1. 1.0 INTRODUCTION Seán Moran

2. SIMPLE? Commissioning is a complex issue requiring: Planning Leadership Teamwork Training Communications

3. 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

4. FACTORS Plant size Process type (continuous or batch) Client infrastructure Contractual arrangements Level of automation or control

5. ROOT CAUSES Poor Planning Ineffective Leadership Rushed Installation Poor Quality Work Too Few Resources Inexperienced Resources Inadequate training Poor design Sabotage

6. DIFFERING OBJECTIVES 1 Construction personnel: Objectives to finish plant construction and to leave site as soon as possible

7. 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

8. COURSE OBJECTIVES PROVIDE EXPOSURE… to the unique problems associated with the start up of process plants. STIMULATE THINKING… orientation to the start up aspects of any type of plant in any industry. ESTABLISH A FRAMEWORK… for anticipating and avoiding financial, technical, operational and organisational problems associated with a start up. GENERATE CONFIDENCE… in planning for and executing a successful plant start up regardless of your organisational position.

9. TERMINOLOGY 1 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. 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.

10. 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.

11. TERMINOLOGY 3 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. 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.

12. TERMINOLOGY 4 WATER TRIALS… are commissioning activities conducted to allow run-in and operational testing of the equipment as well as provide operator training and familiarisation. INITIAL START UP… occurs when feedstocks are introduced to the plant for the express purpose of producing a product for the first time. INITIAL OPERATIONS… used to describe the entire process of precommissioning, commissioning, initial start up, steady production and performance testing of a plant.

13. HOW THE TERMS RELATE: DIAGRAM

14. PROJECT DEFINITION AND SCOPE SERVICES PROCESSES BUDGETS SCHEDULES

15. PROJECT ORGANISATION MANPOWER EXPERIENCE STANDARDS PROCEDURES

16. PROJECT CONTROL COSTS SCHEDULES QUALITY CONTROL

17. PROJECT MANAGER’S ROLE ENGINEERING ADMINISTRATIVE SERVICES CONSTRUCTION MANAGEMENT PLANT START UP

18. PROJECT EXECUTION DIAGRAM

19. 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

20. 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

21. SUCCESSFUL START- UP REQUIREMENTS 3 WHAT IS AT STAKE Company profitability Company reputation Project success Plant effectiveness Personal reputations Your takehome pay