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Pcsu chapter 1
1. Plant Commissioning & Start-Up
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Chapter One
Introduction to Plant Commissioning
and Start-Up (PCSU)
2. 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
The act or an instance of setting in operation
or motion
3. 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.
4. The grass root of chemical plant
constructions
◦ Basic Process Engineering
◦ Detailed Engineering
◦ Procurement
◦ Construction
◦ Operations Training
◦ Commissioning
◦ Hydrocarbon Introduction and Acceptance Test Run
5. To ensure that the plant is brought into
production without risk to:
◦ The personnel
◦ The environment
◦ The equipment
6. 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
7. 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
8. prepare, plan and execute startup
commissioning management
Preparation of specific plant procedures
Management of risks
Safety & environmental compliance
9. Construction
Pre-commissioning,
Inspection and
Operational
Testing
Start up and
Performance
testing
Post
commissioning
Mechanical completion
Provisional acceptance
Acceptance
10. Construction
Pre-commissioning,
Inspection and
Operational Testing
Mechanical completion
Progressive provisional acceptance
Start up and
Performance
testing
Progressive acceptance
Post commissioning
