PM Workshop

Start-up & Commissioning

Start-up & Commissioning

What Is It?
Comprehensive Process of Testing and Starting Facility & Production Systems

What Does It Do?

Demonstrate That the System Can Perform A Means for Owners Acceptance

What Else?
Documents Tests (Part of Quality Plan)

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Keys to Success
Start-up & Commissioning Schedule Production Schedule Utilities Needed

Earliest Date System Needed

Organization Start-up Coordinator System Teams
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Start-up & Commissioning

Keys to Success (Continued)
Documentation Project Quality Plan Standard Forms

Written Procedures
Design Team System Owner Material & Utility Needs Identify and Validate Availability
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Start-up & Commissioning

Keys to Success (Continued)
Regular Meetings System Team Construction Meeting System Readiness Design Verification Past Tests

OAT and FAT

Permits, As Needed
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Start-up & Commissioning

Caution:
Do Not Start Vendor Systems Without Manufacturers Representative

Warranty

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Start-up & Commissioning

Planning
Begin Early in Construction Review P&IDs and PFDs Validate Factory Test/receiving Reports

Identify & Calibrate Instrumentation

Compile Forms for Documentation Participate in Construction Meetings

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Start-up & Commissioning

Scheduling Start-up & Commissioning
Develop Schedule Integrate Into Construction Schedule Must Drive Construction Activities

Administering & Witnessing

Walk the System Validate Set-points Document Tests (Signatures)
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Start-up & Commissioning

Reporting Status
System Team Meetings
Weekly Construction Meetings

Obtaining & Compiling O & M Manuals

From Vendors/manufacturers From Contractors From the Design Team

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Acceptance & Turnover Documents

Performance Tests Signoff and Turnover Warranty

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Start-up & Commissioning

Activities
Pre-commissioning
Design Verification OAT Commissioning FAT

Start-up

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Start-up & Commissioning

Activities (Continued)
Acceptance Tests (Performance Tests) Document What Needs Fix Witness and Signatures Turnover (Warranty) O & M Manual Test Documentation (Option)

Training (Option)

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Start-up & Commissioning

Task Often Overlooked
Failure to Understand Relation to Production Start

Assigned To Others (I & C)

Owner Does Not Know How to Start/operate

Ownership (Designer)
Original Owner on Another Project/not in Field

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Start-up & Commissioning

Junior Staff

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Start-up & Commissioning

STARTUP AND TRAINING
OPERATOR TRAINING FIELD ENGINEERING Respond to RFIs, review submittals, observe construction SYSTEM TEAM Develop Startup plan, checklists, procedures, and performance testing plans CONSTRUCTION Develop SOPs, and Training Manuals with Engineering assistance Construction

Punchlist

Review Startup Plan and SOPs

Punchlist and Fixup

Develop design solutions for process development design issues

Train the Trainer

Pre-startup Checklist

Fix Critical Items

Component Operational Test (check PLC function, check component mechanical operation, energize equipment, run in manual)

Fix Critical Items

On-the-Job and Classroom Training of Equipment Operators

System Operational Test (auto operation, set control tuning, begin process testing using product)

Fix Critical Items

Training Complete

System Performance Acceptance Test (system performance demonstration through a range of operating conditions using product where possible)

Fix Critical Items

System Turnover

Full Line Performance Acceptance Test

Final Inspection Report

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Start-up & Commissioning

CA

Storage
Elect Truck CA

Starch Tank 110-1

Mag Stearate Tank 120-1 Guar Gum Tank 130-1 Calc. Carb. Tank 105-1 Fiber Tank 180-1

Storage
Elect Truck Truck

Storage Elect CA
CA Elect Truck

Dust Collection System 220-1

Ventilation
CA

Electrical
Vent Cyclone Electrical

Truck

CA Storage

Elect

Recycle 800-1

DRY RUN MATERIAL

CAElect

Gain In Wt Feeder 190-1 Mixer 200-1 Mix Transfer Presses 300-x Trimming 310-x 4:1 Merge & Conveyors 320-1 Vision Inspection 330-1 Continued
Liquid Waste Liquid Waste Heat Vent Liquid Waste Vent Reject

Ventilation Hot and Cold Water

LPC LPS CW Elect

CA Bad CWElect Batch Truck to Landfill CA Elect CIP

Mold

CA Elect
CA Elect CA Elect CA Elect

Recycle 900-1

Vent CW Elect

SUPPORT REQUIREMENTS for PROCESS STEPS

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Start-up & Commissioning

Elect CA Truck

Vinac & Benzoflex 140-1

HPC HPS CA

Recycle CA CW N2 DIW

Elect CA Truck

Hinge Coat 140-1

Heater 170-1

Elect HPC HPS CA CA Elect

Coating No.1 340-1 Coating No.2 360-1

VOC Exhaust Heat Reject (Trash) Heat Exhaust Reject (Trash)

SCADA

HVAC

CIP
Permit Plant

Airveyor 380-1
Drains Stacking 390-1
Plant

Elect LPC LPS CA Truck

Paraffin Wax 160-1

City Utility

CA Elect

Gas

City Utility

WET RAW MATERIALS

CA Elect Trays

Conveyor 400-1 Printer / Bagger 600-1 Packaging 700-1

Trays VOC Reject (Trash)

Plant

Elect

City Utility

Wrapping Film (Rolls) Ink

Store

CA Elect

CA Elect Tape Boxes Coding Ink

Pallets Stretch Wrap Film

Vent HPC HPS LPC LPS

Boiler

CW Gas Elect

Coating No.1

Warehouse

VOC Abatement

Permit Elect

SUPPORT REQUIREMENTS for PROCESS STEPS

Forklift

IA CA
Truck PCW PCR CWS CWR

Air Compressor
10-13

Elect

Cooling Tower

Process Chiller

Elect

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