CHAPTER 1:

INTRODUCTION TO PLANT
COMMISSIONING AND START-UP

Dr Noormazlinah Ahmad
FTKKP
SEMESTER II 2020/2021
PLANT COMMISSIONING, START-UPS & SHUT-DOWNS
DKK2462
Definitions
The process of assuring that all systems and components of
a building or industrial plant are designed, installed, tested,
operated, and maintained according to the operational
requirements of the owner or final client
Plant Start-Up and Commissioning
Plant commissioning is the first of many start-ups
Potentially hazardous: ability to operate not proven
Many unknown factors
First startup & subsequent shutdowns and startups
Excellent experience and expertise building for
operators and maintenance personnel.
Plant Start-Up and Commissioning
The grass root of chemical plant constructions
◦ Basic Process Engineering
◦ Detailed Engineering
◦ Procurement
◦ Construction
◦ Operations Training
◦ Commissioning
◦ Hydrocarbon Introduction and Acceptance Test Run
The Objective of Commissioning
To ensure that the plant is brought into production without
risk to:
◦ The personnel
◦ The environment
◦ The equipment
Start-up and Commissioning apply to :

Projects of the entire facilities

Major expansions or additions to existing plants
Re-commissioning of plants and equipment;
Individual items of plant, eg
◦ Boilers
◦ Instrument air compressors etc
Effect on the Plant Operation and
Schedule
Delays in Start-up and Commissioning are expensive
slow start-ups reduce the Return on Investment
◦ delayed revenue stream
◦ Increased cost of delivery
◦ Financial viability
~20-25% of construction time (good planning)
Causes of delays:
◦ 75% due to equipment failure
◦ 20% from inadequate equipment
◦ 5% from process failure
Details vary depending on plant but
procedure remains the same
prepare, plan and execute startup
commissioning management
Preparation of specific plant procedures
Management of risks
Safety & environmental compliance
Construction & Commissioning
How we would like it …..

Mechanical completion
Provisional acceptance
Construction Acceptance

Pre-commission
ing, Inspection
Start up and
and Operational
Performance Post
Testing
testing commissioning
Construction and Commissioning
How it happens …..

Mechanical completion
Progressive provisional acceptance
Construction Progressive acceptance

Pre-commissioning,
Inspection and Start up and
Operational Testing Performance Post commissioning
testing