PROJECT COMMISSIONING, START-UP, & CLOSURE

Our advisory operations, design and construction professionals offer support as construction nears completion in areas of OSHA’s PSSR regulation compliance; construction punch list resolution; facility operational readiness; start-up assistance; claim development or settlement; and contract completion and close out review. 

Seasoned Lumen PMC professionals provide construction project commissioning and start-up process advisory services for both conventional and technically sophisticated projects. Depending on client requirements our services include assistance with development of a commissioning management plan, provision of an independent cold eye review of an existing plan and its execution and control processes, or provision of hands-on management assistance throughout a projects commissioning program. 

Our approach begins with an audit of mechanical completion and pre-commissioning activities to ensure all punch list items have been resolved; individual equipment items have been installed, lubricated, and rotation checked; piping systems have been tested and cleaned and valves and gaskets replaced per specification; and electrical and instrumentation calibration and loop checks are complete. For process units we ensure a pre-startup safety review (PSSR) has been conducted, confirming a systematic and thorough check of the plant before hazardous chemicals are introduced, and the facility has been officially handed over to the operator, typically using turnover packages. We focus on evidence that assures equipment items meet specifications; safety systems are functional; operating and maintenance procedures have been prepared and personnel are trained in their use; and that all utility systems will be started up and checked prior to any chemicals being fed to the unit.

For cryogenic processes in the petrochemical sector our specialists monitor necessary dry out of those sections of the plant exposed to low temperature operations using dry nitrogen after all free water has been purged from the system, or air drying of systems which have not previously been exposed to hydrocarbons or other hazardous chemicals.  We monitor commissioning activities such as chemical cleaning processes and the drying of ambient air through process dryers prior to its use as a drying agent; ensure that dried systems are kept under positive pressure and securely sealed; and check the recording of results. Before introducing chemicals to a unit, we ensure it is purged free of any oxygen, typically with nitrogen, and confirm all systems are checked for oxygen content before start-up.

Other pre-start-up functions we address during commissioning process are management of the removal of temporary supports, blinds, and other equipment installed for testing  and flushing, and implementation of the facilities lock-out/tag-out program.

Our advisors address commissioning of power generation facilities in much the same manner, except for steam blowing. We ensure boilers, superheaters, re-heaters, and steam pipelines are subjected to a continuous steam blowing process matching a specified disturbance factor is conducted to achieve cleanliness prior to commencement of turbine operation.

For start-up advisory operations our specialists work closely with construction and owner operations personnel and engineering or licensors representatives early in the process as a unit is precomissioned and nearing readiness for start-up.  We ensure the planning, scope definition, and control processes for the start-up meet operating manual and owner objectives and the work is to be conducted in a safe and timely manner. Our team recognizes that start-up is a hazardous process since the unit will be in a dynamic condition, operating outside its normal parameters for much of the time, and operators will be checking process conditions and equipment operation on a continual basis, and monitors safety aspects of the process closely.

We commence preparation of our start-up services for a major plant months before the actual start-up operations commence. As construction is nearing completion we participate in system checks jointly with operations personnel who have taken part in the preparation of the operating instructions and the detailed start-up guidelines.  Our focus is to ensure the start-up management process fully addresses key functions such as understanding of facility design elements intended to support start-up (recycle of feedstock to towers vs. flare for example); training by senior operating personnel for less experienced operators; start-up checklist preparation and implementation; and definition of team responsibilities and the personnel authorized to give instructions as the work proceeds. We also confirm that plans are in place for certain important start-up functions such as system chemical cleaning and dry-out, oxygen removal, and feedstock recycling.

As start-up commences our advisors assist with sequencing of process systems and their isolation from those downstream; introduction of initial feed; management of process flow; and ensuring design provisions for recycling of process flow back to the feed or towers on total reflux, or flare disposal are implemented. Once the initial system is lined out and operating according to plan, we ensure the process continues, starting with the flow to the next downstream system and repeating the process until all systems are in operation.

Our advisors provide options that may add cost and schedule value to the start-up process. For example, depending on the type of facility it may be advantageous to pre-inventory parts of the plant before actual operations start. A distillation tower may be inventoried with material similar to the normal feed to the tower, allowing the tower to be started on total reflux and produce specification product quicker than if it started from a black start.

The deliverables of our project commissioning and start-up advisory services are added value to a plant’s pre-commissioning, commissioning and startup program; a start-up ready facility with an independent evaluation of expectations; a safe and operable unit ready for performance testing or continuous operation; and a comprehensive report on its management process.