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1. Workshop on “Plant Commissioning and Start-Up Procedures” Dr. Himadri Banerji
MD EcoUrja Ex Reliance and Tata Organized By :
2. Standard Implementation Path is show here
3. The Commissioning Process Key State Preparation and planning Mechanical
Completion and Integrity checking Pre-commissioning & Operational Testing Start Up
& Initial Operation Performance and Acceptance testing Post Commissioning
4. The Commissioning Process Detail - 1 Preparation and • Appointment of
Commissioning planning Manager or Lead Commissioning Engineer Mechanical •
Appointment of Commissioning Team Completion Members and Support Staff and
Integrity checking • Training Pre-commissioning & • Information Compilation
Operational Testing • Safety and Risk Assessment Start Up & Initial • Commissioning
Strategy Operation Development; • Procedures and Checklist Performance and
Development Acceptance testing • Post Commissioning Post Commissioning •
Detailed Plan and Budget Preparation;
5. The Commissioning Process Details – 1Facility Commissioning Issues Time
phasing construction and commissioning activities Time phasing the commissioning of
the various parts of the plant relative to each other Relationships and timings
determining when various systems need to be available: Electrical, Steam, Water,
Instrumentation Sequencing of the overall plant startup and shutdown to ensure we do
not create unsafe conditions Initial start up Process Control and Shutdown
Performance testing
6. Developing Startup Procedures Engineering and construction companies generally
follow a systematic procedure where by their startup engineers review the process
design several times as it is developed After the first review, a preliminary start-up and
operations procedure is written Decide what must be added to the design to make the
process capable of being started up and operated; By the time the final engineering
flow-sheets have been released a complete startup and operating instructions manual
should have been completed.
7. Issues Considered Are various part of the process too depend on one another Is
there enough surge capacity Are there provisions to prevent abnormal pressures,
temperatures and rates of reaction Where are additional valves and bypass lines
needed Special lines to allow equipment to be started up and rerun product/raw
materials.
8. System Level Activities Utilities systems - steam, instrument air, process water, fire
water, drainage, condensate return Electrical systems Instrumentation and
instrumentation systems; Cleaning and flushing Purging Initial start up and shutdowns
Performance testing
9. Equipment Level Activities Pressure testing & mechanical integrity testing of vessel,
columns and pipe work. Heat Echanger, condensers, coolers etc. Mechanical
equipment and machinery. Control Systems and Instrumentation. Operational testing.
Proof testing and acceptance.
10. What can be done before mechanicalcompletion Utilities commissioning Lube and
Seal-Oil Systems Cleaned Instrumentation and Control Loops Proven Piping, Towers
and Vessels Cleaned Boil-Out, Dry-Out and Acid Cleaning Turbine, Motor and Pump
Run-Ins Nitrogen Purge and Tightness Testing
11. Building Organisational Learning Best Practice Benchmarking Improvement
Industry Processes Standards Corporate Procedures and Knowledge Base Check
sheets Legislation Experience Process Design Specific Machinery &Equipment
12. Procedures Procedures are written routines/instructions that describe the logical
sequence of activities required to perform a work process and the specific actions
required to perform each activity. If there are no written procedures, there is no basis
for monitoring performance, focus for improvement or mechanism by which to capture
learning. The establishment of procedures and routines allow more time and mental
energy to deal with the unexpected, which always happen during commissioning.
13. Commissioning / Startup Logic A Critical Path Network (Plan) with written
procedures with related documents are required. These should define for the facility,
each plant system: • The order in which the systems will be started up. • Individual
activities at each stage. • Operation testing requirements. • Durations, waiting times,
cooling times. • Total duration for starting up each system. • Resources required -
labour, materials, equipment services • Temperatures, pressures, fluid flows used.
14. BY DR.HIMADRI BANERJI MD ECOURJAEX. RELIANCE AND TATA Copyright
www.ecouja.com 15
15. Commissioning / Startup and Shutdown Issues At the facility, system and
equipment level, we want to avoid: • Creation/existence of explosive mixtures, usually
because of the presence of air. • Water hammer and water based explosion effects,
due to contact between water and hot substances (steam, oil, etc.) In particular, during
commissioning hot fluids and gases will be coming into contact with cold surfaces in
places that would be hot under normal operations.
16. Mechanical Completion and Integrity Checking
17. Mechanical Completion and Integrity Inspection Preparation and planning •
Inspection Mechanical Completion • Pressure testing and Integrity checking • Cleaning
and Flushing • Machinery checkout Pre-commissioning & Operational Testing Start Up
& Initial Operation Performance and Acceptance testing Post Commissioning
18. Categories of Process Equipment Distillation Towers / Fractionation Towers Re-
boilers & Other Shell & Tube Heat Exchangers Boilers and Fired Heaters Pressure
Vessels and Pipe-work Fin-Fan Coolers Condensers Machinery/Rotating Equipment
Valves Instrumentation Electrical Equipment
19. Machinery / Rotating Equipment Pumps Steam Turbines Gas Turbines
Compressors Gas Engines Electric Motors
20. Mechanical Completion and IntegrityInspection Involves checking that everything
has been built and it there as per specification. Refer: • Piping Plan Drawings • Layout
and construction drawings • P & ID’s Electrical systems, Instrumentation and control
systems checkout done by appropriately qualified personnel (Electricians and
Instrumentation technicians). General commissioning engineers generally do not get
involved in this in a hands-on manner.
21. Mechanical Completion and IntegrityInspection Procedure Divide plant into
manageable areas; In a large plant, assign individuals or teams to specific areas;
Establish a master set of piping plan drawings and P&ID’s, mark up areas: Individual
commissioning engineers or teams walk every line and mark up every item that can be
confirmed as present on master set of drawings. Use different colored “highlighter”
pens to indicate different services.
22. Mechanical Completion and Integrity InspectionEvery line must be walked!
Physically see every
23. Mechanical Completion and IntegrityInspection Procedure Hints / Tips Ensure
pipes, vessels, valves etc. are all in the right place. Valves are correct type - globe,
gate, control; Vents, drains, steam traps etc. Flanges, bolts, types of bolts. Blind
flanges and swing able blinds in place, correct rating. Check all tag numbers. Punch
list any non-conformances.
24. Pipe Stressing Piping should provide adequately for expansion and contraction
due to temperature changes, without placing excessive stresses on equipment;
Misalignment between matching flanges on pipe work particular where there are
changes indirection (elbows) can cause stressing; Misalignments where pipe-work
connects to machinery, vessels and other process equipment; Can often be seen
visually, or checked with gauges using the same procedures we use to align rotating
equipment.
25. Piping and Equipment Supports
26. Piping and equipment support Mobile supports permit and guide the thermal
growth of equipment undergoing temperature change; If they do not function correctly,
vessels, equipment, pipe work, nozzles heat exchangers etc. may be damaged.
27. Typical Piping Support Methods
28. Piping and Equipment Supports Inspection prior to start up: • Check that installed
according to specification and not jammed; Inspection during warm up: • Check
thermal growth is occurring and supports are responding as per design; • Check that
there is no surface buckling or crimping - this needs to be corrected; • Check
expansion joints; • Check long straight runs of piping for bowing or support shoe that
may have slipped; • Rule of thumb - bowing is excessive if you can see it.
29. Piping and Equipment Supports Inspection after cool-down: • Check that sliding
supports have returned to original positions; • Establish that equipment can expand
and contract as required.
30. Inspection of Spring Supports Before hydro-testing: • Check that spring stops are
installed. (If not, the weight of water in pipe will deform the spring). After hydro-testing
but before heating: • Check that stops are removed; • Check that spring pointer is
positioned to cold setting;
31. Inspection of Spring Supports During and at end of heating: • Check pointer has
not exceeded hot setting; After cool down: • check to establish piping can expand and
• establish that springs can absorb loads.
32. Vessels and Columns
33. Inspection of Vessels and Columns The inspection of vessels, columns and
reactors should be scheduled to be completed before construction has closed them
up; Other inspections - e.g. for completeness or piping, insulation, safety etc. can be
scheduled later; If a vessel has been sealed up by construction, it is your duty to
inspect it, even it construction resist.
34. Inspection of Vessels and Columns Check that distributors have been installed
correctly; De-misters installed correctly and of correct materials, design, type; Vortex
breakers in place; Trays - packed or “bubble-cap” are correct: • Bubble caps not
jammed or damaged, down comers clear, supports all OK.
35. Pressure Testing
36. Pressure Testing - Objectives The objective of pressure testing is to confirm the
mechanical integrity of the plant; Verifying capability of containing the pressures it has
been designed to hold; Ensure there are no leaks and verify that the plant can be
reliably made leak free; Identify any vulnerabilities well before the plant is placed into
service; Meet the requirements of legislation, local, international and industry
standards.
37. Pressure Testing – Responsibilities Pressure tests of tanks, reactors and piping for
mechanical strength and tightness of joints is usually done by the construction team;
Commissioning team representatives should witness and certify the tests; Need to
verify that all necessary safety precautions have been taken;
38. Pressure Testing - Procedures Water for testing and flushing should contain a rust
inhibitor - one low in chloride content for stainless steel lines; After testing, water
should be drained completely from all lines that do not normally carry water, steam or
steam condensate; All low points should be checked for presence of water; Lines
should be dried by blowing hot air, dry inert gas or instrument air.
39. Pressure Testing – Vacuum Systems Final checks of vacuum systems are best
performed by pulling a vacuum and observing the rate of pressure rise in the blocked
in system; Excessive leaks can then be located by applying a mild positive pressure
and testing each flange with bubble solution.
40. Pressure Testing – Procedures 2 Isometric drawings of all systems to be tested
should be displayed on a board and marked up as each section is tested; Hydro
testing of piping and equipment according to code requirements to confirm mechanical
strength should be carried out on groups of equipment naturally suggested by design
pressure and function; All water, steam, condensate, oil, gas and process steam
piping should be hydro tested; Major equipment that has already been tested as part
of manufacturing may be isolated by blanks.
41. Cleaning and Flushing
42. Cleaning and Flushing Need to ensure no construction debris is left in pipes of
vessels - welding rods, bolts, gloves, rags etc. Large debris (lumber, cable, packaging)
should have been removed during mechanical integrity inspections; Small debris
(rags, nuts, dirt) must be flushed out of all pipe and vessels; Where oil coatings must
be removed, chemical cleaning is necessary.
43. Cleaning and Flushing Before flushing is started, check the process thoroughly to
ensure: • Screens have been installed in front of pump suctions. • Blinds in front of
equipment such as compressors and turbines; • “Jumper” spool pieces to allow for
continuity of flow.
44. Flushing Can be handled by geographic plant area; Sections too large for water
flushing: • Pipes greater than 30 in diameter (0.75 m), or • Pipes that should not be
touched with water; Should all be blown out with air or inert gas.
45. Flushing Regardless of whether pipes are cleaned with water, steam, air or
nitrogen, flow velocities should be high enough to ensure that pipes will be suitably
scoured; Need to ensure that the debris from one piece of equipment will not simply be
flushed into another; Water velocities should be at least 12 ft/sec (approx. 3.75 m/sec);
Air velocities a minimum of 200 ft/sec (approx.65 m/sec).
46. Pre-Commissioning and Operational Testing
47. The Commissioning Process Detail - 3 Preparation and planning Mechanical •
Steam and other utilities Completion commissioned and introduced; and Integrity
checking • Dry running trials; • Hot running trials; Pre-commissioning & • Safe-fluid
dynamic testing; Operational Testing • Solvent dynamic testing; • Process fluid tests.
Start Up & Initial Operation Performance and Acceptance testing Post Commissioning
48. Commissioning Utilities
49. Commissioning Utilities Utilities commissioning usually represents the first phase
of commissioning, as these usually need to operational first, before the rest of the
plant can be commissioned; The steps for commissioning each utility should be
planned in detail; Provides planning practice for planning the startup of the main plant.
50. Commissioning Utilities – Broad Guidelines Check supply pressures of all services
- steam, cooling water, instrument air, nitrogen etc. At the most distant points, open
drains, vent valves or pipe flanges and purge until fluids come out clean and rust free;
Purge/blow out lines to each piece of equipment; Check that instrument air is clean
and dry, and at correct pressure; Circulate water to waste water system until water
lines clear and clean; Flush waste water and drain systems to ensure no blockages;
Check operation of steam traps; Drain condensate to waste water until is clean.
51. Commissioning UtilitiesIntroducing Steam Steam usually represents the
first “hazardous” fluid introduced into the “new” system; Admit steam slowly
into the distribution system with atmospheric bleeds open: • Cold pipes will
condense steam in places where it would not under normal operation; • Can
lead to “water hammer”- can distort and rupture lines; After system has been
warmed, slowly raise pressure and blow down the system with traps
bypassed, until clean; Then place steam traps into service and check
operation.
52. High Pressure Steam SystemsSpecific Issues The cleanliness and purity
of high pressure steam systems - particularly where the steam is used to
drive a steam turbine should be checked by use of a “target”; For new boilers,
or new sections added to steam system - blow down at full pressure; When
steam appears clean, fit a target with a “mirrored” surface (ie. Small steel
plate which has been polished, so that it is in the steam blow down stream;
Blow down the boiler or system so that the target is impinged upon for a few
minutes; Check target - ensure there are no small “pock marks” left on the
target. If pock marked - repeat process.
53. Electrical Systems
54. Machinery and System Check-Out Check-out A crew of specialized
individuals need to be mobilized to do the check-out and pre-commissioning
in a plant: • All control loops, settings of PID loops, stroking of valves,
transmitter calibration, etc… • P&ID conformity; is the plant built according the
P&ID, is all instrumentation correctly installed, are they connected, are all
valves correctly installed, etc… • Mechanical installation of all (major)
equipment; levelling correct, alignments done, oil flushing satisfactory, etc… •
Analyzer calibration, checking of tubing, problem assessment and
identification. • Control systems functional check, communications check,
integrity check, safety features checking, emergency stops check, critical
operating parameters checking, etc… • Electrical check-out; check-out of
MCC’s, switchgears, selectivity studies, protection systems, functional
checks, etc…
55. Commissioning Electrical SystemsThe following checks are typical of
what is required Open circuit breakers and switches; Check that all bus-bars
are free of dirt and foreign matter; Check grounding systems for continuity
and resistance. Make sure all electrical equipment, vessels, structures are
connected to the grounding system in accordance with drawings and
specifications; Check that all sealed fittings are filled with proper sealants, all
explosion proof, vapour-tight, dust-tight and weather tight enclosures are
properly closed and secured; Check motor control and power circuitry for
correct hookup.
56. Commissioning Electrical Systems – 2The Following checks are typical of
what is required Check all nameplates and panel directories to ensure that
each circuit breaker and switch does control the proper circuit. Label all
switches even though their application may seem obvious; Close main
transformer primary disconnect switch and switch-gear main circuit breaker;
Check voltmeter at switch-gear for proper voltage; Close first switch-gear
circuit breaker, second, third etc. Close first motor control centre main circuit
breaker, then each motor starter circuit breaker. Repeat for each MCC.
Check overload breakers and heaters to ensure that the correct capacity
units have been installed.
57. Commissioning Electrical Systems – 3The following checks are typical of
what is required Check that all lighting and power circuits are functioning
correctly; Check motor bearings for proper lubrication; Remove motor power
fuses and check main contractor, interlock and sequencing devices;
Uncouple each motor, replace fuses and check direction of rotation by
momentarily pressing the start button, then stop; Check manual, then
automatic operation. Replace all couplings, check drive belts and make sure
guards are installed.
58. Electric Motor Driven Pumps
59. Operational Testing
60. Operational Testing Progresses through several stages; Dry runs of
individual items of equipment Hot testing of individual items of equipment and
systems; Several stages of Dynamic Testing of: • Individual items of
equipment; • Individual Systems/processes in isolation; • The whole new
process plant installation.
61. Dry Runs and Hot Tests Check that motors are connected correctly and
turn in the right direction; Shafts and impellers move freely; Equipment that is
to be operated at temperature, raise to temperature and check; These tests
should be performed by the manufacturer’s representative but witnessed by
members of the client’s operating/commissioning personnel.
62. Hot Testing Equipment Applies to equipment whose leak-tightness must
be tested at operating temperatures and after temperature reversals; Fixed-
bed catalytic reactors that in normal conditions are heated by heat transfer
fluids where leakage would contaminate the catalyst; Critical exchangers
whose steam or cooling water is at a high pressure than the process fluid;
Any equipment having complicated seals through which leakage could occur;
Rotating machinery which must be able to rotate freely at temperature eg.
Steam turbines, etc.
63. Hot Testing Procedures The thermal shock tolerance of equipment must
be determined beforehand; To avoid thermal shock, the temperature of the
heating medium may have to be raised gradually; Time required for a hot test
must be established in advance; Establish a uniform temperature in all parts
of equipment that are supposed to be uniformly hot during operation to avoid
setting up stresses;
64. Dynamic Testing
65. Dynamic Testing Involves operating the equipment, before introducing
“live” process fluid; During dynamic testing, we progress through: • Safe-fluid
dynamic testing; • Dynamic testing with solvent; • Closed loop testing with
process fluid. Once process fluid is introduced, normal plant safety
procedures must come into effect as if it were a live operating plant.
66. Safe-Fluid Dynamic Testing Closed loop dynamic testing with safe fluids
consists of operating equipment systems with air, water, inert gases etc. This
permits flow testing of equipment; Gives first indication of how control loops
work; Establishes performance while there is still time to modify the plant;
Familiarizes operators with the operation of the equipment before hazardous
materials are introduced; Gets rid of a lot of dirt which would be more difficult
to Clear once the process fluid has been introduced.
67. General Principles for Testing For most plants, a period of 2-3 weeks is
usually sufficient for operational testing, after the mechanical dry running of
individual pieces of equipment and hot testing complete; Air and water tests
should be set up in a closed loop with fluids continuously recycled, with loops
as large as possible; The loop should ideally be the same loop that will be
subject to solvent testing; Tests should continue for several days in order to
give all shifts a chance to conduct the same tests; All shifts should be given
the opportunity to start up and shutdown each closed loop test.
68. General Principles for Testing A rough flow-sheet should be developed
for air and water tests, predicting all information that normally appears on a
process flow sheet - flow, temperature, pressure, heat transfer, power etc. will
assist in alerting commissioning team for risks from over- pressuring, over
loading temperature-shocking and stressing equipment;
69. Cautions During Testing Dynamic testing may lead to: • Unusual or
unforeseen differential expansions; • Corrosion • Excessive weight of liquid
into parts of the system; Care must be taken not to collapse or burst pressure
vessels and tanks: • ensure there is always adequate venting; • avoid pulling
a vacuum.
70. Dynamic Testing – Simulated OperationsSafe Fluid Testing Auxiliary
services must be brought into operation first: • water cooling, inert gas
generators, boiler feed water, firewater, steam production, etc. Water is
pumped through the process (except where special conditions do not permit
it) and boiled up in columns; Compressors and blowers should be operated
on air or inert gas.
71. The Value of Dynamic Testing –Simulated Operations Value of simulated
operations will be to allow operator to become familiar with the operation of
the process, before hazardous fluids are introduced; Equipment deficiencies
can become apparent during dynamic testing; Failures and problems more
easily corrected with safe fluids present Leaks should be found and
tightened; Instruments can be placed into service - although selection of set-
points will have to be deferred; Inspect the plant for evidence of design and
construction errors.
72. Dynamic Testing – Simulated Operations
73. Dynamic Testing with a Solvent After safe fluid testing and subsequent
repairs and modifications, we are ready for dynamic closed loop testing with a
solvent; The “solvent” is a relatively safe fluid whose properties are close to
that of the process fluid, or the process fluid itself; In order to allow for
continuous re-circulation of the solvent and the use of different solvents in
different parts of the plant, temporary lines will need to be installed.
74. Dynamic Testing with Process Solvent Introduce the process solvent. (if
there is more than one, introduce only one at this stage); The dynamic testing
procedure used for the safe fluid test is repeated for the process solvent
dynamic testing; After operations with the first solvent have been brought
completely under control, should the second solvent be introduced (if there is
one).
75. Dynamic Testing with a Solvent The purpose of dynamic testing with a
solvent is to check out equipment and instrument loops at, or near design
conditions prior to the introduction of more hazardous process fluid; No
reactions should be allowed to occur during these tests, so as to ensure that
test fluids remain predictable in composition and properties; Guidelines used
for safe-testing apply; Need to plan how solvent will be fed into the system
and later removed.
76. Stages of Dynamic Testing with a “Solvent” Drain safe fluid and purge air
used in the previous test from the system; Dry out equipment where safe fluid
was water. Check flow sheets for where water is likely to accumulate. Fill
systems with the solvent. Ensure provisions made for venting and drains
closed; When adequate levels established, place pumps and compressors
online to complete filling; Start closed loop circulation; Heat up the systems to
simulate operating conditions by placing reflux, re-boiler and condensation
systems into operation
77. Stages of Dynamic Testing with a “Solvent” Systematically check out
instrumentation and control loops; After instruments have checked out, place
as many as possible on automatic control; All shifts should go through
starting and stopping equipment, heating and cooling closed loop systems;
Dynamic “solvent "testing offers the best opportunity for operator training
before the “real thing”; Operate equipment as near as possible to design
capacities; Reliability of emergency shutdown systems and alarms must be
proven; Critical instruments must be calibrated over their full range.
78. Stages of Dynamic Testing with a “Solvent” Deliberately operate
equipment near its limits: Flood columns; Ease compressors into mild surges
and plot surge curves; Overload condensers; Do not fear blowing a relief
valve or two! After tests have been completed, plant should be ready for initial
operation.
79. Closed Loop Dynamic Testing with Process Fluid Finally, introduce
process fluid; During this step, instruments should be calibrated to cover their
full range of flow, temperature and pressure; Ensure that instruments,
process analysers and safety devices are kept work properly during these
processes; After operations with process fluid are brought completely under
control should the final stage of start-up be attempted.
80. Preparing to Introduce Process Fluid Before introducing hazardous liquids
into the plant, we complete additional pressure testing and purging; Need to
check that the stresses and strains of dynamic testing has not caused any
leaks – these must be found and fixed;
81. Pressure Testing and Purging Consists of pressuring and de-pressuring
with nitrogen several times, until at least <3% oxygen is reached; Vacuum
systems should be evacuated and then re-pressured with nitrogen; Long runs
of piping are swept with nitrogen; While under pressure, rate of pressure loss
of the “blocked in "system is monitored as a check for leaks and that no vents
or drains have been left open.
82. Dehydrating by Circulation It is usually not possible to water-free
equipment simply by draining; Only positive method to water-free process
equipment is oil circulation followed by repeated draining of low points;
Ensure sufficient low point drains are provided on piping, control valve loops,
vessels and process machinery; Startup lines - deliver oil to upper part (trays)
of distillation towers (size for 20% of net distillate product rate);
83. Start Up and Initial Operation
84. Preparation and planningMechanical Completionand Integrity checking
Pre-commissioning & Operational Testing • Introduction of process fluid •
Start-up and initial operation • Trouble-shooting and Start Up & Initial
Operation problem correction. • Plant taken to full operations. Performance
and Acceptance testingPost Commissioning
85. Most plants in petrochemical/chemical industry have the following
“general ”form. Feed Reaction Recovery Product Preparation refiningStart Up
from the End of the Process and Work back
86. Start Up Logic It is common practice to buy in product and start up the
last past of the process first and work backwards to the front. E.g. • Start up
refining, get this working and in control; • Then possibly start up reaction and
recovery; • Finally, feed preparation.
87. Into the Initial Operation Once raw materials are fed into the plant –
usually at reduced rate until reaction conditions have been established; As
each section is started up, establish as quickly as possible that process
conditions are as expected; If potentially serious problems develop, there
should be no hesitation on going into an emergency shutdown.
88. Ramping up the Plant Plant is brought slowly to design feed-rates and
operating conditions; Usually done in steps with operating data evaluated and
verified as OK at each step; Plant and laboratory data are now being
collected and should be being evaluated promptly;
89. Coordination and SupervisionDuring Start Up Additional personnel, both
supervisory and “on the- ground” are required at this stage; Cooperation
between startup personnel and plant supervisory personnel is critical at this
stage: • Need a daily meeting at least; • Often, a briefing each shift.
90. Trouble Shooting At this stage, many problem with equipment of the
process itself may become apparent; The commissioning process goes
through what is often an intense (and hopefully short) period of problem
trouble shooting, problem solving, engineering correction and plant
modification;
91. Performance and Acceptance Trails
92. Preparation and planning Mechanical Completionand Integrity
checkingPre-commissioning & Operational Testing Start Up & Initial
Operation Performance and • Performance trails; Acceptance testing • Formal
Acceptance testPost Commissioning
93. The Performance Trials Once the plant is fully operational, the final
“proving trial” or performance run is performed in order to prove the plant can
do what it is supposed to do; The values or range of values for each
independent variable - flow, temperature, pressure, level, concentrations, etc.
to which the plant must be operated to are determined; The plant is brought
up to those conditions and the pre- agreed trial period begins.
94. Before the Trails of Performance RunNeed to Ensure that… Control of
plant operating conditions has been achieved. I.e. temperature, pressures,
levels and analyses are reasonably constant or in the case of a batch
process, there is repeatability; Daily material and energy balanced can be
performed and that these agree with “official” production figures; Product
specifications are being achieved consistently.
95. Need to Verify … Physical operation, capability and capacity of plant and
equipment; Energy and mass balance; Process chemistry; Efficiencies, yields
and quality; All to specification.
96. Acceptance When the plant has met the Performance and Acceptance
test requirements designed by the commissioning team there is usually a
formal acceptance process involving signing of acceptance certificates; Once
the plant is accepted it is officially part of the normal operations - the
responsibility of operations and maintenance; Commissioning is officially
over; The may still be outstanding punchlist items
97. Acceptance Testing It is common practice to prove performance
repeatability and plant integrity as part of the performance test. That is: •
Shutdown and Start Up the plant on several occasions and bring it up to test
conditions to prove repeatability. Also ramp down and ramp up while online; •
Re-inspection of critical process equipment - particularly columns to ensure
they have not been damaged by the performance run.
98. Commercial Significant of Acceptance Formal Acceptance represents
formal acknowledgment that the: • Contractor has full-filled their contractual
obligations; • Commissioning team have full-filled their obligations;
Completion of the Capital Project and transfer to Operations; Expenses and
costs from acceptance onwards are now operating expenses not capital
project costs; All subject to agreed punch-list items.
99. Post-Commissioning
100. Preparation and planning Mechanical Completionand Integrity
checkingPre-commissioning & Operational Testing Start Up & Initial • From
plant on-stream to settled down Operation and in regular production;
Performance and • Adjustments, modifications and fault Acceptance testing
correction; • Completion of outstanding punch listPost Commissioning items
101. Post Commissioning Covers the period immediately after Acceptance;
Outstanding punch-list items are completed; The first routine maintenance
checks are performed, findings evaluated and reported; Process equipment
and items covered by warranty are scrutinized for signs of premature wear-
out or problems; Operating data is collected and evaluated to ensure
consistent plant operations are maintained and sustainable.
102. BY DR.HIMADRI BANERJI MD ECOURJAEX. RELIANCE AND TATA
Copyright www.ecouja.com 103
103. WORKSHOP ON PLANT START UP AND
COMMISSIONINGSEQUENTIAL START UPAUTOMATION IN PLANT
START UP AND COMISSIONINGBY DR. HIMADRI BANERJI(EX RELIANCE
AND TATA)www.ecourja.com BY DR.HIMADRI BANERJI MD ECOURJA EX.
RELIANCE AND TATA Copyright www.ecouja.com 104
104. Automation for Controlled Start Up To advocate the usage of process
integration in industrial practice, it is important to be able to guarantee not
only robust control during near steady state operation, but also to provide
procedures for generating fast and reliable start-up sequences. BY
DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright
www.ecouja.com 105
105. Sequential Start Up and Shutdown UsingAutomation in Plant…Burner
Management System1. Burner Management System in Power Plants General
The Burner Management System must be designed to ensure a safe, orderly
operating sequence in the start-up and shutdown of fuel firing equipment and
to reduce possible errors by following the operating procedure. The system is
intended to protect against malfunction of fuel firing equipment and
associated systems. The safety features of the system shall be designed to
provide protection in most common emergency situations, however, the
system cannot replace an intelligent operators reasonable judgment in all
situations. In some phases of operation, the BMS shall provide permissive
interlocks only to insure safe start-up of equipment. Once the equipment is in
service, the operator must follow acceptable safe operating practices. BY
DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright
www.ecouja.com 106
106. Sequential Start Up…BMS FunctionsThe BMS shall be designed to
perform the following functions:1.Prevent firing unless a satisfactory furnace
purge has first been completed.2. Prohibit start-up of the equipment unless
certain permissive interlocks have first been completed.3. Monitor and control
the correct component sequencing during start-up and shut- down of the
equipment.4. Conditionally allow the continued operation of the equipment
only while certain safety interlocks remaining satisfied.5. Provide component
condition feedback to the operator and, if so equipped, to the plant control
systems and/or data loggers.6. Provide automatic supervision when the
equipment is in service and provide means to make a Master Fuel Trip (MFT)
should certain unacceptable firing conditions occur.7. Execute a MFT upon
certain adverse unit operating conditions. BY DR.HIMADRI BANERJI MD
ECOURJA EX. RELIANCE AND TATA Copyright www.ecouja.com 107
107. Furnace Explosions A common cause of furnace explosions is “Fuel
leakage into an idle furnace and the ignition of the accumulation by a spark or
other source of ignition”. Proper attention to the design of the interlocks and
trip system to provide a safe light up of the boiler furnace is required. BY
DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright
www.ecouja.com 108
108. Furnace Purge…Permissives Before any fuel firing is permitted, either
initially or after a boiler trip, a satisfactory furnace purge cycle must be
completed. Prior to starting a furnace purge cycle, the operator must ensure
that the following purge requirements are satisfied[i]: 1. Drum level within
operating range (not high, not low) 2. Instrument air header pressure within
operating range 3. Fan is in service 4. Purge airflow capable of a minimum of
70% of the full load airflow established through the unit[ii]. BY DR.HIMADRI
BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright
www.ecouja.com 109
109. Furnace Purge…Permissives 5. All flame scanners reading "No Flame“
6. Natural gas block valves are proven closed 7. Fuel oil block valves are
proven closed 8. Air dampers are in the fully open position 9. Natural gas, or
fuel oil, header pressure upstream of block valve is satisfactory 10. Pilot gas
header pressure is satisfactory 11. Burner Control System is energized 12. A
"No Master Fuel Trip condition" condition is established BY DR.HIMADRI
BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright
www.ecouja.com 110
110. Pre Purge Permissives Pre purge permissive condition checks and
furnace purge are to be initiated by the operator from the local BMS panel
(you may see detailed guidelines on cold starting using fuel oil, cold starting
using natural gas from operating manuals). Purge air flow: The total furnace
airflow shall not be reduced below the purge rate airflow (70% of the
maximum continuous airflow capacity). Reducing airflow below these limits
will lead to a MFT, and a new furnace purge will be required. Suggested color
design: Purge Permissives indicating lights: white Purge Available indicating
light: green Purge in progress indicating light: amber Purge complete
indicating light: white MFT reset indicating light: red BY DR.HIMADRI
BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright
www.ecouja.com 111
111. Main Flame Start-Up Sequence The main flame start-up sequence, from
the lighting the of the pilot flame through main flame light-off, is an automated
sequence. Once the start-up sequence has begun, only the “BOILER STOP”
switch and the “EMERGENCY STOP” will interrupt the start-up sequence.
Any interruption of the start-up sequence requires a post-fire purge prior to
attempting to start the boiler again. To initiate the start-up sequence, the
operator activates the “START BOILER” switch. BY DR.HIMADRI BANERJI
MD ECOURJA EX. RELIANCE AND TATA Copyright www.ecouja.com 112
112. Pilot Flame Light-Off Before the burner can be started, satisfactory light-
off conditions for the pilot and main burners must be met. This is
accomplished when the following conditions are satisfied: For the pilot igniter:
1. MFT relay reset 2. Pilot gas header pressure normal For natural gas: 1. All
of the above mentioned for the pilot igniter 2. Natural gas pressure normal 3.
Natural gas control valve is in light-off position BY DR.HIMADRI BANERJI
MD ECOURJA EX. RELIANCE AND TATA Copyright www.ecouja.com 113
113. Pilot Flame Light-Off For fuel oil: 1. All of the above mentioned for the
pilot igniter 2. Oil gun is in place in the burner 3. Oil pressure is normal 4.
Fuel oil atomizing interlocks are satisfied 5. Fuel oil atomizing medium is
provided to the burner 6. Oil control valve is in light-off position Other
Conditions: 1. No MFT condition after purge 2. All flame scanners report no
flame 3. All natural gas, or all fuel oil, block valves shown closed 4. All air
dampers are in light-off position BY DR.HIMADRI BANERJI MD ECOURJA
EX. RELIANCE AND TATA Copyright www.ecouja.com 114
114. Pilot Flame Light-Off Failure to meet any of these conditions shall
prevent the burner light-off operation. To light the pilot flame, the pilot header
vent valve, and, for natural gas fuel, the natural gas vent valve shall be
closed by the boiler control system. Then, sequentially, the igniter transformer
is energized, the pilot gas block valves are open and a 10 second pilot
ignition timer starts counting down. When ignition timer cycle is completed,
the igniter transformer is de-energized and the pilot flame scanner is checked
by the control system. If the pilot flame is present, the main flame light-off
sequence continues. BY DR.HIMADRI BANERJI MD ECOURJA EX.
RELIANCE AND TATA Copyright www.ecouja.com 115
115. Pilot Flame Light-Off If the pilot flame fails, the boiler control system
initiates a pilot flame failure shutdown. Additional attempts of pilot light-off are
permissible provided a successful pilot light-off is made within 10 minutes
after the furnace purge. Note that if the pilot flame continues to fail after
several attempts, the boiler should be inspected to determine the fault and
the condition corrected. BY DR.HIMADRI BANERJI MD ECOURJA EX.
RELIANCE AND TATA Copyright www.ecouja.com 116
116. Main Flame Light-Off Once the pilot flame is made, the boiler control
system opens the header block valves for the selected fuel. A main flame
light-off timer begins a 15 second countdown for natural gas, or 20 seconds
for fuel oil, to establish and stabilize the main flame. At 5 seconds before time
out, the boiler control system closes the pilot block valves and opens the pilot
vent valve. The remaining 5 seconds are used to detect the main flame. For
the typical dual flame scanner design, a main flame failure shutdown is
initiated if both flame scanners return a “no flame” signal to the burner control
system. This will generate a boiler trip, and another furnace purge will be
required. Once the burner is lit, the system is in the NORMAL RUN
CONDITION and combustion controls should be released to modulation
control BY DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND
TATA Copyright www.ecouja.com 117
117. Shutdown Shutdown Per NFPA 8501, section 6-2.4.5, “The normal
shutdown cycle for the boiler shall accomplish the following in the order listed:
(a) Shut off fuel supply to the main burner. (b) Interrupt spark and shut off fuel
supply to igniters, if in operation. (c) For oil: 1. Where used, open the
recirculating valve. 2. Shut off atomizing medium, if desired. (d) For gas, vent
piping between safety shutoff valves to atmosphere. (e) Perform a post purge
of the boiler furnace enclosure. (f) Shut down fan, if desired.” For a safety
shutdown, a manual reset is also required. Normal Boiler Shutdown A normal
shutdown is initiated by operating BOILER SHUTDOWN switch. This will
initiate the shut down sequence listed above. BY DR.HIMADRI BANERJI MD
ECOURJA EX. RELIANCE AND TATA Copyright www.ecouja.com 118
118. Boiler Master Fuel Trip Any of the following conditions shall cause a
boiler trip to occur. This results in the shutdown of all fuel and requires
another furnace purge cycle before any attempt at re-lighting. For fuel oil: 1.
Excessive steam pressure. 2. Low water level. 3. Low fuel pressure. 4. Low
oil temperature. 5. Loss of combustion air supply. 6. Loss of flame. 7. Loss of
control system power. 8. Loss of atomizing medium, if used. BY DR.HIMADRI
BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright
www.ecouja.com 119
119. Boiler Master Fuel Trip For natural gas: 1. Excessive steam pressure or
water temperature. 2. Low water level. 3. High or low gas pressure. 4. Loss of
combustion air supply. 5. Loss of flame. 6. Loss of control system power. BY
DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND TATA Copyright
www.ecouja.com 120
120. Boiler Master Fuel Trip In the event of an MFT, the control system shall
initiate the following: 1. Execute a shut down as listed above. 2. Illuminate the
appropriate indicator lights and alarms. 3. Return the system to the pre-purge
state Boiler restart will be inhibited until all pre-purge requirements are
satisfied. BY DR.HIMADRI BANERJI MD ECOURJA EX. RELIANCE AND
TATA Copyright www.ecouja.com 121
121. Alarms The following is a list of recommended alarm conditions: 1. Any
boiler or burner trip signal 2. High or low water level 3. High furnace pressure
4. Partial Loss of flame (For the typical two scanner system, one indicates “no
flame”) 5. Main fuel shutoff valves closed 6. Loss of control system power 7.
Unsuccessful burner shutdown BY DR.HIMADRI BANERJI MD ECOURJA
EX. RELIANCE AND TATA Copyright www.ecouja.com 122
122. Interface with the CombustionControl System (CCS) The following list, at
a minimum, of signals should be sent to the Combustion Control System: 1.
Controls to purge position 2. Controls to light-off position 3. Normal run
condition: release controls to modulation 4. Main natural gas block valve
open: permissive to place gas control valve in automatic. 5. Master fuel trip:
run boiler load to zero and place combustion controls in manual. 6. Oil
recirculation signal Under the provisions of NFPA 8501, section 6-5.2.3, for a
single burner boiler, the BMS and CCS may reside in the same processor.
This option can reduce the integration complexity and increase the BMS to
CCS interface reliability. BY DR.HIMADRI BANERJI MD ECOURJA EX.
RELIANCE AND TATA Copyright www.ecouja.com 123
123. Operator Interface The above describes a traditional operator interface
using discrete switches and indicator lights. The control designer is
encouraged to incorporate a graphical user interface or similar options in
order to enhance the ease of use and readability of the boiler control system
operator interface Workshop on Start Up and Commissioning Dr. Himadri
Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com
124. SEQUENTIAL START UP AUTOMATION DESIGN PRINCIPLES OF
BURNER MANAGEMENT SYSTEM Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
125. Design Principles of Sequential Start-Up…Case Study in Burner
Management System Design Introduction Burner Management System
Objectives BMS Design Standards and Definitions BMS Logic BMS
Strategies and Hardware ◦ Types of Burner Management Systems BMS
Interface to SCADA Systems Summary Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
126. IntroductionBurnerManagementSystems....a starting point. Workshop on
Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance
and Tata www.ecourja.com
127. Introduction What is a BMS? A Burner Management System is defined
as the following: ◦ A Control System that is dedicated to boiler safety,
operator assistance in the sequential safe starting and stopping of fuel
preparation and burning equipment, and the prevention of mis-operation of
and damage to fuel preparation and fuel burning equipment. 1 1. From NFPA
8501 “Standard for Single Burner Boiler Operation” Workshop on Start Up
and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
128. Burner Management Objective Sequence burner through safe start-up
Insure a complete pre-purge of boiler Supervise safety limits during operation
Supervise the flame presence during operation Sequence a safe shutdown at
end of cycle Integrate with combustion control system for proper fuel and air
flows Workshop on Start Up and Commissioning Dr. Himadri Banerji MD
EcoUrja, Ex Reliance and Tata www.ecourja.com
129. BMS Design Standards Each Burner Management System should be
designed in accordance with the below listed guidelines to control and
monitor all sequences of the start-up and shutdown of the burner ◦ National
Fire Protection Association (NFPA 8501 /8502 or others) ◦ Industrial Risk
Insurers (IRI) ◦ Factory Mutual loss prevention guidelines o Each burner
management system should be designed to accomplish a safety shutdown in
the event of an unsafe condition. (FAIL SAFE) Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
130. BMS Design Standards U.S. National Fire Protection Association
(NFPA) ◦ Governs safety system design on virtually all boilers (regardless of
the process to be used to combust the fuel) ◦ Requires the separation of the
Burner Management System from any other control system ◦ Requires the
use of a hardwired backup tripping scheme for microprocessor based
systems ◦ Requires that a single failure NOT prevent an appropriate
shutdown ◦ Factory Mutual loss prevention guidelines. Workshop on Start Up
and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
131. NFPA 8501 NFPA 8501 Standard for Single Burner Boiler Operation ◦
Single Burner Boilers with fuel input greater than 12.5 mBTU/Hr (Approx. 250
BHP) ◦ Single Fuel or Combination of Fuels (Common being Natural Gas /
No.2 Oil / No. 6 Oil) ◦ Simultaneous Firing Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
132. NFPA 8502 NFPA 8502 Standard for Prevention of Furnace
Explosions / Implosions in Multiple Burner Boilers ◦ Multiple Burner Boilers
with fuel input greater than 12.5 mBTU/Hr ◦ Single Fuel or Combination of
Fuels including Pulverized Coal ◦ Emphasis on implosion protection (larger
boilers with induced draft systems) Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
133. BMS Definitions Furnace Explosions ◦ “Ignition of accumulated
combustible mixture within the confined space of a furnace or associated
boiler passes, ducts, and fans that convey gases of combustion to the stack”1
◦ Magnitude and intensity of explosion depends on relative quantity of
combustibles and the proportion of air at the time of ignition 1. From NFPA
8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner
Boilers” Workshop on Start Up and Commissioning Dr. Himadri Banerji MD
EcoUrja, Ex Reliance and Tata www.ecourja.com
134. BMS Definitions Furnace Explosions can occur with any or a
combination of the following:1 ◦ Momentary loss of flame followed by delayed
re-ignition ◦ Fuel leakage into an idle furnace ignited by source of ignition
(such as a welding spark) ◦ Repeated Light-off attempts without proper
purging ◦ Loss of Flame on one Burner while others are in operation ◦
Complete Furnace Flame-out followed by an attempt to light a burner 1. From
NFPA 8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner
Boilers” Workshop on Start Up and Commissioning Dr. Himadri Banerji MD
EcoUrja, Ex Reliance and Tata www.ecourja.com
135. BMS Definitions Furnace Implosions ◦ More common in large Utility
Boilers ◦ Caused by any of the following: Malfunction of equipment regulating
boiler gas flow resulting in furnace exposure to excessive induced draft fan
head capability Rapid decay for furnace gas temperature and pressure due to
furnace trip 1. From NFPA 8502 “Prevention of Furnace Explosions /
Implosions in Multiple Burner Boilers” Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
136. BMS Basic Definitions Common Terminology ◦ Supervised Manual
Manual Burner Light-off with Interlocks ◦ Automatic Recycling (Single Burner
Only) Automatic Burner Start and Stop based on preset operating range (ie..
Drum pressure) ◦ Automatic Non Recycling (Single Burner Only) Automatic
Burner Start and Stop based on Manual command to start. Workshop on
Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance
and Tata www.ecourja.com
137. Types of Flame Scanners Infrared (IR) Detectors ◦ Single Burner
Applications ◦ More Suitable with Oil Burning Flames Ultra-Violet (UV)
Detectors ◦ Multiple Burner Applications ◦ More Suitable for Gas Burners and
Combination Gas / Oil Burners Self Check Scanners ◦ Flame Signal is
interrupted at set intervals to verify proper operation of scanner Workshop on
Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance
and Tata www.ecourja.com
138. Single Burner BMS Inputs Low Low Drum Level (D) High Steam
Pressure (D) (D) Purge Purge Air Flow Minimum Air Flow (D) (D) Limits Made
Flame / No Flame Hold to Purge SCRL RESET MO DE BURNER FUEL
SELECT FD FAN OFF ON GAS OIL HAND OFF AUTO (D) Fuel Oil Temp
Low Fuel Oil Temp High (D) (D) Fuel Oil Press Low Fuel Oil Flow (A) (D)
Atomizing Medium Flow > Min Atomizing AE TE (D) Medium Common Alarm
Output Press Low (D) Remote Annunciator (By Others) FEEDWATER PSH
PSL STEAM PT PSH FT IGNITER Safety Shut Off GAS LSLL & Vent Valves
LSLL Fuel Fuel Gas Gas FT PSL TSH TSL FS Press Press Low High (D) (D)
PSL PSL OIL Safety Shut Off Control Valves Valve ATOMIZING Control
Valve & MEDIUM Shut Off Valve (D) - Descrete Signal Used By Flame
Safeguard System FT PSL PSH GAS Safety Shut Off & Control Vent Valves
Valve Workshop on Start Up and Commissioning Dr. Himadri Banerji MD
EcoUrja, Ex Reliance and Tata www.ecourja.com
139. BMS Logic Burner Management Systems can be broken down into
“Interlock Groups” Typical BMS Interlock Groups: ◦ Boiler Purge ◦ Igniter
Header Valve Management ◦ Main Fuel Header Valve Management ◦ MFT
(Master Fuel Trip) Logic Workshop on Start Up and Commissioning Dr.
Himadri Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com
140. Purge Interlocks BOILER TRIPPED AND PURGE / RESET PB START-
UP TIMER START FD FAN PERMISSIVES SATISFIED: - MAIN FUEL
VALVES CLOSED - NO FLAME PRESENT - FD FAN RUNNING AND -
MINIMUM AIR FLOW SWITCH MADE - WATER LEVEL SATISFACTORY -
ATOMIZING MEDIUM ON - FUEL SUPPLY PRESSURE NOT LOW
ENERGIZE FUEL RELAY NOT AND PURGE SIGNAL TO CCS PURGE AIR
FD DAMPER IN FLOW SWITCH AND FULL OPEN MADE POSITION
PURGE TIMER SET PURGE COMPLETE NO YES REMOVE PURGE TO
CCS SYSTEM TRIP Workshop on Start Up and Commissioning Dr. Himadri
Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com
141. Igniter Interlocks PURGE COMPLETE AIR DAMPER IN LOW FIRE
FUEL VALVE IN LOW FIRE AND POSITION POSITION ENERGIZE
IGNITER AND IGNITER HEADER VALVES 10 SECOND DELAY 10 SEC
PILOT TRIAL FOR IGNITION TIMER COMPLETE FLAME PROVEN NOT
AND SYSTEM TRIP PERMIT FOR MAIN FLAME Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
142. Main Flame Interlocks IGNITER TIMER COMPLETE FLAME AND
PROVEN ENERGIZE MAIN FUEL VALVES 10 SEC MAIN FLAME TRIAL
TIMER COMPLETE NOT AND DE-ENERGIZE IGNITION COMPONENTS
RELEASE TO MODULATE TO CCS SYSTEM TRIP Workshop on Start Up
and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
143. Single Burner Main Fuel Trip FOR OIL: FOR GAS: - LOWFUEL
PRESSURE - LOWFUEL GAS PRESSURE - LOWTEM PERATURE
(HEATED OILS) - HIGH GAS PRESSURE - LOSS OF COM BUSTION AIR -
LOSS OF COM BUSTION AIR - LOSS OF FLAM OR FAIL TO ESTABLISH E
- LOSS OF FLAM OR FAIL TO ESTABLISH E - LOSS OF CONTROL
SYSTEMENERGY - LOSS OF CONTROL SYSTEMENERGY - POWER
FAILURE - POWER FAILURE - LOWWATER LEVEL (AUXLEVEL
CONTACT) - LOWWATER LEVEL (AUXLEVEL CONTACT) - LOSS OF
ATOM IZING MEDIUM - EXCESSIVE STEAMDRUMPRESSURE -
EXCESSIVE STEAMDRUMPRESSURE - HIGH OIL TEMPERATURE
(HEATED OILS) OR OR TRIP BOILER TRIP IGNITER, TRIP MAIN FUEL
FUEL CONTROL IGNITER VALVES, VALVES, OPEN VALVE TO TRIP MFT
RELAY OPEN IGNITER VENT VALVE CLOSED VENT (GAS ONLY)
POSITION Workshop on Start Up and Commissioning Dr. Himadri Banerji
MD EcoUrja, Ex Reliance and Tata www.ecourja.com
144. BMS System Types Early Burner Management Systems ◦ Hardwired
Systems ◦ Solid State Systems Microprocessor Based Systems ◦ Honeywell
7800 series with fixed Logic. PLC Based Systems ◦ Programmable Logic
Controller (PLC) Based ◦ Powerful, versatile, expandable, more reliable.
Workshop on Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja,
Ex Reliance and Tata www.ecourja.com
145. Early Burner Management Systems Hardwired Systems ◦ Relay and
Timer Driven. Found on older installations ◦ Typical of Late 50’s, 60’s Solid
State Systems ◦ Solid State Processors and Relays ◦ Found on Systems
provided in the 70’s and 80’s ◦ Proprietary Hardware (ie.. Forney and
Peabody) ◦ Spare Parts are extremely hard to find. Workshop on Start Up
and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
146. MicroProcessor Based Systems Microprocessor Based System
providing: ◦ Burner Sequencing ◦ Ignition ◦ Flame Monitoring Fixed Program
with Limited Configuration Changes Components Selected Based on
Requirements ◦ Programmers, Flame Amplifiers, Message Displays
Workshop on Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja,
Ex Reliance and Tata www.ecourja.com
147. Typical BMS Layout AMPLIFIER EP PROGRAMMER AUTOMATIC
PRIMARY SAFETY CONTROL FIELD WIRING FIELD WIRING FLAME
SCANNER Workshop on Start Up and Commissioning Dr. Himadri Banerji
MD EcoUrja, Ex Reliance and Tata www.ecourja.com
148. Micro Processor Capabilities Simple, Cost Effective Features ◦
Selectable Flame Amplifiers / Scanners ◦ Remote Display ◦ Remote Data
Communications via Modbus Port ◦ Modernization kits are available to
integrate with older systems ◦ Spare Parts Normally Readily Available
Workshop on Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja,
Ex Reliance and Tata www.ecourja.com
149. When These Systems are Used “Simple” Boiler Installations ◦ Packaged
Fire tube / Water tube Boilers (Steam / Hot Water) ◦ Single Burner ◦ One Fuel
at a Time ◦ No Flue Gas Re-Circulation ◦ Upgrades from Previous
MicroProcessor Based Systems Workshop on Start Up and Commissioning
Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com
150. PLC Based Burner Management Systems PLC Based Features ◦ NFPA
8501, 8502 ◦ Watchdog timer ◦ UL 508 Certification Redundant Scanners
Logic+ Message Center ◦ Shows program status ◦ Displays alarms ◦ Prompts
operator Workshop on Start Up and Commissioning Dr. Himadri Banerji MD
EcoUrja, Ex Reliance and Tata www.ecourja.com
151. PLC System Basic Design Features Each PLC based burner
management system should incorporate a number of design techniques
which help detect and act upon unsafe failure modes which can occur in any
microprocessor based system. These design features include the following: ◦
Critical Input Checking ◦ Critical output channel monitoring ◦ Electro-
mechanical Master Fuel Trip (MFT) Relay ◦ Redundant Watchdog Timers ◦
Low Water Cut-out Monitoring During Blow Down Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
152. PLC Based System Capabilities Provision for Multiple Fuel Firing ◦
Capped gas input during curtailment ◦ Changeover from gas to oil at any load
◦ Simultaneous firing of waste and fossil fuels Redundant Scanners, change
scanner with fuel Single or Multiple Burner Applications Integration of BMS
with SCADA Workshop on Start Up and Commissioning Dr. Himadri Banerji
MD EcoUrja, Ex Reliance and Tata www.ecourja.com
153. PLC Based Operator Interfaces Features ◦ Clear Written Messages to
indicate status, required operator interaction, trip/alarm indication ◦ High
Visibility through two lines of display ◦ Messages reduce time consuming
troubleshooting ◦ Prioritizes Messages First Out Alarms Warning / Alarm
Messages Status Messages / Prompts Operator Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
154. PLC System Layout Door Mounted Lights / Pushbuttons Logic+
Message SWITCH SILENCE LIGHT Display PLC CPU I/O I/O I/O I/O
COMBUSTION CONTROL SYSTEM FLAME AMPLIFIER (SINGLE /
REDUNDANT) I/O EXPANSION I/O FIELD DEVICES Workshop on Start Up
and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
155. Benefits of PLC Based Systems Flexibility / Reliability ◦ Programming
Software allows changes to system Choice of PLCs ◦ GE / Modicon / Allen
Bradley / Koyo Choice of Flame Scanners ◦ PPC / Fireye / Honeywell / Iris /
Coen Application Specific Quantity of Burners / Fuels is not restricted
Workshop on Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja,
Ex Reliance and Tata www.ecourja.com
156. When to Use PLC Based Systems “Complex” Boiler Installations ◦
Larger Packaged Units / Field Erected Units ◦ Multiple Burners ◦ Multiple
Fuels, On-line Fuel Changeovers ◦ Flue Gas Re-Circulation ◦ Replace
Existing Relay Logic Systems ◦ Requirement to maintain consistent control
platform (spare parts, etc..) Workshop on Start Up and Commissioning Dr.
Himadri Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com
157. BMS SCADA Interface BMS Systems can be integrated into a SCADA
System ◦ Allows Remote Monitoring of Flame Status ◦ Allows Remote Control
of BMS ◦ Events (ie.. Burner trip) can be routed to Historical Portion of
SCADA for fault evaluation ◦ Burner Operation can be trended over time
Workshop on Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja,
Ex Reliance and Tata www.ecourja.com
158. BMS SCADA Interface Interface Methods: SCADA PC MODBUS
COMMUNICATION PROTOCOL MODBUS COMMUNICATION
Communication PROTOCOL Interface (If Necessary) PLC CPU I/O I/O I/O
I/O BMS LOGIC+ SYSTEM FIREYE E110 SYSTEM Workshop on Start Up
and Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
159. BMS SCADA Interface Workshop on Start Up and Commissioning Dr.
Himadri Banerji MD EcoUrja, Ex Reliance and Tata www.ecourja.com
160. SummaryBenefits Associated with Sequential Start Up Automationand
Burner Management Systems ◦ Help Improve plant safety ◦ Help qualify for
reduced insurance cost ◦ Reduce Startup and Down Time with
comprehensive alarming and diagnostics Workshop on Start Up and
Commissioning Dr. Himadri Banerji MD EcoUrja, Ex Reliance and Tata
www.ecourja.com
161. Summary Review of Topics Discussed ◦ Sequential Start Up
Automation, ◦ Objectives of Burner Management Systems ◦ BMS Design
Considerations ◦ Basic BMS Logic ◦ Types of Burner Management Systems ◦
How BMS Systems can be integrated with Plant Wide SCADA Systems
Workshop on Start Up and Commissioning Dr. Himadri Banerji MD EcoUrja,
Ex Reliance and Tata www.ecourja.com
162. SAFETY ISSUES THE WORK PERMIT SYSTEM (Reference Document
: <<AIGA 011/04 >>)Presented by Dr Himadri Banerji EcoUrja
www.ecourja.com
163. Summary Acknowledgement This document is adopted from the
European Industrial Gases Association document TP 10/04 – The Work
Permit System, and acknowledgement and thanks are hereby given to EIGA
for permission granted for the use of their documentPresented by Dr Himadri
Banerji EcoUrja www/ecourja.com
164. The Work Permit System. What is it? A work permit system consists
primarily of a standard procedure designed to ensure that potentially
hazardous routine and non routine work on industrial installations can be
carried out safely. The procedure should define the need for the following
essential steps: Details of the necessary preparatory work Clear definition of
responsibilities Appropriate training of the work force Provision of adequate
safety equipment A formal work permit with or without attached specific
checklists. This work permit: specifies the work to be accomplished and
authorizes it to be started under the strict observance of consigned work and
safety procedures After information and agreement of all other concerned
parties (process, safety, customers, suppliers,…)
165. The Work Permit System :When? For all non-routine works, For
hazardous routine works not covered by procedures, When work is
performed: by your employees and/or third parties
166. The Work Permit System (1/2):For what kind of work? A work permit is
required in case of: Potential oxygen deficiency or enrichment Potential
flammable/explosive atmosphere Potential high temperature/pressure
Potential hazardous chemicals, e.g.: toxic substances Confined space entry,
e.g.: tanks, cold box, pit, normally closed vessels Bypassing or
removing/altering safety devices or equipment Elevated works Introduction of
ignited sources where not permanently allowed (fire permit), e.g.: open flame,
welding, grinding, Electrical troubleshooting or repair on live circuits
Maintenance or repairs in areas or to equipment or lines, containing or
supposed to contain hazardous materials or conditions,
167. The Work Permit System (2/2):For what kind of work? Or also in case of:
Manual or powered excavations Use of mobile cranes Insulation or catalysts
handling Use of adapters Product conversion of stationary or mobile or
portable vessels and containers Temporary or permanent changes,
alterations, modification of equipment or processes, Exposure to traffic,
Exposure to moving/rotating machinery In proximity of vents, liquid of gas On
process lines with gas release Etc..
168. The Work Permit System : Why?1. Because: In charge of the work, you
don’t know everything about the site and the process around about the work
Safety measures have to be prepared You cannot start the work without the
OK of the production personnel or the customer or the supplier The
production needs your OK in order to re-start the plant after your work is
achieved2. To obtain a safe as well as a quick and cost effective work
169. The Work Permit System : Why? In order to define the scope of work for
everyone concerned/involved by and during the work, the Work Permit must
be prepared with: The person responsible for the work The person(s) in
charge of the production, the customer or supplier, who will release the
process before the work starts The other work bodies The person in charge
of HSE measures
170. The Work Permit System : How? Before issuing the Work Permit, you
must: Describe the work to be done List all the specifications and drawings
which are required Issue detailed planning with all involved entities Determine
the logging and tagging procedures Fill-in together the work permit and sign,
The start of the work must be authorized by production and/or user, The re-
start of the process must take place after the work is finished.
171. The Work Permit System :Review of Flowsheets, Drawings
andSpecification Purpose of the review is to ensure all key persons involved
in jobplanning have a thorough understanding of the job. It shouldinclude:
Process fluids and materials involved, Degree of isolation, Effect of other
processes, Power supply isolation, Specialist advice, Location of
underground services and pipes, Location of elevated power cables, Location
of elevated pipelines and walkways, Purging and lock-out requirements,
Pressure, Temperature, Valve identification, Equipment specification,
Operating and maintenance instructions, Materials of construction and
compatibilities
172. The Work Permit System :Work site inspection Anyone involved and
signing the Safe Work Permit must visit the work place in order: •To inspect
the work area Neighbouring activities, site rules, overhead, underground,
access, natural hazards (flood, rain, snow…), etc,.. •To identify potential
hazards Flammable, oxygen, toxic substances, confined spaces, electricity,
pressure, temperature, moving objects, traffic, falls/trips/slips, etc,..
173. The Work Permit System :Development of Work ProceduresPreparation
of a detailed work procedure is essential to ensure the work willproceed
safely in a planned and logical manner: Following requirements to be
considered: Reference drawings, Timing of various operations, Details of any
special equipment, Needs to inform local authorities, safety precautions and
equipment, Emergency procedures, etc,.. The procedure should include:
Logging and tagging procedures: Electricity, process fluids Instrumentation,
utilities (water, air, oil,…) Depressurising, Draining, Venting, Purging,
Flushing, Isolating, Atmosphere checking, Disassembly of equipment,
Method of repair, Reassembly and installation, Quality control, Pressure and
leak testing, Reinstatement of equipment, Hand-back procedure, etc..
174. The Work Permit System : Example form Appendix 1 EIGA/IGC WORK
PERMIT n° …….. Any attached document or log sheet ? YES NO HOW
MANY ……….. List of attached documents ……………….
……………………….…………..……………...
……………………………………………….. 1. WORK ACTIVITY Plant / Unit :
………………...……………….
…………………………………………………………………………………………
………………..………...… Description of work to be done………………....
……..….………….…………….
……………………………………………………………………….......… Permit
valid from :………………………………………………………… Hours/date To :
……………………………………………………………………. Hours/date Have
all relevant departments/personnel been consulted ? YES NOT APPLICABLE
2. POTENTIAL HAZARDS & HAZARDOUS JOBS YES NO YES NO . Jobs
performed by contractors or temporary workers . Maintenance or repairs in
areas, or to equipment or lines, . Potential oxygen deficiency or enrichment
containing or supposed to contain hazardous materials or conditions .
Potential flammable / explosive atmosphere . Manual or powered excavations
. Potential high temperature / pressure . Use of mobile cranes . Potential
exposure to hazardous chemicals (toxic, reactive, . Insulation or catalyst
handling acid, caustic….) . Use of adapters . Confined space entry . Product
conversion of stationary or mobile or portable vessels . Bypassing or
removing/altering safety devices and equipment and containers . Elevated
work . Temporary or permanent changes, alterations, modifications of .
Introduction of ignition sources where not permanently equipment or
processes allowed (fire permit) . Exposure to traffic (road, mail) . Electrical
troubleshooting or repair on live circuits . Exposure to moving / rotating
machinery Others (state) ……………………..……...
………………………………………………………………………… 3. SAFETY
PRECAUTIONS YES NO YES NO YES NO . Draining . Remove hazardous
materials . Standby man . Depressurising . Fresh air ventilation . Elevated
work . Physical Isolation . Atmosphere analysis : . Contractors trained .
Electrical Isolation . Oxygen . Eliminate ignition sources
175. The Work Permit System :Work Planning WORK SCOPE REVIEW
DRAWINGS / FLOWSHEETS INSPECT WORKSITE IDENTIFY SAFETY
PRECAUTIONS COMPLIANCE WITH REGULATIONS DEVELOP WORK
PROCEDURE ASSIGN RESPONSIBILITIES COMMUNICATION
PROCEDURES WORK EXECUTION
176. The Work Permit System :Work Execution PREPARATORY WORK
ISSUE WORK PERMITS SUPERVISION MONITORING WORK
COMPLETED TESTING RE-INSTATE EQUIPMENT RETURN WORK
PERMIT HANDBACK PLANT / EQUIPMENT
177. The Work Permit System :Permit Issuer’s Responsibilities INSPECTING
WORK AREA IDENTIFYING HAZARDS DEFINING SAFETY
PRECAUTIONS OBSERVING PRINCIPLES OF SAFE WORKING
PRACTICES CREATING WORK PERMIT CONDITIONS REVIEWING
WORK WITH PERMIT ACCEPTOR ISSUING WORK PERMIT
IMPLEMENTING HANDBACK PROCEDURE
178. The Work Permit System :Permit Acceptor’s Responsibilities
UNDERSTANDING OF WORK PROCEDURES UNDERSTANDING
POTENTIAL HAZARDS AND SAFETY PRECAUTIONS ACCEPTING THE
SAFE WORK PERMIT OBSERVING PERMIT CONDITIONS COMPLYING
WITH HANDBACK PROCEDURE
179. The Work Permit System :In Brief Many accidents have occurred due to
lack of Work Permit or non observance of its consigned safety measures. The
Safe Work Permit is useful for: The safety of persons in charge of the work
The safety of persons in charge of the process The risk management of the
process and equipment It is not one more administrative paper! Fill in and
follow correctly the work permit, because…. It could save your life!