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Commissioning of

Combined Heat and Power Plants:


Lessons Learned
July 1, 2008
Presented by
Abbe Bjorklund, PE, LEED AP
Sebesta Blomberg & Associates
and
Bruce Nicholson
Cooperative Consulting Services, Inc.

Topics Covered

Beneficial commissioning processes


Roles and responsibilities
Benefits, costs and challenges of a formal
startup/commissioning process
Coordination and conflict between
construction startup/commissioning
OEM coordination issues and how to address

Beneficial Commissioning Processes


from Construction through Systems
Testing, Performance Testing,
Environmental Testing, and Reliability
Testing

Beneficial Commissioning
Processes

Design
Purchase
Install
Construct
Turnover to startup/commissioning
Equipment checkout
System testing/initial operation and system functional testing
Integrated system/plant functional testing
Performance testing
Environmental/compliance testing
Reliability/acceptance testing
Turnover to the Owners/plant final acceptance

Roles and Responsibilities

Roles and Responsibilities

Clearly define roles and responsibilities


through design, construction,
startup/commissioning

Designer
Constructor
Independent Commissioning Authority/Agent
Startup Engineer
Owner

Roles and Responsibilities

Construction and Startup


Where does construction end?
Where does startup begin?
Need to define formally for
each project
Construction testing vs.
Startup testing

Roles and Responsibilities

Startup and Commissioning


Where does startup end?
Where does commissioning begin?
Need to define formally for each project

Roles and Responsibilities

Examples from typical projects

Project Organization Chart


Roles & Responsibilities by Major Phase
Responsibility Matrix Construction Phase
Responsibility Matrix Startup & Commissioning
Phase

Example:
Project Organization Chart

Example
Roles & Responsibilities
Major Phases

Design Phase
Construction Phase
Design
Engineering

Procure

Install

Construction
Completion

Construction
Testing

Turnover
Package

Turnover
to Owners

Engineer of record

Commissioning
Agent
Construction
Manager

Turnover
to SU&C

Startup & Commissioning Phase


Component System
Plant
Testing
Testing
Testing

Startup & Commissioning Management

Construction Management

GTG Vendor

Construction

Startup & Commissioning Support

HRSG Vendor

Construction

Startup & Commissioning Support

General
Contractor

Construction

Startup & Commissioning Support

Inst & Controls

Construction

Startup & Commissioning Support

Electrical
Contractor

Construction

Startup & Commissioning


Support

Mechanical
Contractor

Construction

Startup & Commissioning


Support

Piping
Contractor

Construction

Startup & Commissioning


Support

Example
Responsibility Matrix
Construction Phase
Activity
Startup and Commissioning Program
Development
Typically 50 to 75 items such as:
Review systems turnover package list
Review scoped turnover package documents
Review Project Punchlist procedure

SU&C

CONSTRUCTION ORGANIZATION

CXing
Agent

CM

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X
X
X
X
X
X
X

X
X

OWNER

GTG

Representative

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X

X
X
X
X
X
X

X
X
X
X
X
X

Mech Piping Elec I&C HRSG

Construction Completion
Typically 20 to 30 items such as:
Complete Required Data Sheets and Test Records
Prepare System Completion punchlists
Perform System As-Built

Construction Testing
Typically 25 to 50 items such as:
Perform Nondestructive Testing
Perform Pressure Testing
Verify Installation of Instruments and Controls
Schedule Vendors Required for Construction Testing
Alignment of Rotating Equipment
Megger Cables and Equipment
Verify Installation is in accordance with Design
Required Equipment Maintenance
Interface with Startup on Systems Ready for Turnover
Assemble Initial Turnover Packages and records
Perform Turnover Walkdown and Exception Lists
Initial System Turnover (to SU&C)

X
X
X

X
X

X
X
X
X

X
X

X
X
X
X

X
X
X

X
X
X

X
X
X

X
X
X
X
X

X
X

Example: Responsibility Matrix


Startup & Commissioning Phase
SU&C
Activity

CXing
Agent

Startup & Commissioning Support Team


CM

Owner

Mech Piping Elec I&C HRSG GTG Operations

Component Testing
Typically 40 to 50 items such as:
Administer Startup Safety Tagging Program
Inspect, Test, and Calibrate Instruments and Loops
Test major Electrical Equipment
Megger Testing, Motor Rotation

X
X
X
X

X
X
X

System Testing
Typically 10 to 20 items such as:
Interface with local Utilities
Lineup System for Operation
Initial Energization of Power Supply Systems,
Rotating Equipment Initial Run In
Functional checks of Controls, Equipment & Systems

X
X
X
X

X
X
X
X
X
X

X
X
X

X
X
X

X
X

Plant Testing
Typically 40 to 50 items such as:
Perform Final HVAC Balancing
Fine Tune Combustion Controls
Final Tuning of Instruments, Controls, and Valves
Finalize controls & tuning settings, software
Execute System Functional Test Procedures
Performance, Emissions, Reliability Testing

X
X
X
X

X
X
X

X
X
X

Project Completion
Typically 20 to 40 items such as:
Finalize System Turnover Packages
Finalize Project Punchlist
Perform Turnover Walkdowns with Owners

Benefits, costs and challenges of a


formal startup and commissioning
process

Benefits

A formal program ensures that an organization


with commissioning experience is put in place
Formal program includes

Formal turnover process


Well-documented functional performance criteria
O&M documentation
Operator training program

Benefits

Track deliverables
Identified early in the project
Are a part of the Contract Specifications
Are formally tracked

Benefits
Track progress of construction and commissioning
with tools developed and implemented which allow
for easily tracking the overall process

Master Tracking Matrix


Notification schedule
Deliverables list
Integrated Construction and Startup/Commissioning
schedule
Project punchlist
System turnover exceptions lists

Costs

Turnover process may require an additional


person to manage
Formal documentation of testing activities
Time to develop formal test procedures, checklists
and datasheets
Staff hours for testing are relatively the same
Additional time to formally document test data and
results

Startup & Commissioning Program is typically


2 to 5% of the overall project.

Costs
Any cost increase should be offset at the end of the project
System turnover packages and documentation streamlines the
review and acceptance
Documentation can be reviewed on a system by system basis
System boundaries are defined
Each organization has same understanding of the scope of each system.
Owner's representatives spot checks the progress and results

Warranty claims can be handled smoothly both during the


startup/commissioning phase and after acceptance by the owners
Typically vendors will ask for test data such as:
vibration analysis, meggar records, system cleaning records, lubrication
records

Troubleshooting performed more quickly and accurately


The controls system historian and test data used to help identify root cause

Challenges
Proper planning early in the project with the right
people
Cxing plan that clearly defines roles and responsibilities
Detailed commissioning specifications which are included in
the RFP
All parties embrace a formal startup and commissioning
program and fulfill specified roles and responsibilities

Need an Owner that fully supports a formal startup and


commissioning program
General Contractor develops purchase orders and
equipment specifications that include requirements for
startup & commissioning

Challenges
Involvement of Owners operators in the
startup/cxing process
Initial operation of equipment and testing on a
campus
Some activities are loud, some are sudden and may appear
unusual.
Campus events can impact the activities of the project
Communicate a well thought out startup/commissioning
plan and schedule to the general campus population

Coordination and conflicts between


construction and
startup/commissioning organizations

Coordination and Conflict

Startup Engineer/Cxing entity should report


directly to the Project Manager
The Startup & Commissioning team should be a
peer of the Construction team
Each group has a direct line to the Project Manager

Detailed specifications issued with the RFP


help minimize conflicts later
Detailed lists of deliverables and tracking
mechanisms

OEM coordination issues


and how to address

OEM Coordination Issues

From pre-purchase through construction and


startup/commissioning:
Need to coordinate vendors for
startup/commissioning
Must work as a team
Startup Manager must be able to coordinate and
direct the OEMs

Beneficial Commissioning
Processes

Design
Purchase
Install
Construct
Turnover to startup/commissioning
Equipment checkout
System testing/initial operation and system functional testing
Integrated system/plant functional testing
Performance testing
Environmental/compliance testing
Reliability/acceptance testing
Turnover to the Owners/plant final acceptance

Thank you!
Questions???