleed (prime) pump until it is full of liquid; Start with discharge throttled;Start with discharge throttled; If discharge pressure is satisfactory, open discharge.If discharge pressure is satisfactory, open discharge.
© Max Zornada (2002)Slide 16
Running in PumpsRunning in Pumps Check pump driver and bearings for excessive vibration or Check pump driver and bearings for excessive vibration or
overheating;overheating; Check mechanical (or other) seals for leaks;Check mechanical (or other) seals for leaks; Check power requirements of driver with an ammeter;Check power requirements of driver with an ammeter; After running, close discharge, stop pump, close suction;After running, close discharge, stop pump, close suction; Inspect seals and alignment;Inspect seals and alignment; Temporary screens should remain in pump suction lines through Temporary screens should remain in pump suction lines through
initial startup and for at least a month;initial startup and for at least a month; Operations may dislodge foreign matter not flushed out Operations may dislodge foreign matter not flushed out
during commissioning.during commissioning. Check pump performance against specification.Check pump performance against specification.
© Max Zornada (2002)Slide 17
CompressorsCompressors
© Max Zornada (2002)Slide 18
Pre-commissioning CompressorsPre-commissioning Compressors
Suction and discharge piping of each stage has to be Suction and discharge piping of each stage has to be thoroughly cleaned before flow is passed through them;thoroughly cleaned before flow is passed through them;
Blow clean with steam or air at far in excess of process Blow clean with steam or air at far in excess of process velocity;velocity;
Installation of temporary strainers should be discussed with Installation of temporary strainers should be discussed with the manufacturer;the manufacturer;
All lubricating-oil equipment and lines must be thoroughly All lubricating-oil equipment and lines must be thoroughly cleaned;cleaned;
Fine-mesh filters should be installed upstream of all Fine-mesh filters should be installed upstream of all sensitive points (bearing, pistons etc.).sensitive points (bearing, pistons etc.).
© Max Zornada (2002)Slide 19
Field disassembly of centrifugal Field disassembly of centrifugal compressorcompressor
© Max Zornada (2002)Slide 20
Compressor Fully AssembledCompressor Fully AssembledGas Turbine Driver
© Max Zornada (2002)Slide 21
Compressor Lube-oil SystemCompressor Lube-oil Systemis a microcosm of a plant in itself - vessels, filters, pipes, is a microcosm of a plant in itself - vessels, filters, pipes,
pumps, motors, valves, instrumentation, electrical systems!pumps, motors, valves, instrumentation, electrical systems!Commissioning the lube-oil system can be a major Commissioning the lube-oil system can be a major
commissioning project in its own right.commissioning project in its own right.
Typical of lube-oil Typical of lube-oil systems also found systems also found on:on:
Gas TurbinesGas Turbines Steam TurbinesSteam Turbines PumpsPumps
© Max Zornada (2002)Slide 22
Operational TestingOperational TestingSame as for the process and plantSame as for the process and plant
Operational testing;Operational testing; Dry runsDry runs Hot testing of equipmentHot testing of equipment Dynamic TestingDynamic Testing
Safe fluidSafe fluid ““Solvent”Solvent” Process fluidProcess fluid
© Max Zornada (2002)Slide 23
Dry runs and Hot TestsDry runs and Hot Tests
Check that motors are connected correctly and turn Check that motors are connected correctly and turn in the right direction;in the right direction;
Shafts and impellers move freely;Shafts and impellers move freely; Equipment that is to be operated at temperature, Equipment that is to be operated at temperature,
raise to temperature and checked;raise to temperature and checked; These tests should be performed by the These tests should be performed by the
manufacturer’s representative but witnessed by manufacturer’s representative but witnessed by members of the client’s operating/commissioning members of the client’s operating/commissioning personnel.personnel.
© Max Zornada (2002)Slide 24
Performance testingPerformance testing Performance tests of major equipment such as furnaces, Performance tests of major equipment such as furnaces,
boilers, compressors, turbines, pumps, packages units boilers, compressors, turbines, pumps, packages units etc. should be handled by manufacturer’s representatives etc. should be handled by manufacturer’s representatives but in the presence of qualified inhouse resources;but in the presence of qualified inhouse resources; Engineers, maintenance specialists and operations Engineers, maintenance specialists and operations
staff;staff; Allow inhouse personnel to become familiar with the Allow inhouse personnel to become familiar with the
equipment;equipment; Inhouse staff need to certify the adequacy of the tests.Inhouse staff need to certify the adequacy of the tests.
© Max Zornada (2002)Slide 25
Use of Vendor/Manufacturer RepresentativesUse of Vendor/Manufacturer Representatives
Need to determine the degree to which vendor/ Need to determine the degree to which vendor/ manufacturer’s assistance is required during start up eg. manufacturer’s assistance is required during start up eg. How many representatives and skill/experience levels;How many representatives and skill/experience levels;
Some degree of vendor assistance will always be required - Some degree of vendor assistance will always be required - especially where there may be potential for warranty especially where there may be potential for warranty disputes;disputes;
Vendor personnel should also assist with:Vendor personnel should also assist with: Spare parts reviews;Spare parts reviews; Training of maintenance personnel;Training of maintenance personnel; Preparation of commissioning procedures and Preparation of commissioning procedures and
instructions.instructions.
© Max Zornada (2002)Slide 26
Use of External ContractorsUse of External Contractors
Identification of potential outside contractors who may be Identification of potential outside contractors who may be used as part of commissioning and ongoing maintenance;used as part of commissioning and ongoing maintenance;
e.g. Specialist contractors for:-e.g. Specialist contractors for:- Rotor balancing and emergency repairs;Rotor balancing and emergency repairs; Dismantling, cleaning and adjusting mechanical of Dismantling, cleaning and adjusting mechanical of
mechanical-hydraulic governors;mechanical-hydraulic governors; Companies with expertise in shaft, bearing, labyrinth or Companies with expertise in shaft, bearing, labyrinth or
impeller manufacturing and maintenance.impeller manufacturing and maintenance. Such organisations may wish to get involved during Such organisations may wish to get involved during
commissioning to catalogue equipment and parts, take commissioning to catalogue equipment and parts, take critical dimensions for future reference.critical dimensions for future reference.
© Max Zornada (2002)Slide 27
Distillation ColumnsDistillation Columns
Operational TestingOperational Testing
© Max Zornada (2002)Slide 28
Tests on Distillation ColumnsTests on Distillation Columns
Critical instruments should be recalibrated prior to starting any Critical instruments should be recalibrated prior to starting any tests;tests;
Control valves need to be in good working order - non-sticking Control valves need to be in good working order - non-sticking and capacity should be verified;and capacity should be verified;
If direct flow metering is not possible for critical streams, plans If direct flow metering is not possible for critical streams, plans should be devised for calculating flows based on known data;should be devised for calculating flows based on known data;
Potential limitations of peripheral equipment such as reboilers, Potential limitations of peripheral equipment such as reboilers, condensers, pumps and valves should be considered;condensers, pumps and valves should be considered;
Effects on downstream equipment or other processing units Effects on downstream equipment or other processing units should also be considered.should also be considered.
© Max Zornada (2002)Slide 29
Distillation Column Performance TestingDistillation Column Performance Testing
Performance tests are conducted to obtain data on Performance tests are conducted to obtain data on one or more of:one or more of: Tray efficiency;Tray efficiency; Capacity limitations;Capacity limitations; Energy consumption;Energy consumption; Pressure drop considerations.Pressure drop considerations.
© Max Zornada (2002)Slide 30
Acceptance Testing Distillation ColumnsAcceptance Testing Distillation Columns Need to make every effort to achieve design feed rates and Need to make every effort to achieve design feed rates and
compositions for a reliable acceptance test;compositions for a reliable acceptance test; Specific Areas of Interest:Specific Areas of Interest:
Tray efficienciesTray efficiencies Murphree tray efficiencies, concentration gradients;Murphree tray efficiencies, concentration gradients;
Overall column efficiencyOverall column efficiency Capacity Limitations:Capacity Limitations:
Maximum hydraulic throughputMaximum hydraulic throughput Maximum& minimum throughput for acceptable Maximum& minimum throughput for acceptable
separationseparation Energy consumptionEnergy consumption
© Max Zornada (2002)Slide 31
Distillation column characteristicsDistillation column characteristics
Maximum throughput for stable operations is when the Maximum throughput for stable operations is when the upper limit of vapour-liquid flow capacity of at least upper limit of vapour-liquid flow capacity of at least one of the trays has been reached and the column one of the trays has been reached and the column begins to flood;begins to flood;
Maximum liquid loading depends on the vapour rate;Maximum liquid loading depends on the vapour rate; Maximum vapour loading depends on the liquid rate;Maximum vapour loading depends on the liquid rate; Vapour and liquid rates vary from one section of the Vapour and liquid rates vary from one section of the
column to the other;column to the other; Several types of capacity tests should be considered.Several types of capacity tests should be considered.
© Max Zornada (2002)Slide 32
Maximum hydraulic throughputMaximum hydraulic throughputSeveral types of tests should be consideredSeveral types of tests should be considered
Determination of maximum feed rate while reflux and Determination of maximum feed rate while reflux and reboil rates are increased in proportion;reboil rates are increased in proportion;
Determination of maximum reboil rate with reflux to Determination of maximum reboil rate with reflux to balance constant feed rate;balance constant feed rate;
Determination of capacity of the section of column above Determination of capacity of the section of column above the feed by increasing the feed preheat and reflux to the feed by increasing the feed preheat and reflux to balance;balance;
Determination of capacity of the section of column below Determination of capacity of the section of column below the feed by increasing reboiler heat and decreasing feed the feed by increasing reboiler heat and decreasing feed preheat to compensate so that reflux rate becomes constant.preheat to compensate so that reflux rate becomes constant.
© Max Zornada (2002)Slide 33
Distillation Column TroubleshootingDistillation Column TroubleshootingIs the problem real? What is its magnitude?
Is problem with column or environment?
Is problem with capacity or efficiency?
Collect samples and other data
Calculate actual efficiency
Calculate mass-transfer parameters
Collect data on pressure drop vs rate
Compare observed & calculated pressure drops
Define feasible alternatives
Evaluate Alternatives
Problem in other process units ?
In column control?
In operating conditions
In auxiliary equipment?
Others?
ColumnEnvironment
Capacity?
Efficiency?
© Max Zornada (2002)Slide 34
End of Module of Equipment Specific Commissioning IssuesEnd of Module of Equipment Specific Commissioning Issues