FACULTY : ENGINEERING

EDITION:
TECHNOLOGY
LABORATORY: BIOPRODUCT
REVISION NO:
FACILITY DESIGN LAB
EXPERIMENT: PRE- EFFECTIVE DATE:
COMMISSIONING, COMMISSIONING AMENDMENT
AND START-UP
DATE:
FACULTY OF ENGINEERING TECHNOLOGY
DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

BIOPRODUCT FACILITY DESIGN LAB

LABORATORY INSTRUCTION SHEETS

COURSE CODE BNN 40104

EXPERIMENT NO. 1
PRE-COMMISSIONING, COMMISSIONING AND START
EXPERIMENT TITLE
UP OF OSBORNE REYNOLDS
DATE 7 OCTOBER 2019
GROUP NO. 2
DR NUR HANIS HAYATI BT HAIROM
LECTURER/INSTRUCTOR/TUTOR PUAN MASAYU BINTI MASLAN
ENCIK MOHAMAD SIDIQ BIN MOHD BASIR
DATE OF REPORT SUBMISSION 14 OCTOBER 2019
ATTENDANCE/PARTICIPATION/DISIPLINE: /5%
INTRODUCTION: /5%
PROCEDURE: /15%
DISCUSSIONS: /50%
CONCLUSION /10%
DISTRIBUTION OF MARKS FOR SUGGESTIONS & RECOMENDATIONS /5%
LABORATORY REPORT: REFERENCES: /5%
FORMAT/OTHERS /5%

TOTAL:
/100%

EXAMINER COMMENTS: RECEIVED DATE AND STAMP:

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STUDENT CODE OF ETHICS

DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

FACULTY OF ENGINEERING TECHNOLOGY

I hereby declare that I have prepared this report with my own efforts. I also admit to

not accept or provide any assistance in preparing this report and anything

that is in it is true.

1) Group Leader (Signature)

Name : MUHAMMAD LUQMAN BIN YUSOF
Matrix No. : DN 160341

2) Group Member 1 (Signature)

Name : ROHARDIYANA BINTI ROSLAN
Matrix No. : DN 160345

3) Group Member 2 (Signature)

Name : ASWINI A/P PURUSHOTHANAN
Matrix No. : AN 160118
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1.0 OBJECTIVES

To gain the knowledge and techniques that can be applied in pre-commissioning,

commissioning and start-up of equipment.

2.0 LEARNING OUTCOMES

At the end of the study, student will be able to:

1. Develop high understanding on the commissioning and start-up of bioproduct plant
(C5, PLO4).
2. Display the ability to analyze problems, develop methods for their solutions and
begin to demonstrate a capacity for independent critical thought (P5, PLO2)
3. Demonstrate teamwork skills and lead the team members effectively in conducting
laboratory work and solving problem for the assigned project. (A3, PLO9)

3.0 INTRODUCTION

Osborne Reynolds experiment is used to examine the distinguishing of the flow of the
liquid in the pipe which is also used to calculate the Reynolds Number for each type of
the flow. The design of the device allowed learning the characteristic of the flow of the
fluid in the pipe, the behavior of the flow and also to compute the range for the laminar,
transitional and turbulent flow where the calculation is used to prove the Reynolds
number is dimensionless by using the Reynolds Number formula.

The objectives of this experiment to gain the knowledge and techniques that can be
applied in pre-commissioning, commissioning and start-up of equipment, it involves
running the Osborne Reynolds equipment with different of water volume flow rate. In
this experiment the time taken is fix, which is 20 seconds. The volume of water is
recorded. At the same time, the characteristic of the flow, whether there are laminar,
transitional or turbulent flow are recorded. Based on the data collected, the calculation to
estimate the range for laminar, transitional and turbulent flow is conducted. To prove that
the Reynolds number is dimensionless, the calculation is using the units only and using
the appropriate formula. By that, it is proved that the Reynolds number is dimensionless
parameter.
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The apparatus of the Osborne Reynold used to demonstrate “critical velocity” is

based on that used by Professor Reynolds who verified the nature of the two modes of
motion flowing in a tube, example laminar and turbulent. This experiment replicates the
work done by Osborne Reynolds to characterize laminar, transitional and turbulent flow
in terms of the “Reynolds Number” (ρvd/μ). The Reynolds apparatus allows the
experimenter to visualize the flow and determine whether it is laminar, transitional, or
turbulent. Dye is injected into the bell mouth at the flow tube in order to visualize the
flow. Moreover, the apparatus should be leveled prior to beginning the experiment. The
Osborne Reynolds Demonstration apparatus is equipped with a visualization tube for
students to observe the flow condition. The rocks inside the stilling tank are to calm the
inflow water so that there will not be any turbulence to interfere with the experiment. The
water inlet / outlet valve and dye injector are utilized to generate the required flow. The
figure below shows the apparatus of the Osborne Reynolds.

Figure 1: Unit Assembly of Osborne Reynolds Demonstration

1. Dye reservoir 5. Observation tube 9. Water outlet valve, V2

2. Dye control valve, V4 6. Overflow valve, V3
3. Dye injector 7. Water inlet valve, V1
4. Head tank 8. Bell mouth
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Before running any experiments, it is a must to perform pre-commissioning,

commissioning and start-up. In industry, the pre-commissioning (PC) is one of the
construction activities that includes the verification of functional operability of essentials
within the system to achieve a state of readiness for the Commissioning and Start-up
operation. Some of the pre-commissioning of process units required completion of the
commissioning activities of utility facilities commissioning. The Pre-commissioning may
require an energization of equipment includes running and entire testing of the power
generation systems, testing of emergency shutdown and control systems and dynamic
trials prior to commissioning and start-up operations. The Pre-commissioning is
compulsory due to prevent failure or error on the equipment. Pre-Commissioning
activities includes checking for design conformity, checking the status of electrical,
mechanical and instrument installations, running-in of equipment, flushing and cleaning
activities, and drying.

Commissioning is the procedure of promising that all systems and components of

a building or industrial plant are designed, installed, tested, operated, and maintained
according to the operational requirements of the owner or final client. Both existing units
and new projects are applicable for commissioning. On the other hand, start-up is the
point in a project where all conditions are established with the intent of making products.
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4.0 INSTRUCTION

4.1 Pre - Commissioning

1. The inspection was complete on the Osborne Reynold’s apparatus.
2. The apparatus for Osborne Reynold’s were checked at every component to ensure the
apparatus and all existing parts were similar as the drawing provided.
3. The cleaning procedure was conducted as to remove dye and inserting new volume of
water.
4. All the components of the Osborne Reynolds were inspected and some punch list were
recorded.

4.2 Commissioning
1. The Osborne Reynolds was fully setup as shown in the drawing.
2. The Osborne Reynolds apparatus was placed on a level ground. A level spirit was used
to level the apparatus.
3. The apparatus outflow, inflow and overflow tubes were ensured connected with the
hose.
4. The inlet hose connected with water supply and the inlet valve was opened.
5. The dye reservoir was filled up with the provided blue ink.
6. The stilling tank was filled with the aquarium stones.
7. The inlet valve was opened to allow water to enter the stilling tank as the pump was
started.
8. A small overflow spillage should be ensured through the overflow tube to maintain a
constant level.
9. The water allowed to settle for few minutes.
10. The outflow valve was opened to test the unit. Any presence of water leaking was
checked and then was proceeded to inject the ink.
11. The flow control valve was slightly opened to let water flow through the visualizing
tube.
12. The unit set was ready to use.
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4.3 Start-up
1. The water inlet and outlet valve were opened until it reaches laminar, transitional and
turbulent flow respectively.
2. The characteristic of the water was observed, and the required data were recorded.

4.4. Experiment Procedure

1. The dye injector was lowered until it can be seen in the glass tube.
2. The inlet valve, V1 was opened and water was allowed to enter the stilling tank.
3. Small overflow spillage was confirmed through the overflow tube to maintain a
constant level.
4. The water allowed to settle for a few minutes.
5. Water was flowed through the visualizing tube.
6. The dye control valve, V4 was slightly adjusted and a slow flow with dye injection
was achieved.
7. The water inlet valve, V1 and outlet valve, V2 were regulated and a straight
identifiable dye line is achieved. The flow was confirmed as laminar.
8. Flow rate at the outlet valve, V2 was measured using volumetric method.
9. The experiment was repeated by regulating water inlet valve, V1 and outlet valve,
V2 to produce transitional and turbulent flow.
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5.0 DISCUSSIONS

5.1 Pre-commissioning

Pre-commissioning is a step that involves activity that helps to verify the functional
operability of elements within the equipment or a system to achieve a state of readiness for next
step which is commissioning and start-up operation. In this experiment, the pre-commissioning
activity was done by start checking the similarity of existed equipment with the drawing of
equipment provided as shown in Figure 5.1. This step was done by ticking the checklist as
shown in Table 5.1 below. All the components and elements of equipment should be present
and able to function as it should to run the operation. If any of component are absent or not
functioning, it should be listed in ‘punch list’. In this case, the punch list is shown in Table 5.2
where dye remains inside dye holder was left at small volume and need to be refilled to prevent
shortage of dye during operation.

Table 5.1 shows the check list for pre-commissioning of Osborne Reynolds apparatus
No. Description Notes
1. Check the existing parts and compare with drawing /
2. Drain remaining water in stilling tank /
3. Turn ON pump /
4. Let water fill in the stilling tank /
5. Flush the water out to remove remaining dye /
6. Check each component to ensure able to function /

Table 5.2 shows the punch list for pre-commissioning of Osborne Reynold apparatus
No. Description Notes
1. Dye remains in small volume Dye need to be refilled
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Figure 5.1 shows the manual drawing of Osborne Reynold apparatus.

Next, cleaning procedure was conducted using water flushing method. Water flushing
method was employed to remove remaining dye from previous operation by removing the
remaining water content and refill the water into stilling tank and remove the water again. The
water that flow out after the flushing process was observed and ensure the colour is clear and not
mixed with any dye. The purpose of cleaning the equipment is to prevent excess dye, debris or
contaminants that can damage equipment and delay system startup. This step also vital to ensure
correct determination of flow if the water flow out through visualizing tube are clean and flow of
dye are clear.

Figure 5.2 shows water flushing process as cleaning step of Osborne Reynolds apparatus
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5.2 Commissioning
After pre-commissioning, the next step is commissioning towards the equipment.
Commissioning is a procedure that check the ability of the equipment to run the operation by
using inert fluid or gas. However, in this case water was used in commissioning process because
the process fluid is water. This step was done with using the checklist for commissioning process
as shown in Table 5.3 below. The commissioning process was started with set up the whole
equipment as shown in the manual. Then, inflow, outflow and overflow valves were checked and
ensure connected with hose to allow water flow in and flow out as shown in Figure 5.3. The
process continued with turn ON the pump and let water filled in the stilling tank. During water
filling process, observation was done, and overflow valve was slightly opened to prevent
overfilling the stilling tank.

Figure 5.3 shows the flow of water through outflow, overflow, and inflow valve were tested.

However, there was some problem with the flow of water into the tank where the flow
was not constant even at constant flow rate controlled at the controller. This might be caused due
to weak performance of pump in pumping the water at constant rate. Hence, this problem was
listed in the commissioning punch list. Next, the outflow valve was opened to testing the outflow
of water from the stilling tank. When the water was flowed in good condition and no leaking
detected, the dye was injected to test the flow of dye. The flow of dye was observed through the
visualizing glass tube by adjusting the water flow at different flow rates. Lastly, the unit was
ready to be used as there were no problem with the flow of water, flow of dye, all valves and
pump able to function well.
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Table 5.3 shows the check list for commissioning of Osborne Reynold apparatus
No. Description Notes
1. Turn ON pump to let water flow in /
2. Open inlet valve /
3. Open overflow valve slightly /
4. Check any leaking X-no leaking
5. Open outflow valve /
6. Ensure water flow out through visualizing tube /
7. Open dye flow controller /
8. Check dye flow /

Table 5.4 shows the punch list for commissioning of Osborne Reynold apparatus
No. Description Notes
1. Pump does not pump water at constant rate Pump need to go through maintenance and
(at set value) inspection

5.3 Start-up
Once done with commissioning process, the next step was proceeded with start-up
process. Start-up process is a process that should be done by run the operation with process fluid
and under specific operational conditions. However, it was not the actual run, it was considered
only as simulation of the actual operation. For Osborne Reynold equipment, the start-up process
was done using water as the process fluid and by using the check list as shown in Table 5.5
below. The runs were started by adjusting the flow rates of water flow out and the flow of dye
were observed to determine type of flow whether it is a laminar, transitional or turbulent flow.
Then, proceed to measure the volume of water that can be collected by each type of flow.
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Table 5.5 shows the check list for start-up process of Osborne Reynold apparatus
No. Description Notes
1. Control flow of water to obtain laminar, transitional and turbulent flow /
2. Measure volume of water that can be collected by each type of flow /
under constant time

The flow rate was adjusted to three different rates; slow, medium and fast. Next, the flow
of dye was observed at set flow rate. At slow flow rate of water, the flow shows an orderly flow
as shown in Figure 5.4 because it is a laminar flow where the motion of the particles of the fluid
is very orderly with particles close to a solid surface moving in straight lines parallel to that
surface.

Figure 5.4 shows laminar flow.

When the flow rate of water adjusted to fast flow, where the flow rate was almost at
maximum level, the flow of dye shows different result as shown is Figure 5.5. The flow of dye
dispersed in the water and mix with the water and totally in contrast to laminar flow due to
undergoes irregular mixing in which the fluid moves in smooth paths or layers. In turbulent
flow, the speed of the fluid at a point was continuously undergoing changes in both magnitude
and direction.
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Figure 5.5 shows turbulent flow.

The third flow rate was medium flow rate of water where the flow rate was in between
the slow and fast flow rates. At medium flow rate of water, the movement of dye was not too
orderly but not too irregular. This shows the flow was a transitional flow as shown in Figure
5.6 below where it is a mixture of laminar and turbulent flow, with turbulence in the center of
the pipe, and laminar flow near the edges.

Figure 5.6 shows transitional flow.

On the other hand, the volume of water that can be collected in constant duration of
time for each flow was tested. The constant time was under 20 seconds. As shown in Table 5.6,
for laminar flow, 60 mL of water was collected under 20 seconds while for transitional flow, it
collected 345 mL of water. However, turbulent flow collects 500 mL volume of water just
under 14 seconds and no data under 20 seconds because the maximum collection was 500 mL.
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These results prove that laminar flow was at slow flow rate, transitional flow was at medium
flow rate and turbulent was at very fast flow rate.

Table 5.6 shows the result for start-up process of Osborne Reynold apparatus
Time (s) Volume (mL) Type of flow
20 60 Laminar
20 345 Transition
14 500 Turbulent

Based on the results and observations, it is shows that slow flow rate of water will
resulting a laminar flow, medium flow of water will cause transitional flow and high flow rate
of water will cause a turbulent flow. From the graph plotted in Figure 5.7, it is also showing
that the higher the flow rate of water, the more volume of water can be collected under a short
of time. Laminar flow able to collect the lowest volume of water under 20 seconds, while
turbulent flow able to collect highest volume of water at shorter time, under 14 seconds only.

Volume of water collected vs Type of flow

600
Volume of water collected (mL)

500
400
300
200
100
0
Laminar Transitional Turbulent
Type of flow

Figure 5.7 shows graph of volume of water collected versus type of flow.

Overall, after pre-commissioning, commissioning and start-up process, the equipment

shows that it can be operated normally to study theory of Osborne Reynold despite the punch
list listed in Table 5.2 and 5.4. The punch lists are for future reference and improvement to
allow the equipment to run smoothly for every future operation.
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6.0 CONCLUSION

In this experiment, three different flow types must be achieved. Laminar flow occurs
when a fluid is moving slowly whereas turbulent flow occur when fluid flows at a very
fast rate. In transitional flow, the flow switches between laminar and turbulent in a
disorderly rate. The Reynolds number calculated can be seen increases linearly as the
water flow rate increases. Besides, pre-commissioning, commissioning and start-up of
Osborne Reynolds that were conducted allow the main objective of this experiment to be
achieved which is to gain knowledge and techniques that can be applied in those three
stages. Pre-commissioning, commissioning and start-up stages are vital as they are the
bridge between the phases that involve systems turnover, systems checkout and
performance testing. As such, in pre commissioning, the equipment in Osborn Reynolds
experiment was checked with the help of the drawing provided. At commissioning phase,
the Osborne Reynolds was assembled as a preparation for start-up experiment. The
experiment was carried out by adjusting the valve opening to obtain laminar, transition
and turbulence flow during start-up process.

7.0 SUGGESTION AND RECOMMENDATIONS

To carry out the experiment efficiently, a constant head reservoir for smooth flow
should be ensured before starting the experiment. By this, disturbed flowrate would not
occur which affects the final results. The equipment must be in a clean condition
especially the tube where the dye flows in and the shroud which should only be lightly
colored to help flow visualization. In order to achieve a better result, the experiment
should be repeated three times in order to obtain average and more accurate reading.
Thus, this will reduce deviation from the theoretical results. The person-in-charge should
also be more alert and focus during experiment in order to prevent errors. For example,
the position of the eyes during taking the value of water volume must in the same level of
the meniscus to avoid parallax error. The experiment should also be done at a suitable
and unshaken place. The clip and valve which control the injection of dye must be
regulated carefully so that a lot of dye would not be wasted and laminar flow stream can
be achieved properly.
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8.0 REFERENCES

Almasi, A. (2014). Pre-commissioning, commissioning and start-up of industrial plants

and machineries. Australian Journal of Mechanical Engineering, 12(2), 257-263.
Fares, F., Montenegro, B., Prates, A., Commissioning of Oil & Gas Projects – Current
Status, Evolution and Trends. in: Rio Oil & Gas 2010, Rio de Janeiro, Brazil, set
2010
Hoffman, J., & Johnson, C. (2007). Laminar and Turbulent Flow. Computational
Turbulent Incompressible Flow: Applied Mathematics: Body and Soul 4, 51-55.
HORSLEY, D. Process Plant Commissioning, a User Guide, Institution of Chemical
Engineering, 1998
https://en.m.wikipedia.org/wiki/Osborne_Reynolds Retrive in August 2015.
https://www.academia.edu/18747082/CHE241_-
_Lab_Report_Solteq_Osborne_Reynolds_Demonstration_FM11_2015_
Jackson, D., & Launder, B. (2007). Osborne Reynolds and the publication of his papers
on turbulent flow. Annu. Rev. Fluid Mech., 39, 19-35.
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APPENDIX
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Prepared by/Disediakan oleh : Approved by/Disahkan oleh :

Signature/Tandatangan : Signature/Tandatangan :
Name/Nama : NUR HANIS HAYATI HAIROM Name/Nama : PROF. MADYA DR. ISHAK BABA

Date/Tarikh : Tarikh :