What is commissioning?

- Putting the manufacturing plan into the normal operational duty, along
with that involving Training of the people
- Ensure that the people who run the plant is able to meet the required rate
and quality
- Need to know how to control the plant when things start to drift,
- Adjust the operating condition to meet the requirement of the design
performance
- Need to have the system when to take some action when something
happen, what action to be taken
- Operator Need to appreciate what is the fundamental process required to
be controlled and what is going on along the process( the important of
training)

5 linked elements
Materials-Operating Team-Commissioning Team-The Process-Plant
Hardware

Contract-Design-Install/Construction/Mechanical Testing/Pre-Commission-
Commission-Performance Trial-Handover

Contract
Agreement- Clear as who is responsible for what? Boundary for responsibilities?
Whose gonna do what? Safety? Control? If anything goes wrong, that person will
get the management attention.
Commissioning Team Activities during Design/Construction
Putting together the file for the plant (start building the Data base what you done
why you done that?
Involve in Hazop Studies (how going to operate this plant)
-Team selection (work together)
-Team Building
-Team Training
-Develop commissioning check list
-Check on construction and installation
-Witness mechanical testing where required
Handover from Construction (contractor) to Commissioning Team

-usually hander in section (from beginning raw material to product)

-Defined and clear handover of responsibility and control of each section

Handover from construction

-Is the system leak-proof
-Do material flow correctly?
-Are vessel clean, connected to the correct vessel?
-Do valve open as request and shut?

Pre commissioning Activities

-Check on vessel/pipework
-Check electrics
-Check instrument either all of them work properly? Is it measure right temp? is it
respond fast enough? Respond to the time?
-Check Software work
-Flush pipework
-Leak and pressure test

Commissioning Activities
-Process chemical are introduced
-water and air flow to test the flow, instrument
-equipment is put into operation of their normal duties
-Commissioning is generally carried out in section
-planning is crucial (raw material in who is going to do it, what to do with the
waste)
-Safety is crucial

Start Up Materials
How much materials is to be scrap?
What to do with it?
Can recycle or be sold? Cost of handling?
Ramps up to final condition
How fast to bring up to ideal operation condition?
How fast to bring up to ideal production rate?

When is commissioning Complete?

-Plant has to be fit for purpose
*Product range
*Product quality (acceptable quality)
* Efficiency
*Production rate
*Production length
-Performance trial/Acceptance test complete
Performance trial
All trial criteria must be defined and agreed in advance of the trial
-Duration of trial
-Parameter to be measured
-Values to be achieved
-