Key Elements to a Successful Start-Up

The successful preparation and Start-Up of a new unit involves many elements and it is almost impossible to cover all of the associated activities in one article, as a result, Key Elements for a Successful Start-Up will be broken down into a number of segments.

Start-Up planning

Looking back on all of the activities associated with a successful Start-Up reminds us of the importance of including the Operations Group input in the FEED process, P&IDs reviews and all of the other activities pertaining to the project that would affect the operation of the facility. It is very important to initiate the Start-Up planning and scheduling as early as possible.

It is much more beneficial that you do the planning and scheduling up front and adhere to the schedule than do the planning and scheduling just prior to the activities deadline as so often happens. Every effort should be employed to keep items and entire activities from “falling through the cracks.” One recommended approach which has been proven to be effective many times is the Systems Approach.

Systems Approach

It is a proven fact this the best approach for keeping everyone informed and maintaining control of the project. A large number of the construction groups are not favorably receptive to this approach, so it is wise to have this stipulation discussed before the construction contract is signed. The systems are identified, prioritized and marked up on the appropriate P&ID’s. A system is defined as a grouping of pipe and equipment that is preferably the same specification.

It is the responsibility of the Operations Group to work with the Project Group to prioritize the systems for turnover in a specific manner and this information passed on to the Construction Group. The goal is to get the systems turned over from construction in an orderly fashion allowing some of the commissioning activities to commence at an earlier date. As the work is completed on each system the P&ID’s are redlined to indicate the completed activities.

Construction Period

It is of the utmost importance the Plant Operations and Maintenance Group stay involved with the Project during the Construction Period. They can be utilized in the QA/QC Department which will give them access to most of the Construction activities. There is no better training on the Project for the Plant Operations and Maintenance Group than actually witnessing the piping and equipment being installed, witnessing hydro tests, equipment being set, pumps dialed in, and aligned.

Naturally all of the Operations Group cannot be in the field at the same time, but a rotating schedule can be put in place very easily. At no other time will the Operators have a chance to be involved in an activity like this.

The Maintenance Group assigned to the Project must witness the setting of all equipment, read the Vendor material and spend as much time as possible with the Equipment Vendors. This is an important time for the Maintenance Group as it is their job to maintain the equipment once it is turned over from Construction and the Equipment Vendors are no longer at the site.