SAJJAD KHUDHUR ABBAS

Ceo , Founder & Head of SHacademyChemical Engineering , Al-Muthanna University, IraqOil & Gas Safety and Health Professional – OSHACADEMYTrainer of Trainers (TOT) - Canadian Center of Human Development

Episode 34 : Project Execution Part (5)

Component Assembly

•Transportation of component

•Installation of components at plant sitePolice approval

•Large components – used suitable cranes, usually are leased/rent

– electronically controllable by remote control

•Medium/Smaller components– hoists or fork‐lifts are used

– are ordered to the building site at an early stage and intermediately

stored there.

‐If possible, at the same time, during the assembly of main components, theassembly of medium/smaller components will begin.‐Subcontractor is required to provide suitable packaging or tarpaulin cover(cover for vessel opening such as nozzle, by means of plastic caps)

Transport analysis

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‐Headroom of bridge & tunnel

‐turning circle of vehicle (U‐turn)

Crane

Fork‐lift

Hoist

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PIPE ASSEMBLY

•Begin after the installation of the essential components has been completed.• Depend on several factors. Example: Case

of metal pipe, welding work is required.• The non‐destructive testing also need to

consider.Prefabricated piping

Two possibilities in the fabrication of the piping.

Site‐run piping

PREFABRICATED PIPING

Requires a good and detail piping planning.• Pipe routes are prefabricated on the pipe supplier ’s premises.

• Delivered to the building site in the form of a conglomerate of pipe formations.

Advantages‐ Has a time advantages.‐ During prefabricated phase, construction and component assembly can be excluded.

‐ Building site activities are less.

Disadvantages‐ The collisions and alterations are considerable (cause extra cost needed).

‐ Rubber lined pipe systems must prefabricated (time effort involved).

SITE‐RUN PIPING

•With the aid of the piping and instrumentation flow charts the piping routes areplanned and dimensioned.

•Planning effort – lower and CAD systems ‐ no need

• Probability of collisions –lower

• Planning the piping routes ‐no

•The piping documentation has to be integrated or prepared on ‐ site during the

construction phase

• Disadvantage ‐ not suitable at high temperature.

• Advantage ‐ small nominal widths do not require stress calculation.

• fixed flanges• rotatable flanges• screwed connections• glued joints• welding joints• other fittings

FITTING AND CONNECTIONS

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ASSEMBLY E/MC TECHNOLOGYUsually assembly of electrotechnical equipment is independently from the planterection because of the control cabinets are accommodated in separated rooms.

More difficult is the installation of measuring instruments and cabling. Since a large part of measuring instruments is integrated in the pipes, the assembly occurs within the framework of the piping and fitting assembly.

Cabling will begins with so‐called “cable reels”.

Cable Reels:

Where cable laid from control station to the individual consumer or measuring points in the cable trays.

The cable reel requires an external temperature of more than 5°C. If the externaltemperatures are lower, there will be the risk that either the cables break or thecable trays will be deformed due to the embrittlement of the cable insulation.

The cable reel can be passed through before the assembly of the actual consumer.

The cable connecting plans generated both from the piping plans and from thepiping and instrumentation diagrams that shows the position of the consumer orconnecting points in the plant.

In the majority of cases, cables are laid in protective conduits as soon as they leavethe cable trays.

Finally the cables are connected to the terminal boxes of the motor.

Usually the cable connection work requires separate scaffolds. Moreover, theconcurrent assembly of components and cable reels bears the risk of damaging thenewly laid cables. This applies especially to the insulation work to be done.

It is advisable to carry out the cable reel work only after the completion of theassembly.

The usual time pressure, however, does not allow for such a procedure.

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•Insulation work start after assembly of thepiping.

•The insulation consist of mineral wool layer.

•For longer vertical pieces, dual grip rings usedwhich hold the insulation wool to protectedagainst slipping.

•Finally, insulation caps or moulted partsmounted after pressure and leakage tests.

• Plant Marking and Safety Marking• Commissioning• Cleaning• Pressure Test, Functional Test, System Test• Cold and Warm Commissioning• Warranty Run/ Acceptance

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Presentation Scope

Plant Marking

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1) Marking of the operating resources

2) Pipeline marking

3) Cable marking

4) Safety marking

5) Other markings (at sole discretion of customer)

Marking of the operating resources may be designed as engravedlabels or profile rails with individual letters being inserted.

Fixing of the labels occurs by means of clamps, rivet joints, cable ties etc

For the pipes, marked are done with banderols either directly glued on to the pipes or on to the insulation

Colour of the banderol represent media carried by the pipeline

Comprises the marking of hazardous material according to theOrdinance on Hazardous Substances.

– hazardous substances symbols in yellow/black (skull for toxicmedia, etched hand for acids etc.).

– instruction signs in blue/white (eye protection, breathingprotection, ear protection)

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Safety Marking

Commissioning

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The commissioning coincides with the residual work of theassembly

The person mainly responsible ~ commissioning manager

C.M should be able to use their considerable experience gained in other projects.

It also is subjected to a time schedule that should be adhered to.

Depends on the philosophy of the plant manufacturer.

The considerations regarding commissioning of a plant should already be integrated in the beginnings of the plant engineering.

Furthermore, the optimum implementation of the commissioning activities requires competent commissioning management .

After all, insights gained in the commissioning process should beabsolutely documented to draw advantages for future projects.

Cleaning

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• After completion of the assembly work the preliminary cleaning ofthe building site and the plant has to be carried out. The insidecleaning of the plant is considerably more difficult.

• The containers and apparatus have to be cleaned from inside andthen the piping will be purged.

• In order to protect sensitive plant components, in particular pumps,measuring instruments and control valves, during the flushingprocess it is advisable to shut them off by means of blanks.

a) Sensitive measuring instruments can be removed. Theorifices are to be closed by blind flanges or caps.

b) For control valves, flushing inserts can be ordered andinstalled.

c) Pumps can be protected by installing blanks on the suction and pressure side.

After completion of the assembly work the preliminary cleaning ofthe building site and the plant has to be carried out. The insidecleaning of the plant is considerably more difficult.

There is the alternative to protect sensitive plant parts throughthe installation of so – called start - up strainers or flushingsieves.

Usually, it is flushed from the pumps in the direction of thevessels or apparatuses.

In order to enable the removal of coarse impurities, intervalflushing is advantageous. The flushing conduit will be opened andkept open for a determined interval and will finally be closed again.This procedure can be repeated several times.

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Cleaning

- Generally limited to the assembled pipes.1) The system is filled and then evacuated at the highest point.2) Pressure test applied and time-related pressure drop will be recorded.3) Visual test of all connecting points also carried out.4) Eliminate leakages and finally discharge water from the pipes.

Functional Test- The individual aggregates and measuring points are tested for their correct function- Examples of functional test applied

1) Pump2) Fixtures and fittings3) Apparatus – agitators, centrifuges and etc.4) Black boxes – self contained and operative small plants5) Measuring instruments

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Pressure Test

System Test- Carry out after functional test on each individual aggregates and

measuring points- The controls of the main system will be tested whether the entire

system function work properly or not.

Cold and Warm Commissioning

Cold Commissioning

After inspection of all system controls

Liquid processing plant first filled with water up to control levels

Individual system controls are activated

Flow-through and level controls can be tested and optimized

Timing elements have to be optimized

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Cold and Warm Commissioning

• Warm Commissioning

Testing and optimizing of plant components ( heat supply/heat removal )

Application of the real media Warming up of the steam pipes Shut off discharge valve ( no more condensate ) Connect condenser Heating of the respective heat exchanger

Warm Dry Run

Cooling water system ( with water in the plant )

Plant discharged

Optimization tasksmeasurements

real starting material for 1st time

inter alia, calibration of all quality

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Warranty Run/Acceptance

Main Objective

- To verify the proper function of constructed plant

Warranty Run

1. Before

2. During

3. After/Acceptance

1) Operating condition during test run must be agreed with operator

2) Different loading conditions of the plant are shown and guaranteedqualities are measured

BEFORE

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o Several minor failure or one major failure1) Restart the test run2) List of defect, retrofitting measures and deadlines have to be determined3) If retrofit not success, plant manufacturer face claim for relevant penalty

o Major defect that cannot be remedied by retrofit

1) Entitle operator to reject the whole plant

DURING

AFTER

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o During warranty period1) Plant manufacturer to remedy them but not covered damages caused

by operator due to improper handling

2) Plant manufacturer refer deficiencies to relevant subcontractor

o After warranty period

1) Plant deficiencies is the responsibility of customer and insurances policy

o Operation

1) The operation of plant is taken over by operator staff

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