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Hindawi Publishing CorporationJournal of Industrial EngineeringVolume 2013, Article ID 572072, 12 pageshttp://dx.doi.org/10.1155/2013/572072

Research ArticleIntegrative Approach to the Plant Commissioning Process

Kris Lawry,1

and Dirk John Pons2

1Department of Chemical and Process Engineering, University of Canterbury, Private Bag 4800, Christchurch 8020, New Zealand

2Department of Mechanical Engineering, University of Canterbury, Private Bag 4800, Christchurch 8020, New Zealand

Correspondence should be addressed to Dirk John Pons; [email protected]

Received 20 September 2012; Revised 2 December 2012; Accepted 19 December 2012

Academic Editor: Xueqing Zhang

Copyright 2013 K. Lawry and D. J. Pons. is is an open access article distributed under the Creative Commons AttributionLicense, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properlycited.

Commissioning is essential in plant-modication projects, yet tends to be ad hoc. e issue is not so much ignorance as lackof systematic approaches. is paper presents a structured model wherein commissioning is systematically integrated with riskmanagement, project management, and production engineering. ree strategies for commissioning emerge, identied as direct,advanced, and parallel. Direct commissioning is the traditional approach of stopping the plant to insert the new unit. Advancedcommissioning is the commissioning of the new unit prior to installation. Parallel commissioning is the commissioning of thenew unit in its operating position, while the old unit is still operational. Results are reported for two plant case studies, showingthat advanced and parallel commissioning can signicantly reduce risk. e model presents a novel and more structured way ofthinking about commissioning, allowing for a more critical examination of how to approach a particular project.

1. Introduction

1.1. Background. Plant modications are an ongoing processthroughout the life of any process plant. Reasons for mod-ication include efforts to improve reliability, productioncapacity, quality, or productivity. Seamless incorporation isthe key concern associated with the installation of any newequipment in an operating plant due to the high cost ofprocess downtime. Several steps can be taken to minimisethe risk associated with the installation of new equipmentsuch as hazard and operability studies, project management,

development of redundancy plans, and commissioning of thenew equipment.

Of these, commissioning is an essential activity inmany plant-modication projects and has signicant impli-cations for project success. Yet paradoxically it tends tobe approached in an ad hoc manner. It is oen includedin project plans, so it is not that people are ignorant ofcommissioning. Rather, the problem is that there is a lack ofsystematic approaches to commissioning, so it is frequentlyle to tradespeople and plant operators to manage in what-ever way they see t. is is an undesirable situation sinceit results in unpredictable outcomes. In some cases it caneven cause serious problems. An extreme example would be

the catastrophic failure of the Chernobyl nuclear power plant(1986), which was caused by operators attempting an ad hoctest of the efficacy of a modied emergency cooling system.

is paper presents a structured conceptual model forthe commissioning process, and two cases studies showingapplication to operating plant.

2. Existing Models of Commissioning

2.1. Literature. Many authors have highlighted the value of

commissioning from a range of different perspectives butthey all agree that commissioning and the integration of anew project is critical to the success of any project [110].However commissioning is poorly dened and is interpretedambiguously [6, 11], which leads to inefficient utilisationwithin industry. In this paper commissioning is dened asthe disciplined activity involving careful testing, calibration,and proving of all systems, soware, and networks within theproject boundary [5].

2.2. Current Models of Commissioning. Factors that areknown to affect the commissioning process include thefollowing.

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2 Journal of Industrial Engineering

Existingcommission

strategies(1)

(c) Methodological:analysis of the

situational needsand deliberateselection of a

relevant method

(a) Ad hoc: action-orientated

problem solving

(b) Template:

follow a checklist,or method thatworked before, orcase study from a

similar applicationelsewhere

Prevailing

commissioning is

of tasks(limits options to

assumption that

simply a routineset

outcomes (a) and (b))

F 1: ree common strategies for commissioning, broadly reecting the approaches described in the literature. If commissioning is

perceived to be simply a routine set of tasks, which is a common assumption, then this tends to preclude any more thoughtful approach tothe problem.

(i) Type of project. us situational variables are impor-tant; that is, the factors that resulted in a successful(orfailed) commissioning outcome in one case are notnecessarily transferrable to a different situation.

(ii) Who is in charge of the phase. Commissioning can becompleted by a range of different groups dependingon the project. It can be the equipment manufac-turers, operation team, or a separate commissioningteam depending on scale and requirements of theproject [12]. e relationships between these people

are also important (social dimension) [6, 13], hencealso contractual obligations (see (iv) below).

(iii) Number/type of phases. Commissioning can also bebroken down in several sections such as planning,precommissioning, testing, integration, monitoring,documenting, andhandover depending on thelevelofcomplexity of the project. is requires carefulprojectplanning (see (iv) below).

(iv) Project planning and contractual sufficiency. It iswidely recognised in the literature that commission-ing requires deliberate planning, as opposed to adhoc treatment. us it needs appropriate consider-

ation in the work breakdown structure and projectplanning [14], allocation of resources, transferral ofthose costs into the initial contract [9, 1518], andcreation of specic operating procedures (especiallyimportant for safety-critical plant like boilers [19]).is corresponds to the integration tasks in theproject management approach [6].

e commissioning process hasbeen examined fora widerange of different projects [25, 8, 20, 21]. e predominateapproach can be described as task specic; the literature tendsto identify specic tasks that should be completed as partof commissioning. us the focus has been on completingmultiple checks on a system to ensure it will operate as

expected. us there are many reports in the literature,too numerous to mention, about commissioning experiencesin specic case studies. ese are undoubtedly helpful,especially for lessons learned and application to comparablesituations. ey are also systematic, in a way, especially in theprovision of templates and checklists to guide practitioners.

However there is a lack of holistic or integrative models.ere is much less literature at the next higher level ofabstraction, which is the commissioning process in gen-eral. At this level we are interested not so much in case-

specic experiences but in the fundamental principles andthe methodology. What exists at this level is primarily inthe area of instrumentation and control; some examples are[5, 22, 23].

us the existing commissioning strategies in the lit-erature can be categorised into three types, see Figure 1.ese are (a) ad hoc, which is action-orientated problemsolving; and (b) template, which involves using a checklist,or operating procedure that worked before or in anothersituation. Both (a) and (b) are premised on the assumptionthat commissioning is a routine set of tasks. e third strategychallenges that premise and calls for a deliberately thoughtfulapproach. us the third category in the literature is (c)

methodological, which involves analysis of the situationalneeds and deliberate selection of the most relevant of severalpossible commissioning methods.

2.3. Issues and Problem Areas. A clear refrain in theliterature is that commissioning (i) needs deliberate projectmanagement, but (ii) is too oen not given the attentionit deserves. One of the issues with commissioning, whichcontributes to problem (ii), is that the value thereof is hardto quantify. Justifying the value of commissioning may becompleted using qualitative analysis similar to quanticationof risk in a project [24]. is is based on the consequence andprobability of the system failing to operate as anticipated. In

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Journal of Industrial Engineering 3

other cases there is no attempt at justication at all, so thevalue is not appreciated.

Another issue is the tendency to underresource the com-missioning in the project planning, which is issue (i) above.Underresourcing is due to several factors such as its omissionin the project management. ere is oen a high level of

variability as a result of the case-specic nature making itdifficult to t into the established planning structure. Existingproject management frameworks, such as the PMBOK [9],aregeneral approaches. Whilethey acknowledgethe commis-sioning stage they do not, and cannot reasonably be expectedto, provide case-specic guidance on commissioning. eytreat commissioning very lightly and rely on the practitionerto identify whether or not commissioning is an importantpart of the project. e literature suggests that practitionerstoo oen fail to realise the importance and therefore failto plan sufficiently. Alternatively, project managers maysimply be overly optimistic about the risks associated withthe installation of a new system. Whatever the reason, theresult can be insufficient resources being allocated, withthe consequence of poor completion. Incorporation of abroad conceptual model of commissioning into the projectmanagement practices would be the rst logical step. Com-missioning draws from several project knowledge areas suchas integration, communication, and risk management. elogical approach is to incorporate into the project life cyclebetween the execution and closing phases [4, 6, 8].

2.4. Proem Denition. Current models of commissioningtend to be simplistic, and relevant only to specic areas.ey are focused on the process and consequently tendto produce a somewhat prescriptive list of tasks that need

to be performed. A higher-level reconceptualisation of thecommissioning process, with the development of a moregeneral theory, could be valuable.

e purpose of this work is to develop a more holistic andintegrative theory of commissioning. e specic emphasis ison reducing process downtime, without compromising plantreliability. is is worth attempting as it has the potentialto provide a general framework in which the other moreprocess-specic models can be placed.

3. Approach

We start by reconceptualising commissioning in broad terms.

We categorise the commissioning strategies according tothe operational risk. is results in three categories: direct,parallel, and advanced. We then apply a system modellingmethod to embed these within the broader manufacturingcontext. Finally we apply the new framework to two casestudies to demonstrate the applicability.

4. Results

4.1. Categorisation of Commissioning Projects

4.1.1. Starting Premise. We start with the premise that thevalue of commissioning is essentially one of systematic risk

reduction, that is, used to minimise the risk associated withthe installation of a new piece of equipment. More specicallythe application of commissioning for the installation of newequipment into the process industry reduces the risk ofequipment damage, environmental health and safety, andprocess downtime.

us commissioning is a strategy for treating risk [24].is has the further important implication that the treatment,hence type of commissioning, can be aligned with thedegree of technical risk that the organisation can accept.us we specically link commissioning, as a treatmentstrategy, to the concept of tolerable risk within the riskmanagement literature, and to the concept of strategic riskfor the organisation as a whole [25]. is also has contractualimplications in project-setup phase, where there is a needto differentiate between the commissioning risk elementsand proportion them between the equipment manufacturer,project management organisation, and plant owner [26].

From this starting assumption we identify three cate-gories of commissioning, as strategies in response to organ-isational risk-tolerance. ese are direct commissioning,advanced commissioning, and parallel commissioning. Eachhas strengths and weaknesses. ey can be deployed individ-ually or together.

4.1.2. Direct Commissioning. Direct commissioning is theclassical approach to commissioning where the new equip-ment is installed and the system must remain offline ascommissioning is completed. Direct commissioning is themost straightforward approach as no additional equipmentor simulation is required. e new equipment is installed intoits operational position and the process cannot restart until

the system has been commissioned and is running correctly.ere is a high level of downtime in this process as the wholesystem cannot be operated until the new unit is electrically,mechanically, and operationally tested. ere is also the riskof having to reinstall the old unit if there are signicantcomplications at any phase of the commissioning process.Direct commissioning is oen reserved for well-establishedunit operations such as new pumps and ow meters. Directcommissioning is most effective when it is used on well-established system and ones that are not a key requirementof the process.

4.1.3. Advanced Commissioning. Advanced commissioning

is the process of operating the new unit in advance of installa-tion and in isolation of the main process operation. Advancedcommissioning requires the simulation of all proprietarysystems that interact with the new unit. Simulation can beextremely complicated or simple depending on the levelof interaction between the process and the new unit. (Inthis context simulation can refer to the articial provisionof physical inputs to the new machine or unit, smallerscale models, and mathematical modelling of the functionalbehaviour of the unit.) Advanced commissioning allows forthe electrical, mechanical, and part of the operational testingto be completed. e full functionality of the unit cannotbe proven as the system is being simulated by external

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means, which will always be an approximation of reality.Advanced process is extremely valuable for the developmentof new technology as it allows for the verication of novelprocesses at low risk. e most common type of advancedcommissioning is the development of model systems whichboth simulate the operation of the system and the new

unit. Advanced commissioning can also include computersimulation of new process which provides a cost effectivemethod of developing concepts in the early stages of design.Advanced commissioning is valuable at proving conceptualdesigns of new technology. e main drawback of advancedcommissioning is that the process is only simulated so thereis still the potential that the unit can fail when installed intoits operational environment.

4.1.4. Parallel Commissioning. Parallel commissioning is thetesting of the new system in parallel to the operating system.Parallel commissioning is the most rigorous form of physicaland operational commissioning. It allows for the new unit

to be tested under full operational conditions, with lowrisk of signicant process interruptions due to the addedredundancy of the old system present in an operationalcapacity. However it also has the highest cost as it requires theduplicate hardware systems and additional structural space.e only risk associated with parallel commissioning is theintegration between the two systems. Oen there is some typeof switching or merging component in these systems whichmay require minor process stoppage for installation. Parallelcommissioning is oen completed when it is critical that theprocess must not stop for any extended period of time. Itoen lends itself to processes with few interactions betweennew unit operation and the rest of the process. Parallel

commissioning is seldom utilised due to the requirement ofa process that can accommodate both the new and old unit.

4.2. Conceptual Model. Having identied three types ofcommissioning, we next seek to set those within a conceptualframework. is is worth doing as it has the potential toidentify the situational variables relevant to each type ofcommissioning. is in turn can be used to further build atheoretical foundation, and provide guidance to practition-ers.

4.2.1. Approach. e modelling method uses a structured,deductive process to decompose the process being analysed

into multiple subactivities (functions) and for each deducethe initiating events, the controls that determine the extentof the outputs, the inputs required, the process mechanismsthat are presumed to support the action, and the outputs. emodel was then inductively reconciled with elements of theexisting body of knowledge on this topic, and successivelyrened. e end result is a graphical model that describesthe relationships between variables, thereby providing asynthesis of what is known and surmised about the topic.e model is expressed as a series of owcharts using theintegration denition ero (IDEF0) notation [27, 28]. WithIDEF0 the object types are inputs, controls, outputs, andmechanisms (ICOM) and are distinguished by placement

relative to the box, with inputs always entering on the le,controls above, outputs on the right, and mechanisms below.

4.2.2. Develop Production Capability (Prd-1). e broadercontext is that commissioning occurs as part of the develop-ment of production capability, and our model starts at this

level. (is is already the second level into the model; thetop level, which is not shown here, includes product design,operation of the plant, control of production ow, quality,distribution to market, packaging, health and safety, lean/JIT,among other activities. However the present paper focuses onthe commissioning activities.) See Figure 2. Commissioningis included as element 5 and occurs towards the end of theplant-development process. Other important activities arethe following.

(i) Determine manufacturing/production sequence.

(ii) Design of the production plant, which also includesthe plant layout, material handling, plant control and

automation, and (for manufacturing) the develop-ment of production tooling and ow control, forexample, just-in-time (JIT). Analysis of technologyrisk (9) is another activity associated with the designphase.

(iii) Building the production system (4), and the associ-ated project management activities.

(iv) Decommissioning the plant (7).

(v) Project management (8). We note the importance ofproject management methods in supporting manyof the activities of commissioning. ere are severalmodels of project management that might be inserted

here, including [9, 29], but these are not specic tocommissioning and therefore not detailed further atthis point.

We do notdeal with these other activities here, but insteadmove the focus to the test and commission activities. Beforedoing so, we draw attention to some hollow arrows, whichrepresent errors, in particular design and construction errors,at (2) and (4), respectively, and the possibility for unintendedplant behaviours at (5): low productivity, safety issues, staffusability problems, product quality defects, and so forth. ispoint is important because the commissioning model thatfollows specically seeks to address these risks.

4.2.3. Test and Commission Production System (Prd-1-5). emodel for commissioning a new piece of plant equipmentis shown in Figure 3 (Prd-1-5). e conventional commis-sioning process is included here, as are the new concepts forcommissioning approach. One of the conventional activitiesis to verify instrumentation and control systems (1), whichinvolves the systematic checking of installed hardware againstplant schematics. e checks are progressively done for con-nectivity, cold operation, hot operation, and process control.We do not detail those processes here and instead refer thereader to source material [5] which has information that isuseful to practitioners. e nal objective of commissioning

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Concurrentengineeringconstraints from elsewhere,(e.g. manufacturing,marketing), ergonomics,

styling

Project decision(approval, remedial action)

Develop production capability (Prd-1)

Design theproduction plant

(2: Prd-1-2)

Candidate solutionand context of system

Design ofplant

Design tools, (e.g.computer aided design)

Build productionplant and system

(4)

ResourcesBuilt system

(plant,equipment)

Projectmanagement,

constructionmechanisms

Test andcommissionproduction

system(5: Prd-1-5)

Test schedule,commissioning

approach

Teststimuli

System ready forend user- e.g.productioncapability

Design

errors

Constructionerrors

New plant designwith reduced

risk of failure orharm

Analysetechnology risk(equipment and

operators)(9: MfR)

Manage project(8: Pm)

Control processflow

(3: Prd-3)

Productioncontrol

processes

Manufacturabilityconstraints (feedback

to design)

Supply chain: networks ofothers (includingpartnerships) for

manufacture and deliveryof the organisationsproducts/services

Determinemanufacturing

sequence(1: Prd-1-1)

Design document(instructions for fabrication),

(e.g. specified geometry,materials, manufacturing

process, tolerance) (see Nv-2)

Manufacturingprocess

Decommissionsystem

(7: Prd-7)

Systemrecycledfor otheruse

Research newproductionprocesses

(6: Prd-6)

Novel processes,substantial

improvements on

existingprocesses

Lifetime parts

requirementto storage

Research anddevelopment

Economic viability,efficiency of

technology, hazards,

legal requirements,maintenance needsProjectmanagement alsoprovidesmechanisms tosupport many ofthe other activitieson this page

Risk managementmethods

Occupationalhealth and safety

methods

Unintended plantbehaviours: low productivity,safety issues, staff usabilityproblems, product qualitydefects

F 2: Model for the development of production capability.

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Perform tests onnew machine(4: Prd-1-5-4)

Verifyinstrumentation

and controlsystems (1)

Systematic checking of

installed hardwareagainst plantschematics.

Progressive checkingfor connectivity, cold

operation, hotoperation, process

control (see Practicenote 09:

commissioning capitalplant)

Built hardware

New hardwarewith

operationalcontrols

New machinetakes partial butreal production

load (5)

Provenfunctionality

in principle of

new hardware

Provenfunctionality

of new

hardware

New machinetakes a full

production load

(6)

Plant operatingas intended:

meetingperformance

specifications

Ongoingadjustments to

increaseproductivity and

quality (7)

Projects to furtherimprovement

machine, upgrades

Contractualobligations

fulfilled

Physically set upmachine in

commissioningsituation (3)

New hardwareready to

accept testloads

Select commissionapproach

(2: Prd-1-5-2)

Directcommissioning:

machine taken offlineduring changeover

Factors to consider:

(i) Plant usage, operational needs, desired continuity of production

(ii) Existing parallel flow that can keep plant operational

(iii) Degree to which new technology is well- established. Risks in the new technology

(iv) Feasibility of simulating plant behaviour

(v) Consequences if commissioning process encounters difficulty. Risk tolerance of organisation

(vi) Feasibility of the various commissioning approaches

Advancedcommissioning:

new machineinitially operatedin isolation with

simulated inputs

Parallelcommissioning:

new machineoperated in

parallel with oldand progressively

takes load

System ready for enduser, e.g., production

capability

Unintended plantbehaviours: low

productivity, safetyissues, staff usabilityproblems, product

quality defects

Test and commission system (Prd-1-5)

eapproaches

can becombined

F 3: Model for the test and commissioning activities.

is also well known, to deliver an operational productionsystem (6) that is ready for the client to use.

Where our model differs is the inclusion of a deliberatestage of deciding which of three commissioning approachesto use in the situation (2): direct, advanced, or parallel. Wealso note in passing that the quality and lean imperativefor continuous improvement will generally mean that there

will be ongoing adjustments to increase productivity andquality (7) aer the machine has been commissioned. uscommissioning the machine and closing the contract withthe client may be the end of the involvement of the machinebuilders, but are not the end of the life cycle for the machineitself. is again has contractual implications in the formof service and warranty support from the vendors, and

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Select directcommissioning

approach

Directcommissioning:machine takenoffline during

changeover

Select advancedcommissioning

approach


new machineinitially

simulated oroperated in

isolation

Select parallelcommissioning

approach


new machine

operated inparallel with

old

New

machine

Newmachine

F 4: Relationship between the three commissioning approaches: advanced, parallel, and direct.

reliability centred maintenance by the plant operators. ereis also the decommissioning to consider, which can be a

project in itself. (In extreme cases, e.g., nuclear power plant,the cost of decommissioning is comparable to the initialconstruction cost. If there has been a catastrophic failure ofthe plant then the decommissioning cost can vastly exceedthe construction cost.)

4.2.4. Select Commission Approach (Prd-1-5-2). e decisioninvolves a choice of direct, advanced, or parallel commission-ing. ese are not mutually exclusive. Instead some of themmay be done sequentially, as shown in Figure 4. For example,advanced commission may precede either of the other two.

e various factors relevant to this commissioning deci-

sion are anticipated and clustered in groups: ability torecover from a failed installation, assessed or perceivedtechnology risk, desired operational continuity, and timingconsiderations. e detailed model and the factors withineach cluster are shown in Figure 5. At this stage the modelis primarily logical and qualitative and is intended as adebiasing tool and a guide to action rather than a decisionalgorithm. It is also a framework for further research inthat it proposes subjective relationships of causality that cansubsequently be tested and developed as appropriate. (It mayeven be that in certain areas it could be possible to developa mathematical model to support the decision, particularlyin well-dened areas. Specically, the model incorporatesrisk assessment and it is not impossible that there could bewell-dened situations wherethe variables can be determinedwith sufficient precision that a quantitative risk assessmentcoupled with (say) a Boolean consideration of the otherfactors might make for a sufficient mathematical model.However further research would be required to take it to thislevel of detail.)

us the model proposes that the following decisionfactors are relevant.

(i)Advancedcommissioning is appropriate where tech-nology risk is high, operational continuity is required,and timing constraints are tight.

(ii)Parallelcommissioning is appropriate where opera-tional continuity is required and timing constraints

are tight.

(iii)Direct commissioning is appropriate where tech-nology risk is low, operational continuity can bedisrupted, and timing constraints are loose.

Finally, to complete this part of the conceptual frame-work, a model is provided for the testing activities ofcommissioning; see Figure 6.

5. Case Studies

Two cases studies were completed to determine the relevance

of this commissioning model in the process industry. Firstwas the development of a novel vertical screw system inthe fertilizer industry which used the advanced approachto commissioning. Second was the installation of a shipunloader in the aluminium industry which used a parallelapproach to commissioning.

5.1. Vertical Screw Project. Ballance Agri-Nutrients singlesuperphosphate plant at Awarua (New Zealand) had recentlydesigned and installed a new phosphate rock feed system. Anew vertical screw system was developed to replace the oldgravity feed vertical chute which was prone to blockages inthe highly reactive and humid environment present in the

reaction chamber. e vertical screw was designed to increasethe reliability of the process by forcing the rock into thereaction chamber, hence reducing the number of blockages.Anadvancedapproach to commissioning was completed forthis new project dueto therisk associatedwith theinstallationof a complex and untested unit into a critical position in theproduction line.

e advanced approach to commissioning allowed forrigorous testing to be completed in a controlled environmentwith low risk to production capacity. Commissioning wascompleted in two stages with the development of a modelsystemand fullscale commissioning of the new systembeforeinstallation.

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Select commission approach (Prd-1-5-2)

Select directcommissioning

approach (3)

Directcommissioning:machine takenoffline duringchangeover

Ability to recoverfrom failed

installation (4)

Factors to consider:(i) Existing parallel flow that can keep plant operational

(ii) Permanence of the change

(iii) Ability to cover functionality with other plant

(iv) Ability to accept a temporary reduction in production

Ease ofaccommodating

a failedinstallation

Assess technologyrisk (5)


(i) Degree to which new technology is well established(ii) Risks in the new technology

High risk (severeconsequences withhigh likelihood) oftechnical problemsat commissioning.Note that multiple

approaches can becombined

Low risk oftechnical problems

(mild consequences)

Projectmanagement:

estimate work,resources, and timerequired to completethe commissioning,including any timerequired for further

tweaking to get plantto target productivity/

yield

Select advancedcommissioning

approach (1)


new machineinitially simulated oroperated in isolation

Select parallel

commissioningapproach (2)


new machineoperated inparallel with

old

Riskmanagement:(ISO31000)

predictconsequence

and likelihoodof outcomes(MfR-1-3)

Desiredoperational

continuity (6)


(i) Plant usage, operational needs, desired continuity of production

(ii) Existing parallel flow that can keep plant operational

(iii) Service and warranty support from the vendors

High necessity foroperationalcontinuity

Low necessity foroperationalcontinuity

Timingconsiderations (7)


(i) Availability of times of low demand on plant(ii) Size of operational window compared to expected commissioning

time

Timing is too tightto accommodatecommissioning

Little or no timingconstraint

New

machine

Newmachine

Plant improvement cycle:subsequent optimisation of plantproductivity or quality by testing,

modelling, and simulation

Tolerance levels for risk in this context(may be implicit or explicit). See also risk

attitude (ISO31000).

Perceived size of risk load relative toorganisational capability to carry the

consequences, or personal self-efficacy tofind a solution if things dont work out

F 5: Factors relevant to the commissioning decision.

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Perform tests on new machine (Prd-1-5-4)

System readyfor end user,

e.g.,productioncapability

Built system(plant,

equipment)

Create testcriteria (1)

Reliability required(e.g., MTBF)

Create testenvironment (2)

Load on product,test environment,data acquisition,

and protocol

Criteria andscope ofdesiredsolution

Based on variableload andoperating

environment

Definition offailure/success

Description ofenvironments

(transport,storage, usage)

Conduct test (3)

Learn fromfailures (4)

Predict reliability(5)

Release machineto routine

production (6)

Increase load toaccelerate test

Failure modeand

qualitativeobservations

from test

ImprovedproductFailure data

Statisticalprediction of

reliability

Confidenceintervals and

otherstatisticalmethods

F 6: Model for the test activities.

Development of the model system allowed the basicconcept of the system to be tested. e model was constructedout of crude materials and was tested under a range ofconditions to determine the optimal operating parameters.e full scale vertical screw was designed and constructedbased on the results obtained from the model system.

Commissioning was completed by operating the systemunder a set of conditions established to simulate normal

operation. e simulation was completed by assembling thenew system directly adjacent to its intended future positionin the operational plant. It was wired into the system usingall of the nal wiring components but was not installed intothe process. feed hopper was tted to the inlet of the screwto simulate the priority feed system and water and variousother components were used to simulate the environmentof the reaction chamber. e operation of the vertical screw

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F 7: Advanced commissioning of vertical feed screw during

plant operation. Image shows plant being fed with material via atemporary arrangement while being commissioned. (Photograph byK Lawry and used by permission of Ballance Agri-Nutrients.)

during the advanced commissioning phase can be seen inFigure 7. e process of running the system under simulatedoperating conditions allowed the full commissioning of themechanical and electrical systems. It also allowed for thepartial commissioning of the operation capacity. During thisprocess it was found that several components did not operateas expected. Changes were made to the system and were re-commissioned without any negative effect to the production

capacity of the plant.e process of commissioning prior to the installation of

the vertical screw into the system was extremely successful.Full mechanical and electrical commissioning was completedas the full electrical system was used to drive the advancedcommissioning process. e operational testing identiedseveral design aws in the vertical screw. It also reducedthe uncertainty associated with the operation of this newtechnology.

Advanced commissioning has one signicant drawback;it only reduced risk associated with the installation of the new

vertical screw. e simulated process cannot represent thereal process exactly. ere are several factors such as continu-

ous operation in the highly reactive environment that cannotbe tested until the system is fully installed. Nonetheless theadvanced approach was effective in eliminating latent defectsand thereby reduced the overall risk.

5.2. Tiwai Point Ship Unloader. New Zealand AluminiumSmelters (NZAS) in Bluff installed a new ship unloader onthe Tiwai wharf for the unloading of alumina and cokefrom incoming ships. e new unloader produced by AlesaEngineering Ltd. replaced the forty-year-old unloader thatwas installed when the smelter was rst constructed in 171.e new unloader has a signicantly increased capacitycapable of discharging at 1,000 tonnes per hour (TPH) of

F 8: Parallel operation of old (le) and new (right) shipunloaders on the Tiwai wharf. (Photograph by K Lawry.)

alumina and 600 TPH of coke compared to the old unloaderthat was only capable of discharging 235 TPH of alumina and250 TPH of coke [30]. e new ship unloader was installedwith the aim of reducing the time required for a ship tospend unloading. Less time spent unloading willmean a more

efficient use of shipping resources and the reduction of costsassociated with slow turn around (demurrage).Installation and commissioning was completed by Alesa

underthe guidance of specialist project engineeringcompanyBechtel who work onsite at the Tiwai point aluminiumsmelter. is process had to be completed under tightconstraints as it was critical that there were no processinterruptions. e smelter is a continuous process whichcannot be shut down or restarted without high associatedcost.

It was decided to take aparallelapproach to commission-ing; the old unloader must remain in a fully operational stateuntil the new system has been thoroughly commissioned andproven capable of carrying the full operational load.

Keeping the old ship unloader in an operational statesignicantly reduced the risk of supply interruptions, butintroduced additional concerns relating to the integrationof the two systems. Integration of both unloaders on thesame wharf was completed by limiting the operation of theold unloader to the north half of the wharf, while the newunloader was installed and commissioned on the south half,as seen in Figure 8. Limiting the old unloader to half of thewharf increased the unloading time as the ship had to bemanoeuvred around to allow access to all of the holds. iswas taken as a minimal sacrice to ensure consistent supply.

e main modication that was required for the integra-tion of the new unloader into the existing infrastructure was

the installation of a new conveyor systemto replace the south-ern half of the existing wharf conveyor, clearly this has costimplications. is was completed before the new unloaderwas installed. Both the new and old conveyor systems oper-ated as one continuous conveyor that serviced the new andold unloaders simultaneously. e upgrade of the conveyoracted to integrate the two unloaders into the overall process.e new conveyor and ship unloader were constructed andassembled off site. e units were then transported andlied into place. e use of pre-constructed assembled unitssignicantly reduced installation time, therefore allowinginstallation to be completed in the short window betweenscheduled shipping movements.

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Several complications emerged during the commission-ing, and these extended the project duration. However theparallel approach meant that these had no impact on theoverall production capacity of the smelter. e reductionin unloading capacity caused by the limitation of the oldunloader to the north half of the wharf was quickly offset

by the high capacity of the new unloader even when it wasoperating at a reduced output. Parallel commission provedto be a successful method of commissioning as there wererelatively minor additional costs and the risk of processdowntime was completely mitigated. e old unloader wasdecommissioned once the new unit was fully operational[31].

6. Discussion

is paper makes several novel contributions. First, it pro-vides a novel conceptual framework for the commissioningprocess.e model represents the decision making within the

process, the broader context in which plant commissioningoccurs, as well as making provision for the ner details.e novelty is creating a structured representation of thecommission process, where models are otherwise sparse.Commissioning is generally an ad hoc process, and the

value of this new framework is that it provides a structuredtheoretical foundation for this important activity.

A second contribution is the categorisation of com-missioning into three main types: advanced, parallel, anddirect. is exposes the variability of strategies within thecommissioning process, so it becomes apparent that thereis not merely one universal approach to commissioning.Achieving this adds choice to the project planning. It makes

it clear that there are choices that practitioners can make, andstating these choices encourages a thoughtful considerationof the planning and resource implications thereof. iscategorisation thus adds richness to the conceptual modeland makes the decision points more explicit, without beingprescriptive.

A third contribution is the development of a model foruse by practitioners. e model captures and represents theproposed situational variables (contingency factors) involvedin the process. is is valuable for informing the decisionmaking of practitioners. e applicability of the model hasbeen demonstrated by case studies.

A fourth contribution is the integration of commis-

sioning into other management models. e model pro-vides integration with the risk management and projectmanagement disciplines. is is valuable because it showspractitioners how commissioning may be approached in amore holistic manner. e commissioning model is alsointegrated into a wider model for the development of pro-duction plant, and thereby into manufacturing engineeringincluding quality and lean manufacturing. Space does notpermit full description of this integration, but the point isthat the work shows that this integration is indeed feasible.e model is represented in IDEF0 notation, which is aproduction engineering notation, meaning that it is readilycomprehendible in that context.

Overallwhat hasbeen achieved is to replace the otherwisead hoc process of commissioning with a systematic processcomplete with proposed decision factors and internal modelsof causality. ere are implications for practitioners in themodel, in the form of owcharts identifying the criticalsuccess/failure factors for commissioning. us tentative

recommendations can be made for the best commissioningapproach for a given situation.ere are also implications for further research. e

model is at least partly conjectural, andfurther research couldbe directed at establishing the validity of the proposed causalrelationships. Another strand of research could be directed atfurther renement of the model,and itsextension deeper intospecic cases, that is, further investigation of the situational

variables.

7. Conclusion

Commissioning is extremely valuable to all projects but is

poorly dened in the project management body of knowl-edge. e existing literature on commissioning is focussedon specic tasks, and holistic perspectives are lacking. iswork has reconceptualised commissioning and shown thatit is possible to identify three main types of commissioning(direct, parallel, and advanced) and construct a generalisedconceptual framework around them. is approach to com-missioning has been demonstrated by application to casestudies.

e value of this work is that it presents a different andmore structured way of thinking about commissioning. isallows for a more critical examination of how to complete thecommission fora particularproject, andultimatelythe poten-

tial for a better commissioning outcome for practitioners.For theorists the benet is that a generalised model has beendeveloped, thus a foundation for future advancement of thesubject. We have shown that the commissioning activities canbe integrated into the risk management, project management,and production engineering bodies of knowledge.

Acknowledgments

e authors would like to thank Ballance Agri-Nutrientsand Richard Sweney at New Zealand Aluminium Smeltersfor providing the information required for the cases studies.ese cases studies provided a valuable insight into how

commissioning is completed in industry and would not havebeen possible without the help from these organisations.

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