- Posted by Okechukwu Anosike on September 30, 2009
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Project commissioning is a systematic performance testing and quality control process designed to verify that newly-installed equipment and systems operate according to the intended design and the agencies/customers needs. Some say Commissioning typically begins during the project design phase and continues for at least one year after construction is complete. It requires thorough documentation of system design, construction quality, functional performance tests, and operation and maintenance requirements. The training of facility operators and staff also is a key component of building commissioning since staff may be responsible for some equipment maintenance. Over time, continuous commissioning is the best way to determine whether controls and equipment function properly.
Why Do Commissioning?
Studies have shown that poor communication of design intent, inadequate equipment capacity, inferior equipment installation, insufficient maintenance and improper system operation have all reduced energy cost savings. Typical problems in non-commissioned projects include:
• Poor documentation of project installation and operational requirements.
• Underutilized energy management systems
• Incorrect equipment scheduling
• Existence of snags that wound hinder production time
• Lack of process optimization.
• Negative cash flow
Depending on the complexity of the project, commissioning cost can range from one to four percent of the total cost of the project. An investment in commissioning usually pays of itself in one or three years because it can reduce energy usage and other process snags by up to 15 percent. Commissioning can also reduce future equipment repair cost, downtime and replacement by 15 percent or more. Benefits of commissioning include the following:
Increased in house knowledge and improved equipment operation.
Project commissioning provides the system/company with in-house knowledge for optimizing equipment, system and control efficiencies. Optimization improves coordination within systems/plants and, therefore, improves overall performance. Improved system control extends equipment life and improves operation efficiency by avoiding frequent equipment cycling.
Better planning and coordination for smoother equipment start-up
During project execution commissioning provides better planning, coordination and communication amongst stakeholders. This is considering that commissioning is considered to start of after the design phase of a project. This planning results in fewer change orders, shorter punch/snag list and fewer callbacks. Commissioning also provides faster and smoother equipment start-up due to systematic equipment and control testing procedures.
Better front end performance
Knowing that problem prevention is less expensive than problem correction, commissioning provides front-end performance accountability and quality control by allowing frequent comparison of consistent project construction with project design. This can provide quick feedback to design professionals on the dynamic performance of their design. Proper commissioning reduces liability risk from environmental hazards or equipment failure.
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Category: Chemical Engineering, General Engineering, Plant Scale Up's, Process Engineering, Project Engineering
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