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View Full Version : Commissioning of new Industrial system HOW TOO







RANGER1
20-08-2014, 09:53 PM
This is a pretty open question.

What steps do you take when a system is ready to start.

Example turn on & see what works & test safeties etc

RANGER1
21-08-2014, 04:42 AM
Sorry I should ask in a different way.

What are some good practices for commissioning.
From what I hear in the industry it can be a bit average in some cases.
There is usually a better way, as we get smarter over time (hopefully).

Magoo
22-08-2014, 04:53 AM
Hi Ranger1.
open to being shot down in flames, but here we go. My general procedure after pressure tests and vacuums etc. and doing all documentation to that point.
1/ test and prove power supply L1 2 &3 orientation, set up breakers and protection devises.
2/ Test and prove all field wiring and scale transducers etc. Set all pressure switches with nitrogen.
3/ Tighten all control panel terminals.
4/ Dry run test all operations, usually a generic PLC program that always seem to need tweaking.
5/ Rotation checks of all motors with couplings separated. ( usually need a few jumper wires here and there.
6/ After oil in system and at temperature, manually run oil pump to fill lines etc., sort out load pistons on screw, usually wrong after vacuum.
7/ Run a live start and watch all and everything on laptop PLC operation.
8/ If all good so far, start adding more ammonia
6/ Live with system, and monitor everything. Multi trial periods with loads.
7/ Operator training and more documentation and paperwork.

PaulZ
22-08-2014, 05:10 AM
Hi Ranger
I would agree with what Magoo said, maybe not in the same order. Magoo's list is brief and I am sure he would be able to expand on it.
Many years ago I wrote a commissioning procedure and split it into 3 sections,
*Pre Start checks
*Before starting any plant
*When system is fully charged and operational
This is about 5 pages of things to check off or do and is too big to post here.
Are you asking for yourself or just in general?
regards
Paul

HVACRsaurus
22-08-2014, 05:24 AM
Hi Ranger,

I'd like to get a refrig plant to sing me a song..

Bit like this;

http://m.youtube.com/watch?v=Tr4zb-HHZs4

But more like this;

http://m.youtube.com/watch?v=CDl9ZMfj6aE

I'm still kinda working on it, can't quite get the VSD harmonics to compliment the slide valve rattle :cool:

RANGER1
22-08-2014, 05:58 AM
Hi Ranger
I would agree with what Magoo said, maybe not in the same order. Magoo's list is brief and I am sure he would be able to expand on it.
Many years ago I wrote a commissioning procedure and split it into 3 sections,
*Pre Start checks
*Before starting any plant
*When system is fully charged and operational
This is about 5 pages of things to check off or do and is too big to post here.
Are you asking for yourself or just in general?
regards
Paul

Paul in General as I believe there is a lot of companies who in today's world are "cowboys" but don't know it.
There is always the programmer who thinks he knows more than the rest.
Make changes & say "no need to check as it will be right", check it & it's wrong etc.

I was thinking of more of the pre checks instead of turn it on & then attempt to check everything.
Why would you start multi million dollar equipment before knowing that it is fully protected.
Don't get me wrong there is good people out there & then the others.

Recently did a job to check safeties on an old large plant.
Mostly old style pressure switches.
Calibrated all with nitrogen & calibrated gauge.
Sticker on them, opposition did it year before, all good.
Function test time, that's restrict discharge stop valve, most did not work, some had wires that we're not connected in panel.
One had been running for years apparently with no protection at all.
Bit of a trap.
I accept no one wants to give to much away, as that's there expertise, me included.

People who have worked in petro chem & process plants know how to do it with the best practice,
otherwise people die.

,

mbc
22-08-2014, 06:13 PM
hi paulz could you loaded that One it would be useful for reminding important thing for starting system . ((*Pre Start checks *Before starting any plant*When system is fully charged and operational This is about 5 pages of things to check off or do and is too big to post here )) also as you Know large system and NH3 system or screw system has own attention .

RANGER1
22-08-2014, 10:08 PM
Magoo, Paul One example of pre-checks might be & this is before any real charge of refrigerant is added.