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 Ineffective Leadership Rushed Installation Poor Quality Work Too Few Resources Inexperienced Resources Inadequate training Poor design Sabotage

DIFFERING OBJECTIVES 1
Construction personnel: Objectives

to finish 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 STARTUP 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 STARTUP 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 STARTUP REQUIREMENTS 3

WHAT IS AT STAKE
Company profitability Company reputation Project success Plant effectiveness Personal reputations Your takehome pay