Transcript Process Plant Commissioning

1.0 INTRODUCTION
Seán Moran
SIMPLE?
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Commissioning is a complex issue requiring:
Planning
Leadership
Teamwork
Training
Communications
PROBLEMS
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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
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Plant size
Process type (continuous or batch)
Client infrastructure
Contractual arrangements
Level of automation or control
ROOT CAUSES
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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
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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
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PROVIDE EXPOSURE…to the unique problems
associated with the start up of process plants.
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STIMULATE THINKING…orientation to the start up
aspects of any type of plant in any industry.
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ESTABLISH A FRAMEWORK…for anticipating
and avoiding financial, technical, operational and organisational
problems associated with a start up.
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GENERATE CONFIDENCE…in planning for and
executing a successful plant start up regardless of your
organisational position.
TERMINOLOGY 1
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PRECOMMISSIONING…Precommissioning 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.
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READY FOR COMMISSIONING…Occurs 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
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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
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COMPLETION OF WORK…Means 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.
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COMMISSIONING…Commissioning 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 owner’s work
responsibilities.
TERMINOLOGY 4
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WATER TRIALS…are commissioning activities
conducted to allow run-in and operational testing of the equipment
as well as provide operator training and familiarisation.
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INITIAL START UP…occurs when feedstocks are
introduced to the plant for the express purpose of producing a
product for the first time.
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INITIAL OPERATIONS…used 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
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SERVICES
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PROCESSES
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BUDGETS
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SCHEDULES
PROJECT
ORGANISATION
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MANPOWER
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EXPERIENCE
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STANDARDS
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PROCEDURES
PROJECT CONTROL
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COSTS
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SCHEDULES
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QUALITY CONTROL
PROJECT
MANAGER’S ROLE
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ENGINEERING
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ADMINISTRATIVE SERVICES
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CONSTRUCTION MANAGEMENT
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PLANT START UP
PROJECT EXECUTION
DIAGRAM
SUCCESSFUL STARTUP REQUIREMENTS 1
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OWNER ORGANISATION
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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
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SUCCESSFUL STARTUP REQUIREMENTS 2
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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
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WHAT IS AT STAKE
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Company profitability
Company reputation
Project success
Plant effectiveness
Personal reputations
Your takehome pay
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