While start-up and commissioning may be the final phases of executing a manufacturing project, these critical phases must be planned for well in advance. Without proper early planning, start-up efforts are often reactive, leading to higher risks and costs, missed deadlines, and extended downtime.
So how early should you start planning for start-up and commissioning? The short answer – from the very beginning. By proactively planning for start-up and commissioning during your front-end design phase, you can be sure your start-up process will align with your business objectives and that resources and budget are properly allocated to support and fund start-up. Note: a detailed start-up and commissioning plan should be developed at this point as well.
Next, during the design and fabrication phases of your project, there are several activities related to equipment design, testing, and installation that are likely already part of the project that can be tweaked to minimize the chance of some potential operational issues during the start-up and commissioning phase. This includes designing equipment for maintainability and operability, aligning factory acceptance test (FAT) criteria with equipment specifications, clearly defining equipment shipping and assembly procedures, and including virtual commissioning as part of the design process.
The more planning, coordination, and attention to detail given during the construction phase of your project the easier it will be to streamline start-up and commissioning. This should include developing an agreed upon change management process and documenting all completed construction activities. Then, once this documentation is handed over from the construction team to the commissioning team, you are ready for the final push that will set the stage for a smooth start-up process.
Overall, by planning for your start-up process early, and adjusting as your project unfolds, you can experience a number of benefits such as:
With more than 40 years’ experience working with manufacturers to implement a wide array of industrial projects, the Polytron team is well prepared to help you experience these benefits by guiding you to a successful start-up.
To learn more about developing a start-up and commissioning plan and how Polytron can help you apply a start-up and commissioning lens throughout your project, download our latest white paper, Ensuring Operational Readiness through Early Start-Up Planning.