1.

0 INTRODUCTION

Sen Moran
SIMPLE?

Commissioning is a complex issue requiring:

Planning
Leadership
Teamwork
Training
Communications
PROBLEMS

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
FACTORS

Plant size
Process type (continuous or batch)
Client infrastructure
Contractual arrangements
Level of automation or control
ROOT CAUSES

Poor Planning
IneffectiveLeadership
Rushed Installation
Poor Quality Work
Too Few Resources
Inexperienced Resources
Inadequate training
Poor design
Sabotage
DIFFERING
OBJECTIVES 1
Construction personnel: Objectives

tofinish plant construction and to leave site as

soon as possible
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
COURSE
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.
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.
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.
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.
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.
HOW THE TERMS
RELATE: DIAGRAM
PROJECT DEFINITION
AND SCOPE
SERVICES

PROCESSES

BUDGETS

SCHEDULES
PROJECT
ORGANISATION
MANPOWER

EXPERIENCE

STANDARDS

PROCEDURES
PROJECT CONTROL

COSTS

SCHEDULES

QUALITY CONTROL
PROJECT
MANAGERS ROLE
ENGINEERING

ADMINISTRATIVE SERVICES

CONSTRUCTION MANAGEMENT

PLANT START UP
PROJECT EXECUTION
DIAGRAM
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
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
SUCCESSFUL START-
UP REQUIREMENTS 3
WHAT IS AT STAKE

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