LNG Plant Commissioning Process

Commissioning

What is the process of commissioning?

In some ways, the commissioning process may be seen of as a quality assurance procedure that allows the construction project teams to produce a building that is fully operational and meets all of the specifications. This is a critical contrast between the delivery of a physical structure and the delivery of a facility in complete operating order that is really functional for persons, companies, and the environment as a whole.

The idea of full functioning order necessitates the completion of a number of goals, and there are several elements that influence the performance of a structure and its engineering services in general. Design characteristics that will allow for verification activities such as functioning, pressure testing, and flow regulation are included into the process in general. Procedures that will cover prescribed settings to work, system regulation, and performance testing are also included. The commissioning process must also include user and operator training, as well as the creation of critical system documentation, in order to properly support building operation and usage in the future.

Stages of the commissioning process

In the commissioning process, there are eight steps, which are as follows: preparation, design, pre-construction, construction, commissioning of services, pre-handover preparation, first occupation preparation, and post-occupancy care.

A building’s actual energy consumption in the first year might be up to 25 percent greater than the estimate made during the design stage, and this is ascribed to insufficient commissioning and handover procedures during construction. doing the task successfully

All of the steps listed above, as well as beginning the commissioning process as soon as feasible, assure cost-effective project completion while also allowing the building’s inhabitants to optimize equipment utilization long after the construction process is complete, according to the manufacturer.

The following is a summary of the actions that were carried out at each stage:

Stage 1 – Planning and Preparation:

     - Assemble the commissioning team. 

     - Examine lessons learned and experiences gained from similar buildings and projects. 

     - Clearly define the performance outcomes expected by the client and the end user. 

     - Contribute to the development of a design brief that accurately represents the required performance

Stage 2 – Design:

     - Review the performance results with the client 

     - Ensure that the commissioning process activities have been clearly established 

     - Ensure that the performance outcomes reflect any modifications to the system/project design

Stage 3 – Pre-Construction: 

     - Ensure that the contractors understand the performance requirements. 

     - Verify that the trade contractors have the capability to satisfy the requirements of the commissioning process. 

Stage 4 – Post-Construction:

     - Develop a thorough commissioning program.

     - Carry out pre-commissioning work, which includes checking the installation work and running static tests. Verify and record that the desired performance objectives have been met.

     - Ensure that progress on the creation of the O&M manuals is made on a consistent basis.

Stage 5 – Commissioning of Engineering Services: 

     - Perform the initialization of systems and ensure that they are operational. 

     - Verify that the necessary performance and outcome objectives have been met or exceeded.

     - Performance testing of the building, equipment, and engineering services should be carried out. Make that the specified performance levels have been met and record this in writing.

     - Include members of the facilities management team in the commissioning process.

     - Gather all of the commissioning checklists and test papers in one place.

Stage 6 – Preparation for Handover

     - Examine the quality of the documentation evidence gathered throughout the commissioning process’s activities.

     - Maintain completeness and accuracy of all necessary statutory paperwork.

     - Provide users and operators with instruction and guidance.

     - Create and distribute user manuals for the building.

     - Examine the needs of the customer and respond to any discrepancies.

7. Initial Occupation:

     - Introduce the user to their equipment or premises and demonstrate how it works.

     - Assist the facilities management team with the earliest phases of the building’s operation

     - Refresh commissioning records in line with and after approval of any revisions

     - Update the operation and maintenance manuals to reflect any modifications that have been authorized.

Stage 8 – Post-occupancy care 

     - Seasonal commissioning. 

     - Fine tuning of the building and its engineer services.

     - Building performance evidence is collected and reviewed. 

     - Commissioning records and operation and maintenance manuals are updated in accordance with seasonal commissioning and fine-tuning work. 

     - Lessons learned are produced by comparing building performance to design intent, client stakeholder expectations and industry benchmarks.

Documentation for the commissioning and transfer of services

Building handover information is incomplete without the inclusion of commissioning process verification and test records, which are crucial components of the handover information. It is not only important to have proof that the desired performance objectives have been reached, but it is also important to have knowledge about the method in which the system has been configured for operation in case any enhancement, modification, or fine-tuning work is needed after handover.

The summary commissioning process is the post-installation procedure that occurs prior to the start-up and operation of the system. It assures that the equipment that has been installed and linked will operate at peak efficiency from the beginning, while also validating that the performance of the LNG equipment has been reached. It is possible to complete this procedure on site at the client’s option, and it includes a complete system assessment and optimization, as well as staff training and demonstration, as well as supporting documentation to support equipment usage now and in the future.

Starting up and commissioning your natural gas processing facility is a time-consuming process.

Start-up and commissioning are the last stages of preparations required before a natural gas processing plant or comparable processing facility can be put into production. The operations carried out throughout the start-up and commissioning phases should guarantee that the facility will function safely and in accordance with its design specifications and specifications.

The majority of EPC turnkey contracts include this phase as part of the overall package. Engineers, field technicians, and operations people will comb over every inch of the plant, inspecting hundreds of connections, instruments, valves, and other pieces of equipment. This time- and labor-intensive procedure will take many months. Depending on how sophisticated the facility is, it might take weeks or even months to finish.

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