Pre Commisioning Start Up

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    Start up and Commissioning of Pipelines

    IiPM, Gurgaon 10th July 2009

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    Methodology for Pre-commissioning of new

    pipelines Objectives

    Task Forces

    Responsibility of Project/ConstructionGroup

    Responsibility of O& M Group

    Responsibility of Fire & Safety Group

    Documentation Commissioning

    Handing/Taking Over

    Case Study

    Contents

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    Methodology forPre-commissioning of

    New Pipelines

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    Preparation of pre-commissioning and commissioning

    plan

    Safe commissioning of pipeline system

    Safe and smooth operation of pipeline aftercommissioning

    Proper handing over & taking over of pipeline system

    Preparation of check list for all pending activities

    Liquidation of check list points in a time bound manner

    Objectives

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    Task Forces

    For efficient startup/commissioning specialized task-forcecan be formed including specialists from:

    Projects/Construction Group

    Operations & Maintenance Group

    Fire & Safety Group

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    Responsibility of Projects/Construction

    Group

    The group will ensure:

    Mechanical completion of pipeline system

    Hydro-testing and pigging of entire pipeline

    Inertization of pipeline

    Ensuring readiness of pipeline system for commissioning

    Handing over of pipeline system (including spares, tools,equipment etc) for operation

    Handing over of relevant documents and certificates toO&M group

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    Responsibility of O&M Group

    The O&M group will ensure:

    Verification and taking over of all contract, project and

    operation related documents before pre commissioning

    activities

    All checks for ensuring system integrity and functionality

    Verification of all statutory permissions

    Verification of relevant inspection reports and certificatesetc.

    Verification ofvenders documents for material supply

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    Responsibility of O&M Representative

    (contd..)

    Verification of agreements and MOUs with product

    suppliers and consumers

    Preparation of check list with target completion dates for all

    contracts works and material POs

    Enlisting of all construction surplus materials, and

    equipment with all relevant inspection, test certificates and

    other documents

    Ensure preparation of check list for balance jobs

    Verification and taking over the project DFR, concept note

    and project approvals etc

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    Responsibility of Fire & Safety

    Representative

    Verification of Fire network and equipments as per relevant

    OISD standards

    Check the adequacy of first aid fire fighting appliance as

    OISD Std. 117

    Ensuring placement of fire fighting equipments/instruments

    as per OISD Std. 117

    Check the compliance of safety audits, OISD audits andPre-commissioning audits

    Check the integrity of fire fighting system before start up

    and commissioning

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    Documentation

    The O&M Documentation In-charge shall take over and

    ensure proper distribution of documents related to:

    A. Statutory clearances/Permissions

    Factory License as per factory act 1948

    State Pollution Control Board and Ministry of Environment &

    Forests (MoEF) clearances

    State & Central Electricity Authority Permissions (wherever

    required) Clearance for frequency in case of Radio set, Walky-

    Talky/VHF /UHF

    Clearance from CCOE

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    Documentation

    A. Statutory clearances/Permissions (contd..)

    Permissions/Agreements executed for Railways, Road

    (NH & SH), Canal, OFC and any other crossings

    Authorization for hazardous waste rule (Management &

    handling - 1989)B. Revenue and RoU related documents

    Detailed RoU Survey Reports with Survey Numbers

    Tree & Crop compensation details and documents

    Land acquisition documents, ROU Cadastral Map

    Field management books (FMBs)

    List of disputes / pending complains with detail status

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    Documentation

    C. Construction Related Documents

    Mechanical Completion Certificate

    Hydro testing acceptance certificates

    Equipments Commissioning Certificate with commissioning

    history

    Work order copies and Contracts

    Construction QA/QC records, Procedures and inspectionrecords

    Radiography films and records

    MOUs and agreements with product suppliers andconsumers (Copies)

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    Documentation

    C. Construction Related Documents (contd..)

    Agreements with contractors, venders, material / Equipment

    suppliers

    All taxes and duties statements

    SAT (Site acceptance Test) of all instruments including

    certificates and loop

    testing certificates

    Process Flow Diagram

    As-build drawings such as plot plan, cable route drawing,

    earthing and P&ID etc.

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    Commissioning of

    New Pipelines

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    Commissioning is to bring the constructed / installed

    system to deliver the desired function.

    Pipeline commissioning means introducing crude/product/Gas in the pipeline from originating station, fillingthe entire length and then start delivering to the planned

    receipt system.

    In case of crude pipeline, there may be intermediatestorage stations for operational requirement but ultimatesupply is to be made to a refinery

    In case of product pipeline/Gas pipeline, there may beseveral intermediate delivery stations beforeterminal/dispatch station.

    Objective of Commissioning

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    Preparation of commissioning manual

    A document describing the procedure to be followed for

    commissioning is to be prepared by experienced persons

    The purpose of making the document is to set forth the

    objectives of commissioning of pipeline system and toestablish guidelines for safe commissioning in order to

    achieve the required goals.

    Pre-commissioning check list

    A check list is prepared, which covers the technical, safety

    as well as statutory requirement before the pipeline and

    associated facilities is declared ready for commissioning.

    Pre-commissioning

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    Constituting a pre-commissioning team: A committee of experienced engineers is constituted to

    audit the construction as per pre-commissioning check listand report to the management regarding readiness of thesystem or any shortcomings to be complied beforecommissioning.

    Procurement of consumable/tools/pigs etc: As mentioned in the Commissioning Manual, required

    consumables, tools, pigs, spares and safety equipmentsare to be made available prior to commissioning.

    Availability of product/ crude: As per line fill calculation, the availability of crude oil or the

    product, as the case may be, is to be ensured at originating/ pumping station in coordination with Refinery andMarketing.

    Pre-commissioning (contd..)

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    Pipeline sections are generally commissioned in phased

    manner / in totality based on the situation and

    preparedness.

    After hydro-testing and caliper pigging it is expected that

    the sections are in a fairly clean condition.

    Commissioning

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    Constituting a commissioning team:A committee of experienced engineers is constituted to

    perform the objective of commissioning.

    Scrutiny of audited pre-commissioning check list:

    The committee to ensure the compliance of any

    shortcomings reported in the pre-commissioning check list.

    Identification and deployment of manpower at new

    stations

    Deployment of security personnel at stations

    Arrangement of water and disposal plan

    Commissioning action plan

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    Pressurization of pipeline section with compressed air up

    to 3-5 Kg/sq cm.

    Injection of about 500 to 1000 KL water into the section

    from launching barrel end

    Launching of cleaning (bi-di) pig after introduction of waterin the line

    Maintaining 5-10 kg/sq.Cm back pressure at other end by

    venting the air

    Introducing about 1000 to 3000 KL of water behind the

    cleaning pig

    Launching batching (bi-di) pig

    Commissioning steps

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    Introducing HSD / Crude in the line and maintaining 5 to 10

    Kg/sq.cm back pressure at other end.

    Draining dirty water to storm water drain / pre-fixed drainoutlet at the receiving end

    Receiving cleaning pig

    Again draining dirty water to storm water drain

    Receiving batching pig

    Lining up marketing HSD receipt tank /Refinery or Pipeline

    crude receipt tank

    Flow to be diverted to HSD / Crude receipt tank as soon asoil traces are observed. Temporary facility for waterdraining to be dismantled & permanent blinding put

    Commissioning steps (contd..)

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    Since, before pumping water, line is filled with air at a pre-

    determined pressure, so monitoring and air draining facility

    is kept ready at receiving end to maintain back pressure of

    air at 5 to 10 Kg/sq.cm

    Pumping into an empty line will cause excessive flow rate &current in the motors resulting in frequent tripping. May

    result in increase of interface length.

    As the pig reaches at receiving end, it is taken out. The

    muck & dirt quantity is collected and after analysis it isdisposed off.

    Handing over the system to operating group

    Commissioning steps (contd..)

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    Specific check points/procedure for

    Gas Pipelines

    LPG Pipelines

    ATF Pipelines

    Commissioning steps (contd..)

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    HANDING / TAKING OVER FORMAT

    NAME OF PROJECT : ______________________

    LOCATION : ______________________

    PROJECT IDENTIFICATION : ______________________

    PROJECT COST : ______________________

    PMC : ______________________

    CONTRACTOR : ______________________

    DATE OF COMMISSIONING : ______________________

    Handing/Taking Over

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    I. DETAILS OF FACILITIES TO BE HANDED OVER

    1. _____ INCH DIA. P/L FROM _______ TO ______ (ALONGWITH OFC)

    HAVING DESIGNED CAPACITY OF ______ MMT/MMSCMD AT PRESSURE

    _________KG/CM

    2. ORIGINAL/DISPATCH TERMINAL/ STATION AT : ______________________

    3. RECEIVING TERMINAL AT : ______________________

    4. SV/IP STATIONS ALONG PIPELINE AT : ______________________

    5. ANY OTHER FACILITIES (IF APPLICABLE) : ______________________

    6. HDD (IF ANY) DETAIL : _____________________

    Handing/Taking Over

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    II. IMPORTANT PARAMETERS AND DATES

    1. MECHANICAL COMPLETION DATE OF MAIN LINE WORKS: __________

    2. PIGGING (FOAM, GAUGE, CLEANING PIG & EGP) : __________

    3. HYDRO TEST & DESIGN PRESSURE OF MAIN LINE : __________

    4. MECHANICAL COMPLETION DATE OF RECEIVING : __________& ORIGINATING TERMINALS

    5. INSTRUMENTATION COMPLETION DATE : __________

    OF TERMINAL STATION

    6. COMMUNICATION SYSTEM COMPLETION DATE : __________

    7. SCADA AND TELEMETRY COMMISSIONING DATE : __________

    8. DATE FOR PRODUCT/GAS CHARGING IN THE SYSTEM : __________

    9. FINAL DATE OF COMMISSIONING : __________

    Handing/Taking Over

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    III. STATUS OF SYSTEMS / FACILITIES TO BE RECORDED

    BEFORE TAKING OVER

    (A) Pipeline & CP

    1. Status of ROU, CP test points and Markers OK/ Not OK

    2. Checking of mainline & bypass line valves & Actuator OK / Not OK

    3. Physical Status of SV/IP, receiving & Pump stations OK / Not OK

    4. Performance test of SVs/IP station Done / Not Done

    5. Checking of casing shorting at crossings. Done / Not Done

    6. Status of Temporary CP Removed./ Not Rmd7. Status of captive power system Comm / Not comm.

    with battery bank (wherever applicable)

    8. if pipeline is not charged, is it dried & filled with inert gas Yes / No

    Handing/Taking Over

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    (B) COMMUNICATION & SCADA

    1. Status of communication system Comm / Not comm.

    2. OFC Checking Done/Not Done

    3. Status of SCADA and telemetry system Comm / Not comm.

    (If applicable)

    4. Communication between the RTU OK/ Not OK

    at maintenance bases

    5. Communication between the flow OK/ Not OK

    computers to RTU/SCADA for Master Control Centre

    Handing/Taking Over

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    (C) INSTRUMENTATION & METERING

    1. Status of metering systems (If applicable) Yes/NO

    2. Checking of Instrumentation Panel (If Applicable) Comm/Not comm.

    3. Status of Chromatographs (If applicable) Done / Not Done

    4. Status of Instruments at SVs/RRs/IPs comm/Not comm.

    5. Remote operation of Valves at SVs & Terminals. OK/NOTOK

    6. Status of UPS Comm. /Not comm.

    (D) ELECTRICAL SYSTEM

    1. Checking of Electrical Panel & battery backup (If Applicable) Comm/Not comm

    2. Electricity at terminals/distribution stations from S.E. Board OK/NOTOK

    3. Earthings system Comm/Not comm.

    3. Lighting Comm/Not comm.

    4. Lightening Protection System OK/NOTOK

    Handing/Taking Over

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    (E) FIRE & SAFETY

    1. Status of Fire fighting Systems OK / Not OK

    2. Status of fire detection system at SVs/RRs/lPs & Terminals Comm/Not comm.

    3. Status of on line extinguishing system at SVs/RRs/lPs Comm./Not comm.

    4. Safety audit by Fire & Safety personal from O&M Done/ Not Done

    (F) GENERAL

    1. Status Control Buildings Construction Comp./Not Comp.

    2. Status of basic amenities for security guards at the Done / Not Done

    permanent establishment

    (Security rest room, water, lighting arrangement)

    3. Preparation of final checklist before taking over Done / Not Done

    Handing/Taking Over

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    (G) DOCUMENTATION

    1. Listing & handing over of all procedures, reports, Done / Not Donecertificates, vender manuals, drawings and

    related documents which are to be handed

    over as per Contractual obligation with the venders

    2. Listing & handing over of As builds, Alignment Done / Not Done

    sheet, hydro test report, Pigging report,

    pipeline route map, pipe book, crossing

    details (Hard copy & soft copy)

    3. Revenue records & records for permanent land acquisition Done! Not Done

    4. Certificates related to Metering system Done I Not Done

    (H) SPARES

    1. Commissioning spares Handed over/not handed over

    2. Two years spares Handed over/not handed over

    Handing/Taking Over

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    Case Study: Commissioning of SSPL

    Name of Pipeline : Sidhpur- Sanganer Pipeline

    Length : 517 km

    Pipe Size & Thickness: 18 OD x 0.250 WT

    Pipe Grade : API 5L-X65

    Capacity : 3.4 MMTPA (5.7 Max)

    MAOP : 92 Kg/cm2

    Line fill : 79840 Kl

    Sidhpur - Kot : 28500 Kl

    Kot - Baghsuri : 30500 Kl

    Baghsuri - Sanganer : 20840 Kl

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    Thank You