Start-Up Acceptance

The start-up and operational acceptance of any process facility is a complex undertaking, which requires early planning. As systems are started and functioning, they can be reviewed 

In an API facility, the construction manager is tasked with coordinating the overall construction and installation of the equipment within the process facility. The installation of the interconnecting components must be installed in a quality manner. Rework takes time and delays the entire process. 

An example of typical items that would be verified in the IQ phase of validation and in the commissioning of the remaining facility  

The start-up of an API facility is a complex operation that requires early planning and a complete understanding of all the components of the facility. An operations manual with spare part and regular maintenance procedures must be in place on site for every component in the facility. A list of spare parts required for start up should also be assembled and these materials stored on site for use as required during 

In the review of the API facilities, distinct differences between the requirements and those of a fine chemical facility exist. The product is manufactured under cGMP guidelines. There are validation requirements for the facility, which document how the facility was constructed, how the facility and process will be operated, and how the facility will be maintained. In most new product introductions, the primary driver for API projects is the speed to market. The products 

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Objective Intended for those who are involved with SIS in the areas of design and manufacture of SIS products, selection and appUcation installation, commissioning and pre-start-up acceptance test operation, maintenance, documentation and testing ... 

The device functional checkout should be used to test all individual fiinctions of the sensors, final elements, the operator interface and the maintenance interface. This is the best opportunity to rectify any defects that may have crept into the detail design or the installation. At this stage it troubles nobody else if a malfunction is discovered, the contractor is on hand to rectify problems and it may be some time before the final pre-start up acceptance test is to be conducted. Hence get as much right as possible before the next stage. 

Start-up (acceptance test approval and turnover to production (i.e., a division of operations). 

Does material change phase from its state in normal operation, during the start-up, and shutdown of plant Is this acceptable, e.g. does it involve expansion or contraction, solidification, etc. ... 

Commissioning embraces those activities essential for bringing a newly installed plant into routine production. It includes mechanical completion and provisional acceptance, pre-commissioning, first start-up and post-commissioning. 

PCs all have one thing in common. They monitor the process variables, compare them to values known to be acceptable, and make appropriate corrections without operator intervention. The acceptable range of values can be determined by using melt flow analysis software and/or trial and error when the machine is first starting its production. Using the software approach, the acceptable process values are known before the mold or die is ever built. It should be noted that none of the PC solutions address the problem of the lack of skilled setup people. Most of the PC systems available today are rather complex and require skilled people to use them efficiently or at least start up the line. 

Easy start-up and shutdown Good tolerance for fuel input particle size range High ash fuels can be accepted In-bed catalysts can be applied (tar cracking/gas upgrading) Thermodynamic losses limited Experience with biomass processing Carbon loss with ash... 

With this start-up the most critical machine data are to check No remaining ice, cooling and heating working, and leak rate acceptable. The procedure takes some time, but minimizes problems occuring during the freeze drying process. 

The early experimental work showed that the alkylation reactions could be carried out thermally and by using hydrofluoric acid or aluminum chloride as catalysts. Successful processes were developed with the hydrofluoric acid catalyst, and the first commercial HF unit started up on Christmas Day 1942, having a capacity of 1950 BPD (3). Other commercial HF alkylation units followed quickly. The thermal and aluminum chloride-catalyzed alkylation processes had limited commercial acceptance. 

While specifying some acceptable parameter is a sensible practice to be applauded, it will not generally work if the owner or operator also seeks to impose rules on what is or is not an acceptable chemical treatment program, or also fails to fully involve the successful water treatment vendors early on in the pretreatment and start-up programs. 

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