(180c) Process Plant, Pre-Commissioning, Commissioning and Start-up Digest

Process Plant Commissioning is the first job of many start-ups and it is potentially the most hazardous as we are to prove the ability of the plant to operate. There, always unknown factors and more care and the attention is required into the first startup than into subsequent shutdowns and startups. Experience and expertise gained during the first start-up is used again by plant operators and maintenance personnel for future plant shutdown and startups.

In this paper, the main activity which is involved for pre-commissioning commissioning, startups and effective management for the startup is required, Effective management benefits and poorly managed disadvantage are elaborated.

Introduction:

Effectively managed startup will give significant revenue and poorly managed startup will give reduce the Return on Investment for a new plant. Delay in startup mean delays in when the revenue stream starts and extended and difficult startups add to the cost of delivering the project, which could impact the financial feasibility;

Broader strategic impact is inability to supply customers and markets as promised, creating opportunities for competitors to establish themselves. Experience from start-ups suggests that experienced organizations with well planned startups can startup a plant in do the job in a reasonable short time while poorly managed startups can take time for the startup.

Main cases of delays are [1]:

75% due to equipment failure;

20% from inadequate equipment;

5% from process failure.

Here, three foundation stones of successful startups:

1. Planning, planning and more planning;

2. Technical competence;

3. Good leadership and direction.

Process plant startup is every situation is different and every process plant has different plant startup procedures. Some things do remain the same for overall plants that is, safety, environment, etc. startup requirements.

Reference:

1. Process Plant start-up commission & Troubleshooting Harvard Technology Middle East.2005.