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INTRODUCTION

Commissioning Process Plant Model


Ing. Luis E. Penuela V.
SIMPLE?
Commissioning is a complex issue requiring:
Planning
Leadership
Teamwork
Training
Communications

Process start up model
Ing. Luis E. Penuela V.
Prime course objectives to raise awareness
of these issues on a general level, as to:
WHAT problems will occur
WHY they occur
WHEN they occur
HOW they can be managed and reduced to
an acceptable level

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PROBLEMS
Ing. Luis E. Penuela V.
FACTORS
Plant size
Process type (continuous or batch)
Client infrastructure
Contractual arrangements
Level of automation or control

Process start up model
Ing. Luis E. Penuela V.
ROOT CAUSES
Poor Planning
Ineffective Leadership
Rushed Installation
Poor Quality Work
Too Few Resources
Inexperienced Resources
Inadequate training
Poor design
Sabotage
Process start up model
Ing. Luis E. Penuela V.
DIFFERING OBJECTIVES 1
Construction personnel: Objectives

to finish plant construction and to leave
site as soon as possible

Process start up model
Ing. Luis E. Penuela V.
DIFFERING OBJECTIVES 2
Commissioning personnel: Objectives
to learn the plant
to learn the process
to ensure the as-built plant will work as
intended
to test the installed equipment
to fully commission the plant

Process start up model
Ing. Luis E. Penuela V.
OBJECTIVES
PROVIDE EXPOSUREto the unique problems
associated with the start up of process plants.
STIMULATE THINKINGorientation to the start
up aspects of any type of plant in any industry.
ESTABLISH A FRAMEWORKfor anticipating
and avoiding financial, technical, operational and
organisational problems associated with a start up.
GENERATE CONFIDENCEin planning for and
executing a successful plant start up regardless of your
organisational position.

Process start up model
Ing. Luis E. Penuela V.
TERMINOLOGY 1
PRECOMMISSIONINGPrecommissioning
activities are the non-operating work responsibilities such
as adjustments, cold alignment checks, etc. performed by
the contractor prior to ready for commissioning or
mechanical completion.

READY FOR COMMISSIONINGOccurs when
the plant or any part of the plant has been erected in
accordance with drawings and specifications and the
precommissioning activities have been completed to the
extent necessary to permit commissioning activities to
begin.

Process start up model
Ing. Luis E. Penuela V.
TERMINOLOGY 2
MECHANICAL COMPLETION Occurs
when the plant or any part of the plant has been
erected in accordance with drawings,
specifications and applicable codes and the
precommissioning activities have been
completed to the extent necessary to permit the
client to accept the plant and begin
commissioning activities. The terms ready for
commissioning and mechanical completion are
often synonymous.
Process start up model
Ing. Luis E. Penuela V.
TERMINOLOGY 3
COMPLETION OF WORKMeans that the
contractor has erected the plant in accordance with
drawings and specifications completed his specified
precommissioning work and completed his final cleanup,
painting and thermal insulation work.

COMMISSIONINGCommissioning activities are
associated with preparing or operating the plant or any part
of the plant prior to the initial start up and are usually the
owners work responsibilities.

Process start up model
Ing. Luis E. Penuela V.
TERMINOLOGY 4
WATER TRIALSare commissioning activities conducted to
allow run-in and operational testing of the equipment as well as
provide operator training and familiarisation.

INITIAL START UPoccurs when feedstocks are
introduced to the plant for the express purpose of producing a
product for the first time.

INITIAL OPERATIONSused to describe the entire
process of precommissioning, commissioning, initial start up,
steady production and performance testing of a plant.

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Ing. Luis E. Penuela V.
HOW THE TERMS RELATE:
DIAGRAM
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PROJECT DEFINITION AND
SCOPE
SERVICES

PROCESSES

BUDGETS

SCHEDULES
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PROJECT ORGANISATION
MANPOWER

EXPERIENCE

STANDARDS

PROCEDURES

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PROJECT CONTROL
COSTS

SCHEDULES

QUALITY CONTROL

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PROJECT MANAGERS ROLE
ENGINEERING

ADMINISTRATIVE SERVICES

CONSTRUCTION MANAGEMENT

PLANT START UP

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Ing. Luis E. Penuela V.
PROJECT EXECUTION DIAGRAM
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Ing. Luis E. Penuela V.
SUCCESSFUL START-UP
REQUIREMENTS 1
OWNER ORGANISATION

Adequate overall planning
Detailed long-term preparation
Supportive organisation
Detailed operating and emergency procedures
Established standard and working practices
Effective resource planning
Competent personnel
Trained personnel

Process start up model
Ing. Luis E. Penuela V.
SUCCESSFUL START-UP
REQUIREMENTS 2
PLANT AND EQUIPMENT

Thorough mechanical completion inspection
Closely monitored commissioning procedures
Water trials
Adequate stores and spare part availability
Prepared laboratory
Responsive maintenance support

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Ing. Luis E. Penuela V.
SUCCESSFUL START-UP
REQUIREMENTS 3
WHAT IS AT STAKE

Company profitability
Company reputation
Project success
Plant effectiveness
Personal reputations
Your takehome pay

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