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7/31/2019 4K_-_Startup_and_Commissioning

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PM Workshop

Start-up & Commissioning


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Slides\execution\startup.ppt

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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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4


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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5


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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Caution:

Do Not Start Vendor Systems WithoutManufacturers Representative


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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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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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Reporting Status

System Team Meetings

Weekly Construction Meetings

Obtaining & Compiling O & M Manuals

From Vendors/manufacturers

From Contractors

From the Design Team



10


Acceptance & Turnover Documents

Performance Tests

Signoff and Turnover

Warranty



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Activities

Pre-commissioning

Design Verification

OAT

Commissioning

FAT

Start-up



12


Activities (Continued)

Acceptance Tests (Performance Tests)

Document What Needs Fix

Witness and Signatures

Turnover (Warranty)

O & M Manual

Test Documentation (Option)

Training (Option)



13


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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Junior

Staff



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Construction

Developdesignsolutionsf

or

processdevelopmentdesig

n

issues

STARTUP AND TRAINING

OPERATOR TRAINING FIELD ENGINEERING SYSTEM TEAM CONSTRUCTION

Develop Startup plan,

checklists, procedures, andperformance testing plans

Respond to RFIs, review

submittals, observe construction

Punchlist and FixupPunchlist

Develop SOPs, and

Training Manuals with

Engineering assistance

Pre-startup ChecklistTrain the Trainer

Fix Critical Items

Component Operational Test

(check PLC function, check component mechanical operation, energize equipment, run

in manual)Fix Critical Items

System Operational Test

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

On-the-Job and Classroom

Training of Equipment

OperatorsFix Critical Items

System Performance Acceptance Test

(system performance demonstration through a range of operating conditions using product where

possible)

Training Complete

System Turnover

Fix Critical Items

Full Line Performance Acceptance Test

Full Line Turnover for

Production Operation

Final Inspection Report

Review Startup Plan and

SOPs



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VentilationDustCollection

System

220-1

CA

Electrical

DRY RUN MATERIAL

Recycle

800-1

Electrical

Vent Cyclone

Starch Tank

110-1Storage

Truck

CA

Elect

Gain In Wt

Feeder

190-1

Mix Transfer

Presses

300-x

Trimming

310-x

4:1 Merge &

Conveyors

320-1

Continued

Mag Stearate

Tank 120-1Storage

Truck

CA

Elect Guar Gum

Tank 130-1StorageTruck CA

Elect

Calc. Carb.

Tank 105-1Truck

CA

Elect

Fiber

Tank 180-1StorageTruck

CAElect

Mixer

200-1

Recycle

900-1

Hot and Cold

Water

CA

Elect

CA

Elect

CAElect

CA

Elect

CA

Elect

CACIP

Mold

Bad

Batch

CW

Truck to

Landfill

Liquid

Waste

LPCLPS

CWElect

Liquid

Waste

Elect

Liquid WasteHeat Vent

VentReject

VentCWElect

Vision

Inspection

330-1

CA

Elect

Ventilation

SUPPORTREQUIREMENTS for

PROCESS STEPS


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Start-up & CommissioningCoating

No.1

340-1

CACW

Coating

No.2

360-1

Airveyor

380-1

CAElect

Stacking

390-1

CAElect

Packaging

700-1

CAElect

Conveyor

400-1

CAElect

Printer /

Bagger

600-1

CAElect

Heater170-1

Store

HVAC

CIP

Elect

Gas

Drains

SCADA

Paraffin Wax

160-1

Vinac &

Benzoflex

140-1

Hinge Coat140-1

Boiler

Process

Chiller

Air

Compressor

VOC

AbatementWarehouse

Forklift

Truck

VOCHeat Exhaust

Reject (Trash)

Heat Exhaust

Reject (Trash)

Recycle

N2DIW

Elect

CA

HPCHPSCA

HPCHPS

WET RAW MATERIALS

LPCLPS

Elect

CATruck

ElectCATruck

ElectCA

Truck

Trays

Trays

Ink

Wrapping Film (Rolls)VOCReject

(Trash)

PalletsStretch

Wrap FilmCoding Ink

TapeBoxes

Cooling

Tower

Permit

Plant

City Utility

City Utility

City Utility

Plant

Plant

10-13

IACA

Elect

PCW

PCR

CWSCWR Elect

PermitElect

Coating No.1

VentHPC

LPCHPS

LPS

CWGasElect

SUPPORT REQUIREMENTS for

PROCESS STEPS