Refineries

Commissioning&
Startup of Mechanical
Equipment
Refineries Commissioning& Startup of Mechanical Equipments
• Pre-assessment
• Introduction
• Review Project Phases
Conceptual Studies
Front-end Process Design
Detailed Engineering
Commissioning & Operation
• Integrated commissioning Methodology
A- commissioning Tools Issues
B- Safety during activates
C- Preparation summary
D- Equipment maintainability issues
• Case Studies
• Pre Commissioning, Commissioning and Start-up
Commissioning Management and Organization Chart
Check –Lists, As-Built P&IDs, Equipment Data Sheets
Updated Operating Procedures
Review Construction & Generate Punch-Lists
• Review and Advise during Commissioning of Utilities and Off-Sites
Water, Steam, Air, Electric Power
• Review and Advise during Pre commissioning Activities
• Piping
• Stationary Equipment review (design, component, construction and
compliance)
• Rotary Equipment review (design, component, construction and
Compliance)
• Inert Gas Purging
• Safety
• Commissioning Progress and Status Activities Principles
I- Process Lines
II- Stationary Equipment
–Towers, Reactors, Heat Exchangers, Vacuum Towers & Vessels
Atmospheric Storage Tanks
III- Rotating Equipment
Pumps, Compressors, Electric Motors, Diesel Engines, Steam Turbines
• Isolation Standard
• Alignment (complete with standard software)
• Introduction
Commissioning
1- Planning
2- Mechanical Completion
3- P&ID Checking
4- Pre-commissioning
5- Commissioning
6- Start Up
7-Inetial Operation
8- Performance Test
9- Post Commissioning
Refineries Main Units
Crude Oil
Distillation

Treating Units
Removing Impurities
Crude Oil Refinery
Reforming
Units
Octane rating
Storage Tanks Area

FLOATING ROOF Isomarization

FIXED ROOF

VRU Unit
Cracking
Coker Unit
Sulfur Unit
Penix Molix Unit Other Units Supporting Utilities
Pre-commissioning & Commissioning Organization
* Key Persons To Lead The Execution Teems
* Punch List Teem
* Maintenance Facilities Teem
* Isolation / Boxing Up Teem
Labels, P&ID, Date & Time.
* Flushing / Purging Teem
* QC / QA Teem
* Enhanced Computer Maintenance
Management System Operating Teem
* Hse Instructions & Implementation Teem
* Comprehensive Range Of Tools.
* Procurement & engineering Support Teem
Draw, Trouble Shoot, Recording, Analyses And Control
On high
complexity Commissioning Team
projects
Commissioning
Manager

Client Staff
Commissioning Leader Client Project Engineers

Planning Safety Process Instrument Mechanical Electrical Civil

Specialist Officer Superint . Superint Superint Superint Superint

Process Instrument Mechanical Electrical Civil

Specialist Specialist Specialist Specialist Specialist

Process Instrument Mechanical Electrical Civil

Team for each plant
Engineers Engineers Engineers Engineers Engineers
Commissioning Manager
Key responsibilities:
◼ Project commissioning planning,
◼ Scheduling and resource management.
◼ Participating with Construction regarding scheduling/hand-
over/QC issues/feedback.
◼ Review and acceptance of Construction QA and Inspection
and Test documentation.
◼ Ensuring Commissioning team is familiar with the project
scope and requirements of the Commissioning Plan.
◼ Ensuring Operations knowledge and approval of the
Commissioning scope. Facilitating coordination meetings
with Operations.
◼ Providing the communication interface with the
stakeholders (Engineering, constructions,..
◼ Facilitating site Hazard Assessment
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Commissioning Manager
Key responsibilities:
◼ Providing onsite supervision and management of
Commissioning teams.
◼ Ensure the use of Change Management Procedures.
◼ Ensuring commissioning documentation are fulfilled.
◼ Ensuring that all necessary utilities are available before
commissioning starts.
◼ Ensuring that the facilities of maintenance for all
requirements in the plant.
◼ Ensuring HSE and fire fighting equipment are available ,
before commissioning and ready to be used.
◼ Discuss & agree the prepared daily check list and punch
list for his team leader.
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Commissioning Manager
Key responsibilities:
◼ On low complexity projects, there may be a single
Commissioning Team Leader responsible for a multi-
discipline Commissioning team and the Commissioning
◼ Onsite coordination and supervision of commissioning
activities
◼ Ensuring commissioning documentation requirements
are fulfilled.

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Client Project Engineers

Key responsibilities:
◼Ensure availability to respond to site queries from
Commissioning team.
◼Provide project technical support personnel to
Commissioning.
◼Facilitate review and approval of field changes.

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• Review Project Phases

Project phases
– Conceptual Studies
– Front-end Process Design
– Detailed Engineering
Engineering, Procurement, Construction Management
– Commissioning & Operation
– Work Management and Organization
 Project Process

Conceptual Conceptual Basic

EPCM Operate
Studies Engineering Engineering
Eng., Procurement,
-Determine Select the -Finalize project Construction Manag.
Evaluate &
project preferred scope, Operate asset to
feasibility and Development Produce an ensure
-Cost and operating asset
Alignment with Option's) & performance to
schedule . consistent with
business Execution specifications
strategy Strategy. -Prepare for scope, cost & and maximum
schedule return to the
Execute Phase
Client

IDENTIFY Gate SELECT Gate DEFINE Gate EXECUTE Gate OPERATE

Front End Loading

Conceptual Studies

Define Scope of Work

– Objectives
– Constraints
– Schedule & Budget

Collect Data Necessary to Perform Work

– Equipment & Instrument Data
– Equipment & Piping Layout & Configuration
– Plant Operating Data
– Miscellaneous Data

14 15 Mar 2006 Process Responsibilities.ppt

Conceptual Studies
Perform Work
– Process Simulations
– Engineering Calculations
– Provide Information to Supporting Disciplines

Issue Report
– Summarize Study Results
– Make Recommendations

15 15 Mar 2006 Process Responsibilities.ppt

Conceptual Studies

• Greenfield Development: (New projects)

– High level strategic planning
– Option selection for major opportunities
– A structured selection for concept selection
– Cost and schedule analysis

• Brownfield optimization (Existing fields modification or

revamps)
– Operational ‘know how”
– Cost effective production increases
– Maximized whole of life return from existing assets
Front- End Process Design

•Design Basis
Develop Scope, Design Basis
Collect Information Necessary for Work
Evaluate and Select Licensor
Obtain Information from Catalyst Vendors
Develop Schedule & Execution Plan
Generate Heat & Material Balance
Develop Process Flow Diagrams
Front- End Process Design

•Process Design

Develop P&IDs
Identify Safety Systems
Develop Material Selection Diagrams & Tables
Estimate Utility Requirements
Estimate Catalysts & Chemicals Usage

18 15 Mar 2006 Process Responsibilities.ppt

Front- End Process Design
•Process Design

Develop Equipment Specifications

– Set Equipment Design Conditions
– Perform Hydraulic Calculations & Line Sizing

Generate Instrument Process Data

– Flow Meters & Control Valves
– Indicators & Gauges
– Analyzers
– Pressure Relief Valves

Write Control Systems philosophy

19 15 Mar 2006 Process Responsibilities.ppt
Front- End Process Design

•Process Design

Develop Piping Network Designs

– Cooling Water Headers
– Flare Headers
– Water Systems

Participate in Equipment Layout and Unit Plot Plan

Participate in 3-D Model Reviews

20 15 Mar 2006 Process Responsibilities.ppt

Front- End Process Design
•Process Design

Documentation:
Heat & Material Balance
PFDs
Material Safety Data Sheets
P&IDs
Hazop Reports

21 15 Mar 2006 Process Responsibilities.ppt

Front- End Process Design

•Process Design
– Key Interfaces:
Process Technology Experts
Licensors
Catalyst Vendors
Project Management
HSE

22 15 Mar 2006 Process Responsibilities.ppt

Front- End Process Design

•Process Design
- Key Interfaces:
Other Disciplines
– Piping
– Mechanical—(Stationary , Rotating Equipment.)
– Control Systems
– Electrical

HAZOP Facilitators
Materials Specialist
Construction Management
23 15 Mar 2006 Process Responsibilities.ppt
 Detailed Engineering
Tasks:
Review Vendors Tender Bed Evaluation
Conduct Final Hydraulics Check
– Review Pumps and compressors Calculations
– Check Network Systems
– Review Isometric Drawings

Follow up on HAZOP Action Items

Participate in 3-D Model Reviews

24 15 Mar 2006 Process Responsibilities.ppt

Commissioning & Operation

Review Construction (Check.Shs )& Generate Punch-Lists

Oversee and Advise during Commissioning of Utilities, Off-Sites
Oversee and Advise during Pre commissioning Activities
– Line Flushing (Process)
– Stationary Equipment review
(design, component, construction and compliance)
(Process, Mechanical, Instrumentation, Electrical and Civil).
– Rotary Equipment review
(design, component, construction and compliance)
(Process, Mechanical, Instrumentation, Electrical and Civil).

25 15 Mar 2006 Process Responsibilities.ppt

• Integrated Commissioning Methodology
A- Commissioning Tools Issues

1- Key Persons To Lead The Execution Teems

2- Critical Equipment Special Tools Availability

3- Start Up Spares Availability In Warehouse

4- Execution Teems To Follow Up And Apply The

Daily Instruction Of The Leaders (KP.).
B- Safety During Activities

* * HSE Instructions & Implementation

** Fire Fighting Equipment Availability

**Fire Fighting Equipment Adequacy

** Fire Fighting Equipment Commissioning& Rp.

Main Pumps, Jockey Pumps , Monitors, F.F. Hoses , F.F.
Extinguishers (F.F. Rings, Hydrostatic Test )

** Availability Of PPE.
C- Preparation Summary
1- Water
* Potable Water
* Pure Water
* Caustic Soda -Ash Water

2- Steam * Hp * Mp * Lp

3- Air * Utility * Instrumentation

4- Electrical Power
5- Nitrogen Availability
D- Equipment Maintainability Issues

1- To Confirm Maintenance Facilities

Of Production Equipment
2- To Confirm Accessibility Of Measuring
& Controlling Devices.

3- To Confirm Adequacy Of Equipment

Ancillary Systems (M/S Type)
4- To Confirm Existing Of Equipment
Auxiliary Systems (Anti Surge )
5- To Confirm Existing Of Long Term
Spare. Parts For Major Equipment
COMPR. Rotor –H..Exch Test Rings
• Case Studies
• Tube and Shell Heat Exchanger performance failure
(Counter flow check)
• Heat Exchanger Floating Head failure
(Studs tighten force torque check)
• SS tubes Heat Exchanger failure
(SCC) Phenomenon for SS tubes)
• Tower flooding
(Trays man ways studs tighten check)
• Vertical Heater explosion
(Instrumentation signal sequence check)
30 15 Mar 2006 Process Responsibilities.ppt
• Centrifugal Compressor starting failure
( Anti surge system is not existed)
• Centrifugal pump failure
( Thermal growth check)
• Sundyne centrifugal pump failure
( M/S leaking check port is plugged)
• Centrifugal pump failure
( Wrong RPM)
• Piping pressure test failure
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( Wrong gasket rating) 15 Mar 2006

 Recommendation
• Reviewing Pumps M/S design to check

1- M/S to be Balanced
2- O rings for hot liquids to be compatible material
3- Stationary (hard face) ring to be tungsten carbide
or silicon carbide for all types
• Never use Pneumatic Test
• Never use Rim and Face Alignment procedure
• Avoid poor arrangement for parallel arrangement pumps
• Check the reciprocating intermediate pressures
• Check the balancing line restricted orifice for multi stage centrifugal pumps
• Control Valves bypass globe valve, Size to be the same as control valve size
• Check the direction of rotation of Rotary equipment.
• Check the Thermal growth of Rotary equipment
• Check that Emergency Electrical Power could cover :
* Instrumentation,
* Lighting
* All utilities equipment,
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* All terminal products air coolers,
Process Responsibilities.ppt
• Pre Commissioning, Commissioning and Start-up

Pre-commissioning witnessing activities:

◼ Setting of PSV's.
◼ Piping & vessels flushing and cleaning according to
standard & code procedures.
◼ Gross Leak test.
◼ Machinery alignments and rotation directions checks.
◼ Machinery commissioning ( according to vendor
procedures )
◼ Compressors suction line pickling
◼ Ensuring the existing of equipment internals, in its
correct position and no scales (and properly fixed)
◼ Ensuring the plants to be tidy & clear after the pre -
commissioning & commissioning
◼ Ensuring the accessibility of all instruments devices
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 Pre-commissioning witnessing
• The Commissioning will perform witnessing of critical pre -
commissioning activities:
• Ensuring the maintenance facilities for all equipment.
• For the equipment of hot fluid service , the thermal growth to be taken
into consideration
• Follow up the vessel boxing up procedures complete with the signature
of the safety officer
• Electrical protection relays setting
• 20% of instrument calibrations, at random.
• 100% of power control cable insulation meggering and checking with
ground.
• The above tests will be attended by a suitably qualified commissioning
Engineer, and the relevant Pre-commissioning test sheets
countersigned, on the successful completion of the tests

Commissioning Spares and Equipment

•The commissioning spare parts, special tools, consumables and
equipment that will be required for the commissioning scope of work
should be checked on site.
COMMISSIONING SCOPE OF WORK
• Pre-commissioning witnessing
• Preliminary check
• Functional tests (Electrical Instruments)
operation of control valves, solenoid valves, positioners and SDV’s

• Piping and Vessels Preparations

• Operational tests( auxiliary systems of main mechanical equipment)
• Documentation tasks
• Refinery has to be divided into plants and systems
• Check Lists for each plant
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Commissioning procedures list

• Planning/Progress/ Reporting & Control Procedures

• Commissioned Drawing Procedure

• Comm. Scope of Work per Module
• Commissioning Meeting Schedule Procedure
• Dedicated Commissioning Punch List

• Final Relief Valves Testing Procedure & Schedule

• Operational Test Procedure Description & Schedule

• Permit to Work Procedure, Electrical Isolation Procedures
Commissioning procedures list

• UTILITIES Performance Test & Start-Up Procedures

• Site Acceptance Test Procedure (SAT)Vendors representative)

• Tie - In Procedures

• Blind List Procedures

• Consumables & Tools Procedures

• Spares Control & Handover Procedure

Commissioning procedures list
• All First Fill / Oils / Grease / Procedures

• Drying / Vacuum / Inerting / Purging Procedures

•Test Equipment Procedures

• COMPANY Witnessing / Notification Procedure

• Special tools Availability
• Plant Leak Test (including valves) / Body
& Seat Testing of Critical Valves

• Control Software Modification Procedure

• Control System Test Procedures

Commissioning procedures list

• Pipelines Commissioning Procedures

• Pre-Start-Up Activity Procedures

• Valves Tagging Procedure

• Final Vessels & Equipment Inspection & testing Procedures

• Final Documentation Handover Procedure

• Comm. Safety Review Procedures

• Lubricant/Storage Procedure & Schedule

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Commissioning Documentations
◼ Ready for start-Up certificate
◼ Auxiliary's system definition drawings
◼ Data Base print-out
◼ Commissioning reports
◼ Preliminary checks reports
◼ Functional test sheets
◼ Piping and Vessels Preparations reports
◼ Operational test procedure
◼ Mechanical reports (Stationary-Rotating Equipment)
◼ VENDORS reports (FAT and SAT)
◼ Punch list (final status at the End of the Commissioning)
◼ As-built drawings
◼ List
4 of modifications for Revamp
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◼ End-of-job report
Commissioning Preparation Activities

• Defining plants hand-over sequences

• Development of inspection and test procedures
• Development of the hand-over procedure
• Define schedule, resources, equipment, consumables and deliverables.
• Review equipment recommended commissioning practices
• Develop and populate the database that shall be used for controlling
and monitoring the commissioning activities and progress.

Regular meetings

• (Project team to nominate schedule / frequency) between all stakeholders

(Project, Construction, Pre-commissioning and Commissioning)
management
• Customer, subcontractors, plant operations personnel shall be conducted
to communicate execution and method plans, sequences, constraints,
hazards, risks and progress to ensure that all parties are kept fully
informed
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Checks
The equipment/systems need the following checks:-
• Loop checks to confirm operation of the all transmitters.
• Function checks to confirm the operation of control valves, solenoid
valves, positioners and SDV’s

Loop checks

• After completing the pre-commissioning visual checks, loop checks shall be

undertaken.
• Loop checks will prove signal and ground electrical connections and
calibration of field devices
• Check range and trip settings.
• Loop check sheets SHOULD be included in the plan to record the results of
each check.
Function Checks
• Appropriate function check sheets should be included in the plan.
• After successful completion of each functional check, the function check
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sheets
2 shall be signed by the Commissioning Technician and the
Commissioning Team Leader or Coordinator
Example
Checks Stage 1 A Check Sheet Centrifugal Pump
• Ensure vendor data for installation operation & maintenance
is available

• Check FAT punch lists, confirm all items have been cleared.

• Confirm equipment and nameplate details are in accordance

with data sheet and clearly visible. Record serial number above.
• Confirm equipment and installation is in accordance with
manufacturer’s specification and recommendations

• Confirm the foundation, base and anchor bolts are correct

material, size, and length and have been tighten, Record
torque values
Confirm base plate level and equipped with drain holes

Confirm base grouting in accordance with design standards

Confirm pump rotates freely and direction is clearly marked.

Confirm driver has been installed and initial alignment

Complete and accepted

Confirm equipment, driver hubs & spacer are correctly installed

and secured, record distance between shaft ends.

Ensure guards are fitted and in accordance with area design

requirements

Confirm all associated pipe work is flushed and clean

 Pump Grouting
Motor Equipment

Coupling

Special grouting concrete

Checks

Fault Logging

• Fault logging may be conducted at any stage of

commissioning.
• All faults should be recorded to ensure corrective actions are
implemented.
• A fault log is provided to record instances of faulty equipment,
design, installation or functionality.
• Faults detected with associated equipment or plant, which is
not part of the project scope, must also be documented.
• If significant faults are identified which cannot be rectified by
the Commissioning team, a Non-conformance Report (NCR)
should be raised and the fault dealt with using the NCR follow-
up procedures.
Documentation
• Engineering drawings list
• VENDORS documents list
• Project equipment data sheet and standard lists
• Project equipment specifications and standard lists
• Purchase orders list
• Equipment list.
• As a minimum, the Commissioning shall gather and file
the following documentation,
Commissioning tests, as follows but not limited to:

* Auxiliary systems drawings and equipment lists

* Sets of PID's and PFD's
* Isometrics
* Layout and general arrangement drawings
* Piping specification
* Operating manual
Documentation
◼ Equipment data sheets
◼ Instrument data sheets
◼ Logic diagrams
◼ ESD matrixes
◼ Process control configuration
◼ Electrical distribution one line diagrams
◼ Switchboards one line diagrams.
◼ Cables list.
◼ Electrical selectivity study.
◼ Power balance.
◼ Load shedding/load sharing specifications.
◼ Wiring diagrams.
Documentation

• Lighting layout.

• VENDORS manuals (installation, Pre-commissioning,

Commissioning, operation, maintenance)

• Lubrication schedule.

• Spare parts list.

• Special tools list.

• Subcontracted operations

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 • Review and Advise of Utilities and Off-Sites

◼ Check that Emergency Electrical Power covers:

Instrumentation, Utilities, Lighting All terminal products air coolers,
◼ Check that Instrument Air compressor is operating successfully
◼ Check that main Electrical Power has no any troubles
◼ Check Water system
◼ Check Nitrogen availability
◼ Check Steam system
◼ Check Flare System
◼ Check Fuel gas system
◼ Check Drainage system
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• Review and Advise Pre commissioning Activities

Review of documentation
The commissioning operators will review the piping
reported in the Pre-commissioning dossier and
make sure that:
◼ All pipe-work has been properly flushed and pressure
tested, and that all related test sheets are filled-in and
signed.
◼ All relevant piping check lists have been filled-in and
signed.
◼ All as-built drawings are available.
◼ The commissioning operators will work-out all lines and
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verify the operability and the conformity of the pipe work
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with project specifications and drawings, the key

document being the as-built P I D's.
Review of facilities
◼ Piping low points, high points and slopes
Check these are in accordance with the P&ID, that drains
and vents are installed and equipped with plugs.
◼ Pipe supports
Check spring hanger transit pins have been removed.
Check pipe clamps are tight.
◼ Safety valves
If these vent to atmosphere, check that the exhaust line is
adequately supported and drainable if there is low point.
◼ Insulation
Check that piping insulation on hot and cold service lines is
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2in good condition and has been completed;
 Review of facilities
The following are list of points that will be systematically
addressed during this site survey:
◼ Non-return valves, control valves, certain globe valves
Ensure these are installed with the flow direction arrow (stamped
or tagged on the valve body) in the correct direction.
◼ All valves
Check that packing followers are correctly tightened and that the
valves open and close smoothly.(correct gaskets)
◼ Sample connections
Are these correctly placed, i.e., not in a dead-end?
Are they of the type indicated on the P&ID, i.e., double valve,
block and needle, etc.?
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Is there room enough to insert the sample bottle?
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Review of facilities
◼ Pump suction strainers
Can the strainer body be de-pressured and drained?
Can a drain hose be coupled to the drain connection
without problem?
Is the suction eccentric reducer correctly installed?
Can the strainer be pulled without problem?
Is the discharge NRV. correctly installed?
◼ Spectacle blinds
Can they be swung easily?
Are they installed in such a way that they can be swung
without a shutdown, i.e., between
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Review of facilities

◼ Earthing
In some piping applications flanges and equipment are
coupled by an earthing strap/ loop, check integrity of
strap/ loop and connections.
◼ Gaskets and joints
If soft metal ring joint flanges are installed, ensure that a
check has been carried out, during Pre-commissioning,
of flange face integrity.
This type of flange/joint is often used in hot, high
temperature service, such as catalytic reformer reactor
inlet/outlet flanges.

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 Review of facilities
Blinds :Blinds list must have been prepared by the Pre-commissioning team.
The principal reasons for a blind list are as follows:
◼ To record where the blinds are situated and why
◼ To ensure that the blinds are removed prior to start-up.
◼ The blind list (see attached form) will contain the following information:
- Line number (ex.: P&ID), size and service
- Blind number
- Blind size and rating, i.e., 150, 300, etc.
- Date installed plus signature
- Date removed plus signature.
◼ It is often the case that blinds are installed, during Construction and Pre-
commissioning, for Hydrostatic tests, flushing, etc., and these are frequently
forgotten if not correctly listed.
◼ Blinds will always have a tag or handle clearly labelled for easy identification.
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 Review of facilities
Vessels

The commissioning operators will review the vessels Pre-commissioning

operations reported in the Pre-commissioning dossier and make sure that:

• All vessels fabricated on site, or not tested at the Manufacturer’s, have been
Pressure tested and that all related test sheets are filled-in and signed
• All vessels have been properly flushed, cleaned, and dried-out if applicable
• All internals have been correctly installed and checked off
• All as-built drawings are available.
Accessibility

• Check accessibility of valves and other devices, equipment

Safety

•Check all safety aspects related to piping

•Check operability aspects, such as the location of pressure gauges installed at
rotary 5equipment.
•Discharge
7 that must be readable while manoeuvring the discharge valves.
Process isolation
◼ Authorized Person will initiate a process isolation
certificate.
◼ A valve/spade list and marked up P+ID showing the
isolation points.
◼ Isolation points will be identified with tags.
GREEN TAG - VALVE OPEN.
YELLOW - SPADED/BLINDED
RED TAG - VALVE CLOSED.
◼ The tags are of 2 parts. One fixed on the equipment and
the other attached with Isolation certificate.
◼ Red plastic chains and tie wraps to be applied on
boundary isolation valves.
Subcontracted operations
• A number of operations, part of the Commissioning scope
of work, such as:
- Cleaning, drying-out of pipelines .
- High pressure nitrogen leak testing.
• These operations are usually contracted or subcontracted
to specialised companies.

• The Commissioning Management shall list and plan all

such activities and prepare for each of them the contracts
necessary for the call-out of these CONTRACTORS or
SUBCONTRACTORS.

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 • Inert Gas Purging

◼ Inert gas purging is most frequently required to remove air

to avoid the risk of forming an explosive mixture of and gas.
◼ To avoid the ingress of air into equipment Containing sensitive
catalysts, or wet air into equipment which must be kept as dry
as possible, Such as refrigeration units.
◼ The preparation and execution of Inert gas of all oil and gas
process equipment prior to oil or Gas-in is a Commissioning
responsibility.
◼ Commissioning will especially select the best adapted inerting
method and issue detailed Procedures with support drawings
and sketches.

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 Inert Gas Purging
Types of inert gas
Nitrogen (N2)
◼ Supplied as a gas in high pressure bottles
◼ May also be obtained from Nitrogen plant.

Inert gas purging operations

Four different methods can be considered:
◼ Continuous flow or "sweeping".
◼ Pressurization/depressurization.
◼ Water displacement.
◼ Steam-out.
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 Continuous flow or "sweeping"

◼ Used for small, low-volume systems such as piping systems

up to 4" line diameter.
◼ The principle involved is injecting sufficient quantities of inert
gas to create a turbulent flow in the piping which pushes the
air ahead of it, thus displacing it.
◼ The Reynolds number has to be higher than 4000 to create the
turbulent flow required.
◼ As a general guideline a velocity of 10 feet per second is an
acceptable mean value.
◼ Continuous sweeping of large diameter piping is unsuitable
due to the very high flow required to produce the ideal velocity.

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 Continuous flow or "sweeping"
Proceed as follows:
◼ Close all unnecessary vents and drains and install plugs and
caps except on vents and drains which are to be used for O 2
sampling.
◼ Ensure the system to be purged is isolated from associated
systems, either by valves or blinds.
◼ If blinds are to be installed complete a system blind list.
◼ Select an inert gas injection point or points and a vent point at
the farthest end of the system.
◼ If the inert gas arrives via utility hose, ensure the hose is in
good condition and that the injection point valve is open before
opening the inert gas header valve.
◼ Sufficient injection points should be used to achieve the
maximum flow available.
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◼ Open injection point valves and begin the purge.

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 Continuous flow or "sweeping"
Proceed as follows:
◼ Ideally the atmosphere in the piping should be analysed when
the inert gas volume used is approximately three times the
system volume.
◼ Before testing simultaneously close inert gas injection valves
and vent valves to maintain the system under positive inert gas
pressure.
◼ Sample for O2 at several points, especially on complicated
piping systems, i.e., fuel gas headers. Check for dead ends.
◼ When O2 analyses are satisfactory, stop the purge whilst
maintaining system pressure at approximately 0.1 to 0.2 barg
or as required.
◼ A suitably-calibrated pressure gauge must be installed where
easily visible and used to control the system pressure.
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 Continuous flow or "sweeping"

Important notes
◼ This method must not be used for critical equipment requiring
very low O2 results.
◼ It is normally suitable when criteria are not severe i.e. O2
maximum content 2%.
◼ A secondary problem with this method is that it may prove to
be somewhat wasteful of inert gas and where logistical
problems arise
◼ The following method may be preferable, even for relatively
small system.

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 Pressurization/Depressurization method

◼ This is the preferred method of inert gas or nitrogen purging for

reasons of economy and safety and is used for both vessels and
associated piping
◼ Close all unnecessary vents and Drains and install plugs and caps
except on vents and drains which are to be used for O 2 Sampling
and venting.
◼ Ensure the system to be purged is isolated from associated systems,
either by valves or Blinds.
◼ If blinds are to be installed complete a system blind list.
◼ After ensuring that the inert gas supply is available, check the
integrity of pressurizing Hose (if used) and system pressure gauges.
Gauges should be situated so as to be easily visible from the
injection point valves.
◼ Pressurize the system to between 1 and 2 barg (15 and 30 psig)
depending upon the system design pressure.
◼ Never exceed system design pressure even if safety valves are in
service.
6
6
Pressurization/Depressurization method
◼ Let the system stand for approximately 30 minutes to allow the
gases to become homogenous.
◼ Following this 30 minute period, de pressure the system as
rapidly as possible via the largest diameter vent or vents on
the system.
◼ Repeat this operation but stop de pressuring at about 0.1 to
0.2 barg in order to take an O2 analysis sample.
◼ Samples must be taken from several points, depending upon
the magnitude of the system, and averaged.
◼ According to the O2 content requirement, repeat the
pressurization/ depressurization operation until the
specification is met.
◼ When O2 analyses meet the ongoing specification, proceed to
maintain the system under a positive inert gas pressure.
6
7
Pressurization/Depressurization method

◼ It is better to pressurize/depressurize 5 times up to 1

or 2 barg each time, than to pressurize/depressurize
once up to 5 barg.
◼ In the first case the theoretical final oxygen content
is 25 - 32 times less than the original one.
◼ Under no circumstances should a vacuum be
applied as a safety to equipment without first
checking that the equipment is capable of
withstanding vacuum conditions.
◼ O2 maximum content 2%.

6
8
 Water displacement purging
◼ Simple and economical method of purging
◼ Only applicable where the equipment to be purged is capable
of supporting its own weight when water-filled and when the
presence of residual free water will not consequently affect the
plant operation or cause corrosion problems
◼ In certain applications inhibited water (5% soda ash may be
required, i.e. the system contains stainless steel equipment,to
avoid Chloride SCC
◼ The plant is isolated by valves or blinds from all other
associated systems.
◼ If blinds are to be installed, a plant blind list must be
completed.
◼ All plant drains and vents must be closed and the system
high point vents must be open.
6
9
Water displacement purging
◼ Ensure adequate vents are available to ventilate the system
whilst filling with water so as to avoid over pressuring.
◼ Connect the water supply to the plant to be purged
◼ When the plant is full, check any dead end points for trapped
air.
◼ Connect the inert gas supply to the highest point or points on
the plant.
◼ Check that the unit drain plant can dispose of the volume of
water to be dumped.
◼ Begin inert gas injection whilst simultaneously opening one low
point drain.
◼ Warning: The flow of inert gas into the plant and the flow of
water out of the system must be regulated so that the plant is
always under a positive pressure.
7
0
Water displacement purging
◼ If care is not taken to do so, there is a high risk of pulling both
the plant and the inert gas supply system under a vacuum.
◼ This will also prevent air from being drawn into the system.
◼ Gradually increase the inert gas injection rate and draining
rate.
◼ When water drained completed, close all drains and allow the
system pressure to build up to at least 0.2 to 0.3 barg then
stop nitrogen injection.
◼ Analyse (sample) the plant system for O 2 content.
◼ Normally this should be very low if the procedure has been
correctly followed.

7
1
 Steam-out
◼ It is widely accepted due to its overall economy and ease of
operation.
◼ In some processing installations certain vessels and systems
may be provided with permanent steam-out lines and this
greatly assists in purging operations.
◼ Petroleum processing installations do not always have steam
raising facilities and in this case temporary steam generators
will be used.
◼ Steam is obviously unsuitable for purging equipment which
must remain "dry".

7
2
 Steam-out
The general procedure is identical.
◼ If flexible hoses are used, ensure they are adequately
armoured and passed for steam service.
◼ Air and water hoses must not be used.
◼ Always ensure the plant equipment is capable of withstanding
the steam temperature..
◼ Inert gas could equally be used
◼ A minimum of personnel will be present on site during the
operation.
◼ Ensure piping insulation is as complete as possible before
introducing steam.
◼ Personnel must always be adequately clothed when working in
the proximity of steam lines.
7
3
Outstanding Commissioning Items
◼ All outstanding commissioning items or faults must be detailed on the
Punch List, which forms part of the Start-up Acceptance form
◼ This list identifies each outstanding item of work, the responsible group
for completing the work and the expected due date for completion.
◼ Any outstanding faults which are not in the project scope are to be listed
on the Observations List (included in the Project Start-up Acceptance)
◼ Items listed must be categorised as start-up critical (“A” items) or start-
up non-critical (“B” items).
◼ “A” items are safety, environmental, equipment or process critical.
Start-up may not proceed with outstanding Punch List items categorised
as “A” items.
◼ “B” items are not safety, environmental, equipment or process critical.
Start-up may proceed with outstanding Punch List items categorised as
“B” items.
◼ Project acceptance will only proceed when all Punch List items (“A” and
“B”7 items) are completed.
4
 Approvals and Project Start-up Acceptance

◼ On completion of commissioning, as per all sections of this

plan, the Project Start-up Acceptance form shall be signed off
by the onsite Commissioning Coordinator
◼ The signatories will satisfy themselves that all requirements of
the Start-up Acceptance form are met, including the completion
of all safety, environmental, equipment or process critical items
(“A” items) listed on the Punch List.
◼ The Project Start-up Acceptance form shall then be distributed,
along with the Punch List and Observations List, with copies to
the Plant Operations Supervisor and the Project Engineer.
◼ The original shall be retained with the project file.

7
5
 • Safety
◼ Do not clean, service, or repair equipment or piping without
relieving all pressure in the system.
◼ All sources of ignition must be turned off and fire extinguished
prior to installation or repair.
◼ Obtain a hot work permit before welding in or near the unit.
◼ Never enter a vessel without an entry permit and proper safety
precautions. Even when a vessel has been cleaned and purged
with air, toxic and/or combustible gases may be trapped in
pockets inside the vessel
◼ Never enter a low point or pit in the plant area without checking
for adequate air with a portable oxygen meter (a proper reading
is about 21% oxygen) and verifying the absence of combustible
and/or toxic gases.
◼ Appoint a group of fitters to assure tighten for all plants studs
and not exceeding tighten torque table
7
6
 Safety
◼ Prevent leakage of gases and liquids, especially those that may
be toxic, combustible
◼ Do not bypass alarms and emergency shutdown systems.
Check alarm lights, horns, and emergency shutdown systems
on a regular basis to ensure their proper operation.
◼ Keep block valves upstream and downstream locked open,
when the pressure safety valve is in service.
◼ Check pressure safety valves on a regular basis to ensure their
proper operation.
◼ Rotating equipment such as fans and pumps are provided with
belt or coupling guards. Keep these guards in place at all times
during operation of the equipment.
◼ Electrical equipment must be maintained by qualified
personnel. Tag and lock-out electrical switch gear whenever
motor driven or electrical equipment is being serviced.
Safety
◼ Check that Emergency Electrical Power covers:
Instrumentation, All utilities equipment, Lighting All terminal
products air coolers,
◼ Any motor driven equipment that is equipped with a local
"HAND-OFF-AUTO" control switch should always be
operated in the "AUTO" mode.
◼ This is done by placing the local "HAND-OFF-AUTO" control
switch into the "AUTO" position. In this position, the PLC has
control of the equipment. The switch must be in the "AUTO"
position for the PLC to be able to shut down the equipment.
◼ Always be sure the fired heater has been purged of all
combustibles before lighting the pilot.
◼ Do not operate the fired heater without adequate combustion
air and hot oil flow. Never exceed the manufacturer's
maximum recommended heat release. Be alert for flame
impingement and hot spots
7
8
Safety
◼ Whenever the fired heater is shut down for a long period of
time, blind off the fuel gas supply line because gas may leak
through the valves and fill the heater.
◼ Take proper safety precautions to avoid thermal burns.
◼ Never exceed the maximum allowable temperature and/or
pressure ratings shown on the equipment nameplate tags.
◼ Keep roads, walkways, and building exits clear.
◼ Keep telephone numbers for the local fire department,
ambulance, and emergency personnel clearly posted.
◼ Thoroughly review the material safety data sheet (MSDS)
for each chemical and material used in the unit.
◼ Thoroughly review all company safety standards and
procedures.
7
9
 Environmental Protection
All personnel must be aware of the following:
◼ Keep flanges and other connections properly tightened to avoid
leakage of gases and liquids.
◼ Keep the packing nuts on valve stems properly tightened.
Leaks may develop after repeated usage. Replace stem
packing when necessary.
◼ Check vents, drains, sample taps, and similar connections for
leaks. Install plugs, caps, or blind flanges on all openings.
◼ The mechanical seals or packing on compressors and pumps
may leak slightly. If the leakage becomes excessive, service or
replace the item as necessary;

8
0
 Environmental Protection
◼ Check pressure safety valves for leaks. Once a valve relieves,
it may not reseat completely.
◼ Do not drain any liquid or other waste onto the ground. If a
closed drain is not available, collect the liquid or other waste in
an approved container following all necessary safety
precautions.
◼ Liquid or other waste that ends up on the ground for any
reason (spills, accidents, leaks, etc.) must be cleaned up and
disposed off in accordance with all applicable regulations
◼ All waste materials removed from the unit, such as spent filter
elements, must be disposed of in accordance with all
applicable regulations.
◼ Do not vent gas to the atmosphere, Use an appropriate vent or
flare system whenever possible.
8
1
Initial Start-up
Step Pre-Start Checks Comments
1. All construction, maintenance and repair work is Mechanical team,
completed, and all punch list items are clear. performance &
maintenance team (PMT),

2. Field checks against P&ID completed

3. Fire fighting system is available

4. All blinds that require to be removed have been Blind list updated
removed
5. PSV Checklist is completed and signed off. Block valves sealed open,
bypasses closed
6. P-restart Valve Position Checklist is completed
and signed off.
7. All control and shutdown systems are available. Loop testing complete −
Control valve stroke checks and line up checks Jumpers and bypasses −
carried out and defects rectified removed
Control valve checklist −
signed off.
Initial Start-up
8. Filter elements available

9. Hot Oil heaters are available for service.

10. Glycol are available

11. Utilities are available −Instrument air

−Electrical Power
−Flare System
−Nitrogen
−Fuel gas
−Drainage system
12. All electrical equipment available

13. Purge is completed , Low pressure N2 leak test is Purging by 7 psi

done
14. System is under N2 pressure

15. System is O2 free and under N2 pressure.

16. After pre-start completed, approval for start-up

has been received from management
8
 Pre Start-up Testing
• Where function testing cannot be performed without operating
the equipment or plant being commissioned, the tests must be
undertaken in parallel with the Plant Operations.

• Where pre start-up testing is required, Operations are

responsible for ensuring that process and plant conditions
allow safe starting and operating of the equipment under test
• Commissioning Progress and Activities Principles

I- PROCESS LINES
CHECK SAFETY VALVES TESTING CERTIFCATES

1- Line Flushing Sequence

2- Steam Purging/Blow Sequence
3- Install Any Internals Of
The Stationary Equipment
4- Hydrostatic Test
5- Drain& Air Drying (Reinstatement)
6- Boxing Up ( Tighting Torque Rpt.)

7- Rupture Discs Check And Installation

STAINLESS STEEL PIPING

FOLLOW THE STANDARD &TESTING PROCEDURES
8- Tightining Test:

* Apply Suitable Plant Air Pressure To

The Each Loop ( H.Ex., Vessels, Towers, Re-boilers

* Holding Pressure Up To 4 Hrs

* Pressure Drop (0.05 Bar/Hr) Is Accepted

9- Circulating Of Pump Soda Ash 5% By Using Pump

To Avoid The Stainless (Hair Crack Due To Existing
Of Chlorine In Water)
10- Check Flanges Correct Gasket Rate

11- Check Corrosion Scarifying Probes In All

Commissioning Operation (Inspection Rpt)
II- STATIONARY EQUIPMENT

A -Towers ( All Trayed Columns)

1- Column Tunneling
2- Filling And Cleaning Procedure (As Api Std)
3- Inspection & Safety Rpts Review
4- Re-placing The Trays
5- Boxing Up ( Tighting Torque Rpt.)
6- Hydro Static Test
7- Drain & Air Drying
B- Reactors

1- Open Top & Bottom Access Flanges

2- Cleaning Procedure (As API Std)
3- Inspection & Safety Rpts. Review.
4- Check The Cladding Material -API 941
5- Place Screen Basket At Dumping Nozzle
6- Boxing Up ( Tighting Torque Rpt.)
7- Hydrostatic Test
8- Drain & Air Drying
9- Opening In-out Nozzles
10- Catalyst Loading According To
Vendor Procedure (Process Job.)
11- Boxing Up ( Tighting Torque Rpt.)
Hydrogen Service

Material selection and PWHT requirements for vessels in hydrogen

service also require special consideration.

Ultra former reactors with a design temperature of 975°F

and a hydrogen partial pressure of 230 psia should use
1 Cr-1/2 Mo or 1-1/4 Cr-1/2 Mo steel. As base material
Cladding: 347SS (18Cr-10Ni-Cb)----SA-312

A- Hydrogen blistering

B- Hydrogen Embrittlement

C- Hydrogen Decarburization

For resistance to hydrogen attack, see API 941.

14 June 2021 89
14 June 2021 90
 Hydrogen blistering

Schematic of hydrogen Extensive hydrogen blistering on

blistering
14 June 2021 the surface of steel pressure vessel
91
At Elevated Temperature Hydrogen Decarburization

Reactor

Mono Hydrogen atoms “H”

14 June 2021 92
 Reactor shell

Material defect
Mono Hydrogen atoms “ H ”
is very active CH4 H4 C

H2 HH2

14 June 2021 93
 Reactor shell
Internal Chrome
Steel cladding

Hydrogen blue flame

14 June 2021 94
 High Temperature Hydrogen Embrittlement

Fe3C + 2H2 3Fe + CH4

Link-up of micro fissures and formation of continuous cracks due to

14 June 2021 severe decarburization 95
 Base material for reactor

Temperature F

1.25 Cr 0.5 M
2.25 Cr 1 M - V
1 Cr .5 M

C.S

14 June 2021 96
Hydrogen Partial Pressure psia
C- Heat Exchangers
1- DATA SHEET & INSTALLTION RPT. REVISION

CHECK TESTING RINGS AVAILABILITY IN W.H. ( F.H. TYPE)

2- OPENING

3- CLEANING PROCEDURE (AS API STD )

4- INSPECTION & SAFETY RPTS REVIEW.

5- BOXING UP ( TIGHTING TORQUE RPT.)

H.EX..PROKEN STUDS

6- HYDROSATATIC TEST (AS API STD )

7- BOXING UP ( TIGHTING TORQUE RPT.)

8- DRAIN & N2 PURGING

 Heat Exchanger Construction

1-Floating Head Heat Exchanger

CHANNEL OUT
HEAD BONNET
COVER
VENT
TEMA AES TYPE Hx

CHANNEL
HEAD

TUBE
SHEET SHELL
DRAIN
IN
TUBE TUBE
HEAD CHANNEL
BUNDLE
COVER HEAD BAFFLE
PLATES
FLOATIN VENT
G HEAD

TUBE DRAIN
SHELL
SHEET
14-Jun-21
2- “U” Tube Heat Exchanger

OUT
TEMA AEU TYPE Hx VENT

DRAIN
14-Jun-21 IN
 VENT

DRAIN

14-Jun-21
3-Fixed Tubes Heat Exchanger

Tube Bundle is completely welded

OUT
TEMA NEN TYPE Hx

DRAIN
14-Jun-21 IN
Types Of H.Ex. Failure

1- Tubes Leaking
2- Tube Sheet Leaking
3- Tubes Plugging
4- Shell Plugging
5- Stainless Tubes Hair Cracking (Chlorine effect)
6- Counter flow
H.Ex. Leak Test
• Visual Leak Test
• Hydrostatic Test
• Sample Lab. Test
• Sample Chemical Lab. Test
 Hydrostatic Test
Hydrostatic test will supervised and responsibility of Inspection
department

• Test blinds (capable to withstand the test pressure),

to be installed at inlet and outlet nozzles of shell and tube sides.

• Fill shell side with water (alkaline water for stainless steel tubes,
use soda ash 5% concentration) to avoid Chloride SCC

• Apply pressure in shell side, check tubes leaking (outside or inside)

• Drain the tube water

• Apply pressure in tube side, check tubes leaking, tube sheet leaking
 HYDRAULIC TESTING

Shell Side Test

Testing fluid

leaking
Tube

leaking
Tube Sheet

14-Jun-21
Tube Side Test
Testing fluid
U Tube

leaking
leaking Tubes
Tube Sheet
Tube Side Test
Testing fluid
Floating Head

Floating Head
14-Jun-21
Leaking Tube Sheet Leaking
FLOATING HEAD
DETAILS FLOATING HEAD

Split Rings

14-Jun-21
TEST RINGS
TEST RINGS KIT
PACKING

14-Jun-21
Example of Design Fatal mistakes

Normal procedure for H.Ex. maintenance

EXAMPLE (I)

2 nd. floor

1 st. floor

On site Maintenance facilities of Heat Exchangers are not possible

ROAD
Solution 1

IS TO CONSTRUCT A NEW
STEEL PLATFORM
 Solution 2 IS TO CHANGE THE H. EX”S. DIRECTION

2 nd. floor

1 st. floor

BOTH SOLUTIONS 1&2 ARE VERY DIFFICULT AS :

1- THE PLANT IS IN OPERATION & H.C. IS CIRCULATED

2- INLET &OUTLET PIPING CONNECTIONS HAVE TO BE MODIFIED
3- LIQUDATED DAMAGE DUE TO PLANT STOPPAGE
Solution 3 IS TO USE SPECIAL CRANE ATTACHEMENT

THIS NOT THE PRPER WAY FOR

SAFETY PRECAUTION
EXAMPLE (II)
Access passage enough for
hoisting and mobilization

To workshop for maintenance

EXAMPLE III Tower

Accessibility of Measuring Element

is not safe or easy
FLOATING HEAD COVER STUDS WAS FOUND BROKEN DURING
PLANT START UP , BUT IT WAS TOO LATE

THE STUDS WAS OVER STRENTHED DUE TO EXTRA

TIGHTING TORQUE DURING VENDOR ASSEMPLY

THIS PROBLEM CAN BE AVOIDED

DURING PLANT PRE-COMMISSIONING
 Start Up And Shutdown
On initial start up and shutdown the heat exchanger can be subjected to damage
Such as thermal chock, over pressure or hydraulic hammer
This can lead to leaky tube to tube sheet joints because of excessive thermal
expansion of tubes or the shell.
New H.Ex. Start Up Procedure
1- Check H.Ex. Parts no loose bolts,
2- All valves in the shut position
3- Check H.Ex Leaks
4- Hydrostatic Test
5- Drain Water
6- Purge the H.Ex with inert gas to avoid the possibility
of explosion during gas or liquid filling
7- Temperature changes should be slowly, and flow rate
gradually increased
H.Ex. Shutdown Procedure
Stop the hot fluid first
H.Ex. Valves should not be closed while it is full of liquids.
III-ROTARTING EQUIPMENT
A-PUMPS
1- CENTRIFUGAL PUMPS
Data Sheet & Installation Rpt. Revision
1- Check Base Grouting
2- Check Start Up Spares In W.H.
3- Open Suction And Discharge Nozzles
4- Check Any Foreign Materials
5- Check Piping Strain
6- Free Rotation In The Direction Of Rotation
7- Disconnect Coupling
8- Check Rotor Run Out
9- Check Rotor End Play / M.C.
10- Check Cooling System &Apply Hydrostatic Tests
11- Boxing Up (Suc.& Dis.) ( Tighting Torque Rpt.)
12- Drain Lube Oil System
13- Clean With Solvent
14- Fill With Flushing Lube Oil
15- Measure Thermal Growth If Recommended
16- Check The Shims Thickness Under The Prim mover Is
At Least 2 mm
17- Apply Alignment Procedure
Preferable (Reversal Or Optical Method
18- Correct Alignment Readings
19- Check Earthing Connections
20- Check Mechanical Seal Barrier
Fluid System If Any.
21- Check Vibration Probes If Any
22- Check Cooling System If Any
23- Check Auxiliary Systems As Flushing, Quenching If Any
24- Check Any Attached Pressure Gauge
25- Preparation For Start Up
26- Suction Valve To Be Opened
27- Discharge Valve To Be Closed
28- Suction Line Strainer Change Sequence
Starting With Narrow Mesh
29- Start Up / Record Sheet As Api Std.
30 - Stop – Flush L.O. & Fill Recommended One

31- Start Up / Record Sheet As Api Std.

32- Check NPSHA For The Atmospheric Suction Pumps
NPSH
1- NET POSITIVE SUCTION HEAD REQUIRED

YOU CAN GET FROM PUMP MANUAL

2- NET POSITIVE SUCTION HEAD AVAILABLE

YOU CAN CALCULATE FROM PUMP SITE

TO AVOID SUCTION CAVITATION AND FOR SAFE OPERATION

NPSHA > NPSHR

 Examples of Cavitation Damage
• Increase of noise and vibration, resulting in
shorter seal and bearing life.
• Erosion of surfaces, especially when pumping
water-based liquids.
Cavitations erosion of an impeller, indicated by the porous
appearance of cavitated regions on the surface
Cavitation
What is cavitation's
phenomenon
It is an action of fluid vapor attack on the parts of
equipment which produce suction pressure less than vapor
pressure of the pumped fluid.
This action will cause:
loss of the weakest component element of suction parts
material due to bubble explosion on the surface of suction
parts causing cavities .
Vapor bubble explosion on surface could be 60,000 psi.

Cavitation Can Occurs In

• Centrifugal Pumps
• Positive Displacement Pumps
 Water Vapor Pressure Graph

P
Kg/Cm2

80
Liquid
Add
Temp
60

Lower Pressure

40
Vapor
Vapor
20
14.7 Psi
212

150 200 250 300

T F0
 B

Liquid
Flow

A
 Water Vapor Pressure Graph

P
Kg/Cm2

80
Liquid covert to vapor Liquid
Add
by two methods Temp
60
1- Add Temp
Lower Pressure
2- Decrease Pressure
40
Vapor
Vapor
20
14.7
Psi 212

150 200 250 300

T F0
 Vapor Pressure Graph through
pump the impeller

P
Kg/Cm2

Liquid Cavitation's
converts start
to Vapor
Vapor LIQUID
pressure
limit VAPOR
Vapor
converts
to Liquid

Impeller length
 FLUID VAPOR
BUBBLES

Pump suction parts

cavities

Pump suction parts

After attack
LOST ELEMENTS IN SUCTION PARTS

SUCTION PARTS THE WEAKEST ELEMENT

MATERIAL ( LOST ELEMENT )

CARBON STEEL

CAST IRON
CARBON
STIANLESS STEEL

BRONZ

BRASS ZINC
What is the parameters affecting
NPSHA
•SUCTION PIPE LENGTH
•SUCTION PIPE DIAMETER
•LIQUID SPECIFIC GRAVITY
•INTERNAL SURFACE OF SUCTION PIPE
•LIQUID SURFACE ALTITUDE
•VAPOR CONTAMINATION
•SUCTION PIPE LEAKS
•SUCTION PRESSURE
•LIQUID TEMPERATURE
•LIQUID VISCOCITY
•LIQUID VAPOR PRESURE
•ATMOSPHERIC PRESSURE
 PVS
NET POSITIVE (+) SUCTION HEAD

PS v Z

Z liquid surface height ft

PSV Vessel pressure psig
PS Pump suction pressure psig
V liquid velocity ft/sec
Pf Friction Pressure drop psi
Pa Atm. Pressure psi
Vp Vapor pressure psia
Sp.gr liquid specific gravity
hL Suction head loss ft
g 32.2 ft/sec.sec
NPSHA IS NOT

PS
THE SUCTION
GAUGE PRESSURE

OR
PVS

LIQUID LEVEL IN
THE SUCTION VESSEL

Z
 1 PVS

General Equation

Z
V

NPSHA = Z + V 2 + { (P vs +Pa) – Vp } 2.31 - hL

2g Sp.gr
 IF
The Suction
Ps P sva
+ Z - hL
Sp.gr = Sp.gr
pressure is
known

Z + V2 { Psasva – Vp } 2.31
NPSHA =
2g
+ Sp.gr
- hL

2
V { Psa – Vp } 2.31
NPSHA = + ( ft )
2g Sp.gr
 Boiled
water

Positive
Reading

PS Z

Z < hL
 PS

PVS

Negative
Pressure

PS
Z < 6m
ATMS
Practically
PS

FOR ANY TYPE OF PUMPS

- Z = 6 mt of water

ATMS

SUCTION NEGATIVE
ALTIDUDE NOT MORE THAN
6 METERS
 ATMOSPHERIC
10,033 mt
PRESSURE SPACE OF WATER

SPACE

76 Cm
MERCURY water

ATMS ATMS
CENTRIFUGAL
PUMPS LOSSES
FRICTION LOSS
EDDY LOSS
LEAK LOSS
H ft THEORITICAL HEAT LOSS
CURVE

ACTUAL
CURVE

Q g.p.m.
100 200 300 400 500
 v PS

PS
6 mt WATER
v

PS
 VAPOR PRESSURE

1
1 P
T
T P

FIG-1 FIG-2

1- Heat up a little of water

in a pot up to boiling point
100 C ( valve 1 is opened)
2- Take off the heating source,
simultaneously close valve 1.
 Closed
Cool Down
T P Gauge

3- During cooling down, Start to record the P

Gauge relevant to Temp.

4- Apply Absolute pressure Equation .

P Absolute P Gauge + 1
(bar)
 Vapor Pressure P Gauge + 1
( bar ) absolute

5- Record the Absolute Liquid vapor

pressure.

Temp C 100 95 90 80 70 15

P Gauge 0 - 0.1 - 0.3 - 0.5 - 0.7 - 0.98

1 0.9 0.7 0.5 0.3 0.02

Vapor Pressure
 Examples
Crude oil level is 8 feet above center line
of a pump , Vessel pressure is Atmospheric
Vp is 4 psia
Sp gr. is 0.8 Friction loss : 12 ft of liquid
Atmospheric pressure is 14.7 psia
( Neglect velocity head (
Solution

NPSHA = Z { (Psv + Pa) – Vp } 2.31

+ - hL
Sp.gr
{ 14.7 – 4 } 2.31
= 8+ - 12
0.8
= 8 + 31 - 12
= + 27 ( ft )
Compare with NPSHR
Examples
Crude oil level is 8 feet above center line
of a pump , Vessel pressure is Atmospheric
Vp is 14 psia
Sp gr. is 0.85 Friction loss : 2 ft of liquid
Atmospheric pressure is 14.7 psia ( Neglect velocity head (

Solution
NPSHA = Z + +{ (Psv+ Pa) – Vp } 2.31 - hL
Sp.gr
{ 14.7 – 14 } 2.31
= 8+ - 2
0.85
= 8+ 2 - 2

= + 8 ( ft )

Compare with NPSHR

 Examples
negative
If the liquid level Z= - 12 ft
, Friction loss is 1 ft of liquid
, Atmospheric pressure is 14.7 Psia. at 150 F
, water sp gr. is 0 . 982 ( Neglect velocity head (
,Vp = 3.7 psia FIND NPSHA
Solution
NPSHA

Z ( Pa – Vp ) 2.31
= +
Sp
. gr
hL ( ft )

( 14.7 – 3.7) 2.31 1

= -12 + ( ft )
0.982

= + 12.8 ( ft )

Compare with NPSHR

Examples
If crude pump suction pressure is – 5 psig
Vp. is 4 psia ( Neglect velocity head (
Sp gr. is 0.8 , Atmospheric pressure is 14.7 psia.
FIND NPSHA

Solution
{ (Ps + Pa) – Vp } 2.31 ( ft )
NPSHA =
Sp.gr

{ ( 14.7 - 5 ) – 4 } 2.31 ( ft )
=+
0.8

= + 16 . 46 ( ft )

Compare with NPSHR

Examples
If the liquid is butane and level is z = - 8 ft
System pressure is 60 psia.
Temperature is 90 F ( Neglect velocity head (
Vp = 44 psia at 90 F, butane sp.gr is 0.58
Friction loss : 12 ft of liquid, FIND NPSHA

Solution
NPSHA

Z ( Psva – Vp ) 2.31 hL
= + ( ft )
Sp
. gr

( 60 – 44 ) 2.31 hL
= -8 + ( ft )
.
0.58

= + 43.7 ft

Compare with NPSHR

 Examples
If crude pump suction pressure is +1 psig
Vp. is 13 psia ( Neglect velocity head (
Sp gr. is 0.85, Atmospheric pressure is 14.7 psia. FIND NPSHA

Solution

{ Psa – Vp } 2.31
NPSHA = ( ft )
Sp.gr

= { ( 14.7 + 1 ) – 13 } 2.31 ( ft )
0.85
= + 7.33 ( ft )

Compare with NPSHR

PUMP ROTOR
AXIAL THRUST
P d

P d P d
BALANCED
ZONE

PS P d
UNBALANCED
ZONE

PS P d
UNBALANCED
ZONE

BALANCED
P
d P d ZONE
BALANCING Balancing Room

DRUM Balancing Line

Balancing Drum
P1 P2 P3 P4

P4 P0
P0 P1 – P0
+
P2 – P1
+
P3 – P2
+
P4 – P3 P4 – P0
P4 P0

P1 – P0 + P2 – P1 + P3 – P2 + P4 – P3

P4 – P0 P4 – P0
BALANCING Balancing Room

DRUM BALANCING LINE

Balancing Drum
12 22 32 42

42 2
2 12 – 2
+
22 – 12
+
32– 22
+
42 – 32 42 – 2
42 2

12 –2 + 22 – 12 + 32 – 22 + 42 – 32

40 40
 Mechanical seal and bearings arrangement

Balancing
Pressure
Room

P4 P
Ps

Ps P 4 P
Pumps
arrangement

Poor arrangement
Good arrangement
Q = 2Q1

P P

Q1 Q1
 CENTRIFUGAL PUMPS IN PARALLEL

P psi
or
H ft PUMP A , B COMPINEND
CURVES NEW Q -H

P Constant
Q 2Q
300 600
Q g.p.m.
Centrifugal Pumps Ns

Volute
Discharge Discharge
 FLUIDS FLOW
KINAMATIC ENERGY P2

P1

Plus Thermal energy

2
2 V2 P2
V1 P1 CONSTANT +
2g
+ 2g

v <v
2 1 P >P
2 1
TOTAL ENERGY DIMENTIONS

2 2 2
ft ft
V sec sec 2
= ft
= ft
= ( ft )
2g 2
sec 2 sec

Lb
3
P ft
2 ft
( ft )
= Lb
= 2
=
density 3
ft
ft
FLOW KINAMATIC ENERGY

V2 P
2g +

velocity

suction Impeller volute

shroud
167
 CENTRIFUGAL PUMPS CURVE

P psi
or A

H ft
B

Q g.p.m.
100 200 300 400 500
CENTRIFUGAL PUMPS
CURVE LOSSES
FRICTION LOSS
EDDY LOSS
LEAK LOSS
THEORITICAL HEAT LOSS
CURVE
P psi
or

H ft
ACTUAL
CURVE

Q g.p.m.
100 200 300 400 500
Wearing Wearing
rings rings

Mechanical
Seal
 PUMPS SPECIFIC SPEED
Very high Head
Very Low Flow
High Head
High Flow

Very high Flow

Very Low Head
 PUMPS SPECIFIC SPEED
NS

RADIAL FRANCES CAPLAN MIXED FLOW PROPELLER

NS = 500 800 1200 2000 3000

Q
1/
2 N = RPM
N
NS = 3 / 4 Q = FLOW RATE (GALLONS. PER MIN).
H H = HEAD PER IMPELLER (FEET )
 ξ Q
1.0
10000 GPM
0.9 3000
0.84 500
1000
0.8 300
200
100
0.68 0.7 50
30
0.6
0.5

0.4 10 GPM
0.3
0.2

0.1
555 1250
500 1000 1500 2000 2500 3000
N Q NS
NS 3/ 4
IF H
N = 1500
2000 RPM
Q = 100
1600GPM
GPM
2000
1500 1600
100 15000
80000
H = 81
256FT/ /Impeller
FT Impeller NS 3/ 4 NS 1250
555
256
81 64
27
PUMPS POWER

W HP = WATER HORSEPOWER W HP = ρ H Q

B HP
ρ
B HP = H Q
= BREAK HORSEPOWER
ξ
WHERE

ρ = LIQUID DENSITY

P = PUMP DIFF. PRESSURE

Q = PUMP FLOW RATE

ξ = PUMP EFFICINCY
 1 HP = 75 kg. m / sec
HOW TO ESTIMATE
PUMP POWER 1 HP = 550 Ib. ft /sec

Q.P
P = bar WHP =
75
W HP = 0.037 P Q 3
Q = M hr
M3 /hr Kg / cm2
WHP =

B HP = 0.037 PQ 75

ξ
Kg 100*100
m3
WHP = *
P=psi sec *3600 m2 75
WHP = 0.00058P Q
Q = GPM Kg
100*100 m
WHP = *
3600 * 75 sec

B HP = 0.00058 PQ
ξ WHP = 0.037
Kg m
sec
EXAMPLE

CALCULATE MOTOR HP. FOR

1-PUMP (A) HAS D.P = 20 PSI

Q = 2000 GPM

2-PUMP (B) HAS D.P = 400 PSI

Q = 100 GPM

FOR BOTH PUMPS

WATER. HP. = 0.00058 * 20*2000 HP.

= 23.2 HP
177
 NS PUMP (A)
ξ Q
1.0

0.9 10000
GPM
0.85 0.8 1000
3000
500
300
200
0.7 100
50
0.6 30
0.5

0.4
10 GPM
0.3
5 GPM
0.2

0.1
3800

500 1000 1500 2000 2500 3000

Q = 2000 GPM 1000 2000

NS NS 3800
H / Imp = 20 * 2.31 = 46.2 ft 3/ 4
46.2 178
PUMP A N = 1500 RPM

1 /2 D.P/impeller = 2O*2.31 = 46.2 ft

N Q
NS = 3 / 4 Q = 2000 GPM
H
1/2
1500 * 44.7
NS = 1500 * 2000 = = 3800
3/4
46.2 17.66

ξ = 0.85
BRAKE HP = 23.2/0.85 = 27 HP.

Motor HP = 27 * 1.2 = 33 HP
179
 NS

PUMP (B)
ξ Q
1.0
10000 GPM
0.9 3000
1000
500
0.8 300
200
100
0.7 50
30
0.6
0.5

0.4 10 GPM
0.3 5 GPM
0.25 0.2

0.1

60 500 1000 1500 2000 2500 3000

Q = 100 GPM 1000 100

NS NS 60
H/ Imp = 400 * 2.31 = 924 ft 924
3/ 4
PUMP B N = 1500 RPM

1/ D.P/impeller = 400 * 2.31 = 924 ft

2
N Q
NS = 3 / 4 Q = 100 GPM
H
1/2
1500 * 100 1500 * 10
NS = 3/4
= = 90
924 117

ξ = 0.24
BRAKE HP = 23.2 /0.24 = 97 HP.

Motor HP = 97 * 1.2 = 116 HP

181
 Compressors intermediate pressures

3 Stages Gas compressor has

Outlet pressure P3 = 127 barg
Inlet pressure P0 = 1 barg
what are the intermediate pressures
1st 2nd 3rd stage
stage stage
P0 P1 P2 P3

1 barg 127 barg

14 June 2021 182
 1st 2nd 3rd
stage P1 stage P2 stage
P0 P 3
127 barg
1 barg
Assume
r is The equal Pressure Ratio between stages. AND R= P 3

P1 P2 P3
P0
r = = =
P0 P1 P2
P1 P2 P3 r
3
= P 3
3
r = * * P 0
P0 P1 P2
Generally
3 3 N
r = R r = R r = R
183 14 June 2021
R =r = P3 3 (127 +1)
=
128
= 64
= 2
P0 (1+1)

3 3
r = R = 64 = 4

P1 = r * P0 = 4 * 2 = 8 bara = 7 bar g

P2 = r * P1 = 4 * 8 = 32 bara = 31 bar g

P3 = r * P2 = 4 * 32 = 128 bara = 127 bar g

Centrifugal Pump
Connection

Ball Valve

Check Valve

Ball Valve

Strainer
Vertical
Inline
Centrifugal
Pumps

Sundyne Driver
Pumps

Coupling

Gearbox

Pump
Gearbox M. Seal

Pump M. Seal
Centrifugal pumps
in series

P1 Pd
Q Q Q
P0 P1

P
Pd = P1 + P
Centrifugal
pumps H ft
COMPINEND
in series NEW Q -H

HT = HA + HB HT
PUMP B

HB
PUMP A

HA

100 200 300 400 500

Q g.p.m.
 OPERATING POINT RPM = 3000
P IMP. DIA. 10

H ft
.
C
ξ

KW

100 200 300 400 500

230 Q gpm.
Pump Head
Positive Displacement
–Reciprocating Pumps
-Rotary Pumps

Relief
Valve

Rotary pumps
B-COMPRESSORS
* CENTRIFUGAL
CHECK BASE GROUTING

DATA SHEET & INSTALLTION RPT. REVISION

1- WHARE HOUSE CHECK

START UP SPARES
COMPLETE BALANCED ROTOR
MECANICAL SEALS CARTRIDGE
SPECIAL TOOLS
2- COOLING SYSTEM COMMISSIONING

3- CHECK ANTI-SURGE SYSTEM

ACCORDING TO VENDOR INSTRUCTION
* UIC (ANTI- SURGE INTEGRATED CONTROLER)
*FLOW TRANSDUCER
*INTERMEDIATE GAS COOLERS COMMISSIONING
*INTERMEDIATE SCRUBBERS
*SIMULATION TEST OF ANTI-SURGE VALVE
*SITE CONTROL PANEL COMMISSIONING
** Centrifugal Compressor Operation

S CRUBBER ANTI-SURGE ANTI-SURGE ANTI-SURGE

SCRUBBER SCRUBBER SCRUBBER
VALVE VALVE VALVE

COOLER COOLER COOLER

1S t Stage 2 Nd Stage 3 Rd Stage

14 June 2021 194

4- APPLY PICKLING PROCEDURE FOR COMP.
SUCTION LINE

5- CHECK GAS MICRON FILTER ELEMENTS

6- CHECK BUFFER GAS PRESSURE

7- DRAIN LUBE OIL SYSTEM

8- CLEAN WITH SOLVENT

9- CLEAN THE LUBE OIL RESERVOIR WITH

SPONGY RAG BUT NOT WITH CLOTHING RAG

10- FILL WITH START UP OR FLUSHING LUBE OIL

11- CHECK GAS MICRON FILTER ELEMENTS

12- CHECK DRIVER SOFT FOOT

13- OPEN SUCTION AND DISCHARGE NOZZELS

14- CHECK PIPING STRAIN

15- CHECK ANY FOREIGN MATERIALS

16- INSTALL RECOMMENDED START UP STRAINER

IN SUCTION LINE

17- DISMANTLE ALL THE COVER STUDS &TAKE

OUT COMPRESSOR COVER

18- CHECK ALL INTERNAL CLEARENCES

(COMPARE WITH VENDOR VALUES)

19- RETIGHT STUDS AS VENDOR TIGHTING

PATERN AND TORQUE VALUES

20- LOCK ALL COVER NUTS BY LOCK WASHERS

21- DISCONNECT COUPLINGS

22- CHECK ROTOR RUN OUT

23- CHECK ROTOR END PLAY / M.C.

24- BOXING UP (SUC& DIS.) ( TIGHTING TORQUE RPT.)

25- RE-PLACE COUPLINGS SPACER (STUDS OF H.S.

COUPLING IN SEQUENCE)

26- APPLY ALIGNMENT PROCEDURE

PREFERABLE (REVERSAL OR OPTICAL METHOD

27- CORRECT ALIGNMENT MEASUREMENT BY

ADDING THERMAL GROWTH VALUE.

28- CHECK MECHANICAL SEALS LEFT & RIGHT

POSITION (NDE& D.E)
29- INSTALL THE TWO MECHANICAL SEALS

30- INSTALL THE VIBRATION PROBES

32-SUCTION LINE LUBE OIL STRAINER CHANGE

IN SEQUENCE

33- PREPARATION FOR START UP

31- CHECK LUBE OIL RUNDOWN TANK AND

FILL WITH LUBE OIL

35- CHECK LUBE OIL PRESSURE AT ALL

BEARINGS AND GEAR BOXES

36- FREE ROTATION IN THE DIRECTION OF ROTATION

37- START UP / RECORD SHEET AS API STD.

38- CHECK GAS D.P. ACROSS FILTERS

39- CHECK LUBE OIL D.P. ACROSS FILTERS

40- CHECK BUFFER GAS D.P. ACROSS LABYRINITHS

41- RECORD ALL THE OPERATING PARAMETERS IN

THE STANDARD OPERATING SHEET

42- OPERATING TIME AS VENDOR

RECOMMENDATION
43- CHECK THE VIBRATION LEVELS

44- STOP – FLUSH L.O. & FILL WITH VENDOR

RECOMMENDED LUBE OIL.

45- RECORD ALL THE RUN DOWN PARAMETERS IN

THE STANDARD OPERATING SHEET
 To Lube Oil Reservoir
LUBE OIL
Rundown 7000 mm Above
SYSTEM Tank Machine C/L

Lube Supply Oil Header

From Lube
Oil Control Electric
Valve Motor

LSC

G box HSC

Centrifugal
Compressor

200
To Main Lube Oil Reservoir Lube Oil Drain Header