commissioning process plant model

5/20/2018 Commissioning Process Plant Model

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INTRODUCTION

Commissioning Process Plant Model

Ing. Luis E. Penuela V.


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SIMPLE?

Commissioning is a complex issue requiring:

Planning

Leadership

Teamwork

Training

Communications

Process start up modelIng. Luis E. Penuela V.


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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 toan acceptable level

Process start up model

PROBLEMS

Ing. Luis E. Penuela V.


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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.


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ROOT CAUSES

Poor Planning

Ineffective Leadership

Rushed Installation Poor Quality Work

Too Few Resources

Inexperienced Resources

Inadequate training

Poor design

Sabotage

Process start up modelIng. Luis E. Penuela V.


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DIFFERING OBJECTIVES 1

Construction personnel: Objectives

to finish plant construction and to leave

site as soon as possible



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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



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OBJECTIVES

PROVIDE EXPOSUREto the unique problemsassociated with the start up of process plants.

STIMULATE THINKINGorientation to the startup aspects of any type of plant in any industry.

ESTABLISH A FRAMEWORKfor anticipatingand avoiding financial, technical, operational and

organisational problems associated with a start up.

GENERATE CONFIDENCEin planning for andexecuting a successful plant start up regardless of your

organisational position.



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TERMINOLOGY 1

PRECOMMISSIONINGPrecommissioningactivities are the non-operating work responsibilities such

as adjustments, cold alignment checks, etc. performed by

the contractor prior to ready for commissioning ormechanical completion.

READY FOR COMMISSIONINGOccurs when

the plant or any part of the plant has been erected inaccordance with drawings and specifications and the

precommissioning activities have been completed to the

extent necessary to permit commissioning activities to

begin.



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TERMINOLOGY 2

MECHANICAL COMPLETION Occurswhen the plant or any part of the plant has beenerected in accordance with drawings,

specifications and applicable codes and theprecommissioning activities have beencompleted to the extent necessary to permit theclient to accept the plant and begincommissioning activities. The terms ready forcommissioning and mechanical completion areoften synonymous.



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TERMINOLOGY 3

COMPLETION OF WORKMeans that thecontractor 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 areassociated with preparing or operating the plant or any partof the plant prior to the initial start up and are usually the

owners work responsibilities.



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TERMINOLOGY 4

WATER TRIALSare commissioning activities conducted toallow run-in and operational testing of the equipment as well as

provide operator training and familiarisation.

INITIAL START UPoccurs when feedstocks areintroduced to the plant for the express purpose of producing a

product for the first time.

INITIAL OPERATIONSused to describe the entireprocess of precommissioning, commissioning, initial start up,

steady production and performance testing of a plant.



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HOW THE TERMS RELATE:

DIAGRAM

Process start up model


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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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PROJECT EXECUTION DIAGRAM



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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



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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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SUCCESSFUL START-UP

REQUIREMENTS 3

WHAT IS AT STAKE

Company profitability Company reputation

Project success

Plant effectiveness

Personal reputations

Your takehome pay


commissioning process plant model

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