Commissioning and Startup Training Curriculum

Mod 7 - Utilities

Module from the Commissioning and Startup Training Curriculum curriculum.

Module 7 — Utilities Commissioning · Learning Objectives · 1. Commission steam system from boiler to users including superheater warm-up and condensate recovery. · 2. Start up cooling water system with correct chemical treatment and biocide dosing. · 3. Commission instrument and plant air systems to target dew point and pressure. · 4. Inert system with N2 and verify oxygen levels prior to hydrocarbon introduction. · 5. Commission fuel gas and flare systems with purge and pilot verification. · Utility Commissioning Order

Order	Utility	Rationale
1	Plant air	Powers instrumentation and valves
2	Instrument air	Required before DCS loop live
3	Nitrogen	Needed to inert HC systems
4	Cooling water	Required before heat input
5	Steam	Requires CW for turbines and condensers
6	Fuel gas	Requires N2 inerting done
7	Flare	Must be live before HP HC lines pressurize
Steam Commissioning Steps
Step	Action
1	Boil out boiler with alkaline solution (TSP/Na2CO3, 212 °F, 24 hr)
2	Drain, flush, refill with treated BFW
3	Raise pressure slowly to ~15% design; blowdown
4	Raise to design, warm header via bypass, drain condensate
5	Steam blow piping per Module 3
6	Back in-service: slowly crack supply valves, watch temperature
7	Place PRVs in service per set pressure tiering
Cooling Water Commissioning
Step	Action
1	Fill tower basin with treated water
2	Start makeup / blowdown control
3	Start CW pumps; verify net flow
4	Dose corrosion inhibitor, dispersant, biocide
5	Verify chemistry: pH 7.5–9.0, conductivity, ORP for biocide
6	Chlorine / bromine residual target 0.3–0.5 ppm
7	Pass water through all users sequentially
Nitrogen Inerting Criteria
Service	Target O2
Hydrocarbon vessel — pre-feed	<1.0 vol%
Reactor loop — pre-H2	<0.5 vol%
Cryogenic service	<10 ppmv O2
Hydrogen service	<200 ppmv O2
Lube oil reservoir blanket	<4.0 vol% (hot work)
Instrument Air Specifications
Parameter	Spec
Pressure	90–125 psig typical, ISA-7.0.01
Dew point	-40 °F (<10 ppm H2O) at line pressure
Particle	<40 µm
Oil	<1 ppmw
Flow margin	20% above peak design
Flare Commissioning
Item	Check
Purge gas	N2 or FG at minimum velocity to prevent air ingress
Pilot flame	All pilots lit and confirmed at ground panel
Thermocouple	Each pilot TC reading >300 °F
Seal drum	Water level maintained, auto-makeup
KO drum	Empty, LT working, pump-out aligned
Relief valve lineup	All PSVs lined up to flare before pressurization
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Source: Commissioning_and_Startup_Training_Curriculum_v1.xlsx · Sheet: Mod 7 - Utilities

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