With over two-anda- half decades of expertise in engineering, plant construction and commissioning of cuttingedge biodiesel plants, BDI stands at the forefront of sustainable energy solutions. In the complex process of commissioning a biodiesel plant, two distinct phases, namely cold commissioning and hot commissioning, play a major role. Cold commissioning consists of detailed electrical testing, including crucial tasks such as motor rotation checks and signal testing of instrument. In contrast, the hot commissioning phase involves the introduction of feedstock into the plant and the establishment of a stable and seamless production process. The company’s commitment to top plant performance is exemplified by the collaborative approach taken during the hot commissioning phase. BDI’s dedicated teams work closely with its customers at every level, fostering a productive partnership aimed at achieving plant acceptance. The cornerstone of this collaboration is the creation of a secure working environment, ensuring that safety remains paramount throughout the process. In this field report, BDI’s division director, senior engineer and commissioning leader, Markus Hahn, invites readers to explore the phases of commissioning and gain an insight into the firm’s proven protocols that provide the foundation for successfully completing each step.
Cold commissioning phase: ensuring electrical integrity
The beginning of the cold commissioning phase follows mechanical completion. During this critical time, effective coordination between the customer, subcontractors and BDI’s expert teams is essential to ensure a safe working atmosphere for those involved. During this phase, electrical and instrumentation (E&I) engineers take the lead and are supported by expert process engineers. These engineers are constantly expanding their knowledge base and developing into versatile technicians who are able to view challenges from multiple perspectives. Typical responsibilities of process engineers encompass tasks such as preparing and supervising rotation checks, analysing the final installation from a process engineering standpoint through piping and instrumental diagram (PID) checks and conducting operator training. Seasoned engineers may even undertake more intricate duties, including minor mechanical or electrical adjustments, tailored to their wealth of experience. While routine issues such as missing signals, loss of communication or non- acting valves are quickly solved by the experienced cold commissioning team, more complicated challenges require more time, expertise and effort to be solved. Of paramount importance is the establishment of a strong foundation for the forthcoming hot commissioning phase. This phase serves as an opportunity for the future hot-commissioning leader and other process engineers to familiarise themselves with the plant layout and engage with the client through informative interactions. Early face-to-face dialogue with the customer is instrumental in fostering mutual trust and developing an understanding of each other’s special requirements. The highlight of cold commissioning is undoubtedly the successful electrical completion of the plant. This milestone signifies the customer’s acceptance of the electrical installation’s integrity. At this point, confidence prevails that the entire electrical system operates flawlessly, with Safety Integrity Layers (SIL) loops rigorously tested and proven secure. This key moment calls for celebration, acknowledging the teamwork that has brought the project this far. BDI’s transition from cold to hot commissioning is marked by the introduction of methanol and the establishment of an active ATEX zone (Atmosphères Explosibles) within the facility. This boundary was established over the means of 70 plants to provide a safe working environment, in which very included party knows the safety measures to consider. With the customer’s perspectives and requirements in mind, the company carefully orchestrates the preparatory activities leading up to this phase. Tasks typically include rotation checks, water runs, safety system evaluations and comprehensive operator training.
Hot commissioning phase: Fusing expertise for operational excellence
The hot phase of commissioning represents the culmination of efforts, where all elements come together seamlessly. As the final phase of the project, it requires the concerted efforts of everyone involved. Depending on the size of the project, the commissioning team may consist of up to 30 experts, including shift workers, project managers, commissioning managers, programmers and R&D support. Effective orchestration depends on careful organisation, skillful coordination and forward planning by the project manager and commissioning manager that considers the unexpected. Human dynamics are the biggest challenge in hot commissioning and often surpass the complexity of plant operations. Balancing customer expectations, maintaining focus across shifts and ensuring harmonious teamwork are the main concerns of the commissioning manager and team. Maintaining an overview and staying up to date on tasks is their primary goal. To this end, regular meetings are held with the client, the commissioning team and the supporting functions in the office. With preparations in place and all parties informed, the hot commissioning phase begins. While careful testing during the water trials will contain potential leaks, the introduction of the first feedstock remains an exciting endeavor. This moment, whether for a new plant, a retrofit, batch processing, or continuous flow, sparks excitement. Every BDI engineer invests their utmost effort to witness the designed process, spring to life – a source of immense professional pride. Even its most seasoned engineers find commissioning an endeavor to relish. Over weeks of commissioning, the plant gradually activates unit by unit, encountering minor obstacles along the way. These challenges vary in nature and range from a quick solution on site to problems that require the involvement of its back office or suppliers. In the rare case of equipment failure which requires long lead times, the BDI engineers find innovative solutions to overcome complications and ensure that the equipment can be put into operation. Regular discoveries of misdirected oils and greases lead either to an investigation of the causes or to the clean-up of the problems by its colleagues. The commissioning process provides invaluable experience that goes beyond office-based training. BDI offers all the staff the opportunity to develop from supervised apprentices into reliable, integral members of the commissioning team. It is a pleasing sideeffect of commissioning to see colleagues enjoying the challenges, improving their understanding of the complexities of the plant and refining their fault-finding skills. As commissioning progresses, the unavoidable transition to 24/7 continuous operation becomes obvious. This crucial phase is a decisive moment for both the operators and staff. During the first night shifts, there are often operational deviations that cause understandable concerns. Experienced staff are brought together with rookies during these carefully planned shifts to enable the plant to be commissioned and the operators to be trained at the same time. This joint effort culminates in the achievement of a steady production of the plant operating at its intended capacity. The decisive moment comes with the production of the first drop of biodiesel that precisely meets the specifications of EN14214. This achievement becomes a celebration for both the team and the customer, as both parties have the proof that the hard work paid off.
Triumph of acceptance: Time’s up, we’ve completed the run
In the area of commissioning, the head of commissioning is the torchbearer for critical decisions. This role requires full concentration and a willingness to respond even in the middle of the night – and the chances of latenight calls are rather high. As time goes on and 24/7 shifts mature, these late-night calls become less frequent. Knowing that the facility is under the direction of a capable leader provides a sense of security and allows the commissioning manager to focus on the acceptance process ahead. The acceptance run represents the ultimate challenge and culminates the team’s efforts. The meticulous preparations that precede this crucial moment involve the fine-tuning of the plant operation by the BDI team in order to meet the contractual benchmarks. These benchmarks, which include parameters such as duration, source material and quality, are anchored in the contract. The customer’s laboratory and staff are prepared for the important task of taking samples and carrying out careful analyses. Once the customer’s commissioning teams and BDI have coordinated the timing, the momentous acceptance run is set in motion. In the days that follow, there is a palpable tension at the plant. There are concentrated faces in the control room, while the commissioning manager and the project manager have sleepless nights. Anticipation is in the air as everyone waits for the upcoming results, longing for confirmation of success or clues for adjustments. Finally, the momentous announcement comes: “Time’s up, we’ve completed the run.” There is a flurry of excitement in the control room, but the work continues. While most operators and engineers feel a measure of relief, a dedicated team continues to collect data and analyses the results for the client. The following days initiate a decisive meeting, where the acceptance run’s outcome is revealed. Experience teaches that a negative result can be a severe blow to the team in view of the collective effort involved. In the field of BDI plants, however, such an outcome is very unlikely. The joy of a positive result is immeasurable. To complete a project that may have stretched over years with a customer who is satisfied with the performance is an incomparable achievement. Even though the customer is in charge of a fully functional plant now, the company’s role remains unchanged. Its involvement goes beyond project completion. Instead of a simple handover and departure, the company continues to offer a range of services, including annual support, advanced operator training and production support. These offerings serve to foster lasting relationships and strengthen the bond built on trust. BDI lives for developing fitting solutions, designing the perfect fit for each plant and building the customers’ trust in the experience.
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