Module III

Piping Fundamentals

PIPE:
It is a Tubular item made of metal, plastic, glass etc.
meant for conveying Liquid, Gas or any thing that
flows.
Defined as a pressure tight cylinder used to convey
fluid under pressure in applicable material of
construction.
It is a very important component for any industrial
plant. And it’s engineering plays a major part in
overall engineering of a Plant.
 PIPING

• . The term Piping means not only pipe but

includes components like fittings, flanges,
valves, bolts, gaskets, bellows etc.
 Scope of piping engineering
• 30% of total cost of a typical chemical process plant
goes for piping, piping elements and valves.
• A significant amount of operating cost is also used for
forcing the flow and significant amount is used for
maintenance of piping. So proper sizing and
optimization is very important.
• Piping layout influence the safety, maintenance,
operation, cost of the plant.
• 50% of detailed engineering man hour is required for
the piping design.
 Primary load on piping
• Internal fluid pressure
• External pressure
• Gravitational force
• Weight of the pipe
• Fluid force due to relief or blow down
• Pressure wave generated due to water hammer.
• Tension, compression, torsion leading to normal
and shear stress leading to deformation.
 Secondary load
• Displacement of pipe connected to storage
tank.
• Vessel expansion.
• Vibration from the rotating equipment.
• Contraction and expansion of pipe
• Cyclic loads
• Failure under such load is often due to fatigue
failure.
 ENGINEERING MATERIALS
• (1) METALLIC (2) NON-METALLIC (3)COMPOSITES
(i) FERROUS (i) ORGANIC
(ii)NON-FERROUS (ii) INORGANIC
 
• FERROUS NON-FERROUS ORGANIC INORGANIC
• Carbon Steel Nickel Plastics Ceramics
• Low Alloy Steels Monel Thermo-Plastics Graphite
• Stainless Steels Brasses Thermo-Setting Glass
 Piping design
• Welded pipe (butt,lap,spiral, fusion,
resistance,Submerged arc welding(SAW))
• Seamless pipe-piercing operation, extrusion, casting etc.
• Code for pressure piping :-
• ASME
• ASTM
• ANSI
• NFPA
• API
 Pipe size
• Iron pipe size
• 2 inch IPS has an out side dia of 2.375 in and its
inside dia vary from 2.157 in to 1.503 in according
to the required wall thickness.
• Nominal pipe size(1/8 in to 30 in) 24 pipe sizes
listed for carbon steel.
• Schedule number
• Below ½ in used for instrumentation piping
• Tubes – out side dia
 CM4120
Unit Operations Lab
Piping Systems

• ASME Boiler and Pressure Vessel Code

• ASME B31: Code for Pressure Piping
• ANSI Standards – dimensions for valves, piping,
fittings, nuts/washers, etc.
• ASTM Standards for piping and tube
• API – Specs for pipe and pipelines
• AWS, NFPA, etc.

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 CM4120
Unit Operations Lab

Piping Systems

ASME B31 is the applicable standard for

design of most piping systems in chemical
plants
• B31.1 – Power plant boilers
• B31.3 – Chemical plant and refinery piping
• B31.4 – Liquid petroleum transport
• B31.7 – Nuclear power plant radioactive fluids

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 CM4120
Unit Operations Lab

Piping Systems

ASME B31.3 – Chemical Plant and Refinery

Piping Code
Includes:
• Process piping in chemical and refinery plants
• Process piping in pharmaceutical and food
processing
• Process piping in textile and paper plants
• Boiler piping

12
 Schedule number
• Sc= 1000P/S
• P= internal pressure in psig
• S= allowable working stress in Psi
• t = (PD/2S)+C
• D= outside pipe dia in inches
• t= thickness of pipe in inches
• C = corrosion allowance
 Material of construction
• 150 different material specified by ASTM
• Carbon steel
• Alloy steel
• Non ferrous
• Plastic
• ASTM A-106-seam less pipe specification
• ASTM A-53- seam less
• ASTM A-83- tubular
 CM4120
Unit Operations Lab
Piping Systems

The Design Process – a three step approach

• Design for Flow
– Find min. diameter to achieve desired flow velocity
• Design for Pressure Integrity
– Find min. wall thickness for process and external
conditions
– Find appropriate rating of in-line components
• Re-check for Flow Criteria

15
 CM4120
Unit Operations Lab

Piping Systems

Design for Flow

• Determined by economics
Piping system must provide reliable service for expected
life
Smallest diameter usually is lowest cost

16
 Tests for piping
• Hydrostatic
• Check analysis- chemical composition
• Tensile
• Bending- suitability for bending operation
• Flattening- check suitability for forming
operation
 Pipe joints
• Threaded joints-unions and coupling
• Flanged joints –welding neck, slip on, lap joint,
socket welding, threaded flange, integral
flange.
• Welded joints
• Expansion joints
• Socket and spigot joint
 Flange classification
• Raised face- widely used
• Male and female
• Tongue and groove- ammonia service
• Ring joint
• Flat faced facing
• Oval, triangular, square flanges
• Gaskets- asbestos combined with other
materials, metal gaskets.
 Pipe fittings
• Welded pipe fittings
• Flanged pipe fittings
• Screwed pipe fitting
• Elbow, tee, cross, reducer, cap, union,
coupling,
 Cast iron pipe and fitting
• ASA- American standard association
• AWWA- American water works association
• AGA- American gas association
• Bell and spigot joints
• Flange
• Compression coupling
• Threaded
 Valves
• 1.Gate valve
• 2.Globe valve
• 3.Non return valve –Check valve
• 4.Ball valve
• 5.Butterfly valve
• 6.Diaphram valve
• 7.Plug valve -Cock
• 8.Needle valve
• 9.Safety valve
• 10.Solenoid valve
• 11.Control valve
• Valves may also be classified by how they are
actuated:
• Hydraulic
• Pneumatic
• Manual
• Solenoid
• Motor
 Valve selection
• Fluid to be handled
• Operating condition
• Flow characteristics and frictional losses
• Size of valve
• Any special requirement- quick opening
 Purpose of valve
• 1.On-off service
• 2.Throttling- Controlling
• 3.Diverting
• 4.Unidirectional flow
 Parts of valves
• Valve body containing flow control element-
disc,plug,gate,ball etc.
• Stem
• Bonnet-gland,stuffing box
• Hand wheel
 Gate valve
• On-off service
• Not recommended for throttling
• Minimum resistance to line flow
• Low pressure drop
Gate valve
Gate valve
 Globe valve
• Controlling the flow
• On-off service
• High pressure drop
• Seating arrangement offer resistance to flow
Globe
valve
Globe valve
 Non return valve
 Types of non return valve-
• 1.Swing check valve
 2.Lift check valve
• 3.Ball check valve
-Providing flow in one direction
• Prevent back flow
Lift check valve
Plug
valve
Plug valve
 Safety valve
• Spring loaded safety valve
• Weight loaded safety valve
• To release excess pressure
• Safety purpose
• Boilers,pressure vessel,compressor etc.
Spring loaded safety valve
Weight loaded safety valve
 Control valve
• Automatic control
• Pneumatic or hydraulic
• Consists of valve,Bonnet and actuating
mechanism
• Sliding stem control valve-linear motion of the
valve plug-globe valve,angle valve,Three valve
• Rotary shaft control valve-rotary motion of the
valve plug-Ball valve,butterfly valve
Control valve
Actuator
Bonnet Assembly
 Expansion joints
• This joint permits longitudinal expansion or
contraction of the pipes, which is due to the
change in temperature.
• Corrugated bellow (packless joint) (made of
Cu)
• Loop joint (made of Cu)
• Gland and stuffing box (slip joint)
 Pipe supports
• Structural steel pipe support
• Pipe shoe
• Pipe roll stand
• Hangers:-
• Adjustable clevis hanger
• Adjustable swivel type hanger
• Pipe clamp with chain type hanger
• Adjustable roller hanger
• Spring hanger
 Blinds
• Line blind is used to seal off a line or piece of
equipment.
• It provides more positive and reliable seal
than a conventional valve.
• Figure 8 blinds
 Piping layout
• Process requirement
• Transmission of excessive stress from piping to
equipment, and the transfer of vibration from
equipment into the piping system.
• Economy
• Operational accessibility
• Maintenance and replacement
• Excessive stress in piping system
 Piping stress
• Stress due to internal and external pressure
• Residual stress after fabrication
• Stress due to temp change.
 Magnitude of temp stress
• S=ECT
• S = stress
• E= modulus of elasticity
• C= coefficient of expansion
• T= temp change.
• Force = stress x metal area
 Methods for relieving expansion stress

• Flexibility in the piping layout – L bend, Z

bend, U bend.
• Expansion joints.
• Cold springing
 Terminology in piping
• Anchor- point where piping is fixed.
• Bleed- a small valve provided to draw off liquid
• Blind
• Block valve
• Control valve
• Drip leg
• Hanger
• Spool, trap, strainer
 Optimum Diameter
• Pumping power cost
• Capital cost
• Total cost – optimum
• Optimum dia
 Schedule number
• Schedule number = (Ps X 1000)/S
• Ps = safe working pressure psi or N/mm2
• S = safe working stress psi or N/mm2
• Schedule 40 pipe is commonly used for
general purpose.
• Estimate the safe working pressure for a 4 in,
schedule 40 pipe, carbon steel, working temp
100C. The safe working stress for butt welded
steel pipe up to 120C is 6000 PSI.
• Ps= (SC.NO x S)/1000
• = (40 X 6000)/1000
• = 240 PSI
 Pipe size selection
• For turbulent flow
• Carbon steel pipe D = 293 G 0.53 d -0.37
• SS pipe D = 260 G 0.52 d -0.37
• D = economic pipe optimum dia mm
• G = mass flow rate Kg/sec
• d = density in Kg/m3
• 1.Estimate the optimum pipe dia for a water
flow rate of 10 kg/S at 20 C. carbon steel pipe
will be used. Density of water 1000kg/m3.
• 2.Estimate the optimum pipe dia for a flow of
HCl of 7000 kg/h at 5 bar, 15 C, SS pipe.
• 1. Ans = 77.1 , use 80 mm pipe.
• 2.Density = (36.5/22.4) (5/1) (273/288)
• = 7.72 kg/m3
• D= 260 ( 7000/3600) ^0.52(7.72)^ -0.37
• = 172.4 mm
• Use 180 mm pipe
• Calculate the line size and pre drop for a
material flow rate 10000 kg/hr, temp 2oC,
pipe material carbon steel.
• Density of material = 1306 kg/m3
• Viscosity = 0.9 Cp
• G = 10000/3600 = 2.78 Kg/sec
• Q = 2.78/ 1306 = 2.13 x 10^-3 m3/s
• Area of pipe = Q/ velocity
• Assume velocity 2m/s
• Area = 1.06 x 10^-3 m2
• Dia of pipe = 0.037 m = 37 mm
• Use economic pipe dia formula = 35.4 mm
• Take 40 mm pipe.
• Fluid velocity = Q/ area of pipe = 1.7 m/s
• Nre = 9.9 x 10^4
• f= 0.0027
• hf =
VP = 4.13 x 10^10 G^1.84 µ^0.16 d ^-1 D ^-4.84
VP = pressure drop KN/m2
G = kg/s
D = dia of pipe mm
d= kg/m3
 Classes of insulation
• Class I – Heat conservation
• Class II – Cold conservation
• Class III – Personal protection
• Class IV – Frost proofing
• Class V – Fire proofing
• Class VI, VII, VIII – Acoustics proofing
 Thermal insulation
• Assure effective operation of process
equipment
• Conserve valuable heat
• Protection of personnel against skin damage
• Cost reduction by conserving heat
• Protection from climatic change
 Insulation materials
• Fibrous
• Granular
• Cellular
• Reflective
• Composite type
• Asbestos- hydrated magnesium silicate
• Diatomaceous earth
• 85% Magnesia and 15 % asbestos
• Mineral wool – silica, rock, slag etc.
• Vegetable cork
• Expanded polystyrene
• PUF
• Perlite (LNG, Ammonia etc)
• Glass wool
 Reflective insulation
• Heat is transferred across an air space produced
by two solid body by means of radiation,
convection and conduction.
• If the width of the air space is properly chosen
and the temp drop across the air space
maintained some optimum value, convection
will be negligible.
• Transfer of heat by conduction through air is
low, due to low thermal conductivity.
• Metal separated by spacers at a distance
• The metal must have low emissivity and high
reflectivity so that the transfer of heat by
radiation will also be low.
• Insulation so constructed is called reflective
insulation.
• Buildings, cold storage insulation and process
industries.
• Polished aluminum sheet is widely used
• According to temp level of operation
• 1. Low temperature – below room temp, used in
refrigeration service.
• 2. Medium temperature – from room temp to
1900 F. most piping insulation for heat saving fall
into this classification.
• 3. High temperature – above 1900 F, refractory
ceramics available in molded forms or can be
cast in place.
• Up to 600F, 85% magnesia is most commonly
used insulation.
• Diatomaceous silica type insulation is suitable
for temp up to 1900 F.
• Mineral wool has an excellent temp utility
range -150 to 1700F.
 Forms of insulation
• Blocks
• Blankets- felt
• molded
 Selection of insulation
• 1.Physical properties:-
• Thermal conductivity
• Specific heat
• Coefficient of expansion
• Compression, tensile and impact strength.
• Hardness
• Fatigue resistance
• Fire resistance
• 2.Chemical properties:-
• Analysis
• Corrosive nature
• Effect of chemicals in pipe or vessel being
considered.
• 3. Installation characteristics:-
• Toxicity
• Action on skin
• Overall workability
Factors governing the selection of insulation

• Select the material to withstand working temp

range.
• Choose an inexpensive low thermal
conductivity type.
• Choose type and form which has sufficient
durability and structural strength to withstand
severe condition.
• Specify the proper methods of application.
• Pick the most economic insulation from a fixed
charges – heat saving stand point.
 Erection of insulation
• Two general rules for apply to all insulation
erection.
• 1. surface should be cleaned thoroughly before
insulation begins.
• 2. if the insulation is installed in several layers, all
joints should be staggered.
• Block insulation is used for vessels, HE etc.
• Galvanized bands are used for securing insulation
on towers, HE etc.
• Top and bottom heads with bands which are
secured to studs or nuts welded to the heads.
• To aid in support the blocks, steel angles are
welded around vertical vessel.
• Insulating cement is used in the joint.
• Pipe insulation;- molded pipe insulation is
fitted to pipe and secured by loops of wire or
bands.
• Outdoor insulation is covered with a weather
proof jacket such as roofing paper or
galvanized steel or aluminum sheeting.
• Valves and fittings are insulated with segments
of blocks or pipe insulation of the same
materials
• Some cases flanges should be avoided from
insulation.
• Low temp insulation:- some means of preventing
water vapour entering the insulation.
• A vapour barrier can be installed to minimize the
movement of water vapour.
• Vapour proofing felt consits of asphalt sealing
compound followed by weather proof jacket.
• Another successful vapour proof barrier consist of
sheet of aluminum foil laminated between layers of
kraft paper and finished with special vapour seal
adhesive.
 Refractories
• Temp above 1900 F, refractory materials are
used , usually cast in the form of bricks.
• Furnace, reactors etc.
• Selection depends on physical and chemical
properties as well as economy.
• Physical properties:-
• Specific gravity
• porosity
• Cold strength
• Softening point
• Load test
• Dimension changes at high temp
• Thermal expansion
• Spalling- thermal, mechanical or structural
• Thermal conductivity
• permeability
• Chemical properties:-
• Chemical composition
• Chemical reactions with refractories
 Types of refractories
• Alumina- silica – more resistant to silicous
slag.
• Silica
• Basic- magnesite, chrome etc, more resistant
to basic slag.
• Insulating refractories- clay with some
combustible material.
• Special refractories – SiC, zirconia
 Heat losses through insulated surface
• q = Delta T/R
• q= heat flow
• Delta T = total temp drop from inside fluid to outside air.
• R= summation of all resistance
• Heat flows through the fluid inside the pipe by
convection and conduction through the pipe wall and
insulation.
• Heat then passes into the surrounding air by a
combination of convection and radiation.
 Optimum insulation thickness
• As the insulation thickness is increased the
costs of heat losses go down while insulation
costs go up. The point at which minimum total
cost is reached may be described as an
optimum value.
 Critical radius of insulation
• In case of a cylinderical pipe or a spherical
shell; the additional insulation increases the
conduction resistance of the insulation layer
but decreases the convection resistance of the
surface because of the increase in the outer
surface area for convection. The heat transfer
from the pipe may increase or decrease,
depending on which effect dominates.
• rc= k/h (cylinderical)
• K= thermal conductivity of material
• h= outside heat transfer coeff.
• rc = 2k/h (spherical)
 Insulation efficiency
• Defined as the diff between the heat loss
through the bare pipe and that through the
same pipe when insulated, divided by heat
lost through the uninsulated pipe.
 Buildings
• Instrument control centers, critical machinery and
operation required controlled atmosphere are
enclosed by buildings.
• There are three types of structures for process plants.
• 1. Totally enclosed structure, the conventional
industrial or commercial building
• 2. partially enclosed structure which is a simple type
of roofed shelter.
• 3. un enclosed structure which is a structural support.
 Buildings
• Simple and lighter construction
• Single story structure
• Climate
• Flat roof are common
• Buildings for process equipments
• Office buildings
• Change house
• Cafateria
• Recreation center
• Medical facility
• Laboratories
• Warehouses
 Partially enclosed structure- shelter

• Large process pumps and compressors,

generators etc housed in a sheltered area.
• Over head cranes or mono rail
• Barrel storage
• Salvaged equipment storage
Unenclosed structure-outdoor process unit

• Major portion of the process or operating

equipment housed without shelter.
• Eliminate the problem of heating, ventilating
• Reduction of initial costs by elimination of
walls and roofs.
• More safer
• Accumulation of noxious or flammable and
explosive vapours are rare in outdoor plants.
 Safety in plant design
• Hazards in process plant:-
• 1. Physical hazards
• 2. Chemical hazards
• 3. Mechanical hazards
• 4. Electrical hazards
• 5. Hygienic
 Safety in Process design
• PROCESS RISK MANAGEMENT METHODS USED
DURING THE DESIGN PHASE CAN BE PUT INTO 4
CATEGORIES:
– Inherent
– Passive
– Active
– Procedural
• TARGET IS A FAIL-SAFE INSTALLATION
 Inherent safety
• The basic philosophy of inherent safety is build
safety into the design rather than have add on
systems.
• There fore inherent safety reduces the
severity of the hazard and the likelihood of a
hazardous incident simultaneously.
 ISD CATEGORY DETAILS
Intensification minimizes inventories of hazardous
materials.

Substitution replaces hazardous materials with safer

materials.

Attenuation uses hazardous materials under the least

hazardous conditions.

Limitation changes designs or conditions to reduce

potential effects.

Simplification reduces complexity to reduce the

opportunity for error.

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 Active safety systems (Engineered safety
system or Add on safety)
• Design of control systems
• Alarms, Trips
• Pressure relief devices
• Automatic Shutdown systems (ESD)
• Redundancy (duplication of key equipments)
• Fire detection and leak detection
• Fire fighting equipments
• Sprinkler systems
 Passive safety systems
• Dike
• Underground drainage systems
• Fireproofing
• Fire wall
• Blast wall
• Flame arrester
• Refrigeration system
• Plant layout
• Equipment layout
• Hazard area classification
 PROCEDURAL SAFE DESIGN
• Procedural — Prevention or minimization of
incident impacts using:
• Safe operating procedures and operator
training
• Administrative safety checks
• Management of Change
• Planned emergency response
 DESIGN IN OVERALL SAFETY MANAGEMENT
Art M. Dowell, III, Layer of Protection Analysis, 1998 PROCESS PLANT SAFETY
SYMPOSIUM, October 27, 1998 Houston, TX
 Plant constructions
• Project engineer should have some
understanding of
• Construction planning
• Labour and labour relations
• Actual construction operation
 Construction planning
• Design drawing and Specification give the
detailed information to construction department.
• Construction engineers should study the
preliminary engineering data and scale models of
plants to be erected.
• Selection of derricks and hoisting equipments.
• Positioning of construction equipments
• Planning of errection
• Constructional labour distribution
• Labour disputes
• Labour rates
 Construction operations
• Site preparation
• Driving of pile
• Temporary buildings
• Temporary water supply
• Road ways and rail
• Excavation operations
• Installation of underground facilities
• Electrical conduit and underground piping
• Foundation construction
• Erection of derricks
• Erection of elevated reinforced concrete
structure and structural steel.
• Erection of major equipments
• Installation of piping
• Pipe identification
• insulation
• Buildings:- office buildings, ware houses,
change houses, canteens, M/C shop, lab etc.
• Final stages of construction :-
• Instruments, electrical apparatus, small piping
for instrumentation,
• Cleaning of site
• Installation of safety equipments
 Commissioning of Process Plants
• Mechanical Completion
• P& ID Checking
• Pre commissioning
• Commissioning –
• Cold commissioning – Wet and Dry
• Hot commissioning – Live commissioning
• Start up
• Initial stages of operation
• Performance run
• Post commissioning
 Commissioning
• Mechanical completion
• Precommissioning
• Commissioning of control systems
• Commissioning of utilities, offsite
• Process Commissioning
• Guarantee run- performance and acceptance test.
• Handed over to the owner
• Post commissioning documentation
 Mechanical completion

• Mechanical completion is the term used to

cover the phase between equipment
installation and the start of precommissioning.
• In which components of plants are proved to
be mechanically fit for their process duty.
• Main contractor or equipment supplier is
usually responsible for this phase of the work.
• Prove that an installed plant component is
suitable for commissioning.
• Checking that equipment is installed correctly.
• Basic components of equipment operate
mechanically as specified.
• Components are suitable for
precommissioning
 Precommissioning

• Precommissioning refers to preparing the plant for the

introduction of process materials and its main object is
to eliminate any problems which might arise at later
and more critical stages of plant operation.
• Ensure that correct maintenance manuals are
available.
• SOP are available
• Check that laboratory facilities are adequate
• Ensure that all necessary chemicals and raw materials
are available onsite.
 Precommisioning activities
• Check list preparation
• Cleaning of pipe lines- Purging, cleaning, flushing , drying
• Pressure testing
• Leak testing
• Catalyst loading
• Loading of packing
• Steam line charging
• Calibration of instruments – precommissioning of field instruments.
• Instrument loop testing
• Shut down system, interlocks
• Starting up of individual equipments
 Control system commissioning
• DCS, PLC, SCADA
• Field wiring /instrumentation- sensor,
transducer, transmitter, actuators, switches,
relay, solenoid, contactors.
• Computer hardware- power supply,
card/rack/frame assemblies, operator station
• System software
• Input/output- analogue, discrete,pulse
• Configurable software- database, alarms, trips,
interlocks, overview, trend display, alarm lists.
• Application software – sequences, application
diagnostic, management information
programme.
 Process commissioning
• Process commissioning begins when the
precommissioning test have been completed
and faults corrected to the satisfaction of
commissioning manager.
• Final checks – all safety equipment such as
safety shower, eye wash, breathing set, fire
extinguishers, first aid etc.
• All inspection equipment removed ( ladder)
• Strainer cleaned and replaced
• Temporary screens to protect pumps and
valves in place where necessary.
• Lighting
• All source of ignition removed
• Relief system
• Access for emergency vehicle not obstructed
 Typical sequence of process commissioning
• Utilities:-
• Electricity
• Water and its treatment
• Compressed air
• DM water
• Fire water
• Cooling water
• Boiler
• Condensate
• Nitrogen
• Refrigeration
• ETP
• Laboratory
• Tank farm
• Ancillary equipments :-
• Ventilation and fume extraction system
• Scrubber and absorber
• Vacuum system
• Intermediate storage tank
• Flare stack
• Reaction:-
• Continuous
• Batch
• Exothermic/ endothermic
• Raw materials feed at correct temp
• Catalyst activation
• Controlling of reaction parameters
• CW, emergency system
• Product storage
• Quality control
• Completion of commissioning:- commissioning
stage is not complete until it has been
demonstrated to the customer that the plant
is fit for purpose for which it was designed.
 Performance and acceptance test
• Plant capacity
• Consumption of raw materials
• Quality of finished products
• Consumption of utilities
• Reliability
• Quantity and composition of effluents
• interruptions
• There are three possible outcomes from the
performance test
• 1. it achieve design output and efficiency
• 2. If it is does not achieve either output or efficiency,
the reason can be identified and the problem
rectified in the next convenient plant shut down.
• 3. If it is does not achieve either output or efficiency,
due to design error, in this case contractor will have
some financial liability.
 Post commissioning documentation

• Records
• Audits and reviews
• Maintenance records
• Log sheet
• Accident report
• Stack analysis
 Start up and commissioning
• Once the plant is mechanically complete, efforts
will be made to start up and commission the plant.
• Following are the important step involved in start
up and commissioning.
• 1. Mobilization of commissioning crew.- training
• Mechanical, electrical, instrumentation, chemists,
process.
• 2. Clearing up the plant and site
• 3. Inspection and testing
• - Check all the parts are properly fitted
• Check list preparation
• - Mechanical integrity of the plant
• - Leak test
• - Pressure test
• - Electrical machinery and instruments are
also given special tests.
• Whatever deficiencies observed are rectified.
• 4. Mobilization of materials
• Raw materials
• Steam
• Cooling water
• Power
• BFW
• Chart paper
• Ink
• Lubricating oil, greese, solvents, catalyst
• 5.Charging various items:-
• Lubricating oil, solvents, catalyst
• Activation of catalyst
• Furnace , heater:- curing of refractories
• 6. section wise start up
• 7. Performance testing
• 8. Check the quality of final and intermediate
product
• 9. capacity is gradually raised
• 10. consumption of raw material and utilities
are brought down to guarantee level.
• 11. Commissioning
• 12. Trial run
• 13. Handed over to the owner.