For projects to be successful, they must take a systems-based approach starting right from the beginning. Let’s explore what that means and how to implement it effectively.
What Is a Systems-Based Approach?
You often hear project managers and commissioning professionals talk about the importance of a systems-based approach. Traditionally, project managers develop a Work Breakdown Structure (WBS), which divides the project into work packages. While this is useful for organizing tasks, it doesn’t necessarily align with how systems will be started up at the end of the project.
Similarly, construction teams develop work packages in the sequence that best suits the construction process. However, to ensure successful commissioning and startup, work needs to be handed over in a subsystem and system format. This is where a systems-based approach comes into play.
Adapting the WBS into a Systems-Based Approach
A systems-based approach means adapting the WBS to ensure that the project’s activities, physical assets, and documentation deliverables are grouped by subsystems and systems. This alignment with commissioning and startup ensures that these components are handed over as fully complete and functional units, rather than in incomplete pieces.
Starting a systems-based approach at the beginning of the project defines clear goals for each subsystem and system. This prevents the common issue of differing definitions of “done” and ensures that design and construction teams know exactly what is needed for commissioning to proceed effectively.
Why Is a Systems-Based Approach Important?
When a project is broken down into subsystems and systems, it allows for smaller, functional areas to be tested before they are integrated into the larger plant or process. This makes it easier to identify and resolve issues early, ensuring a smoother overall startup.
Additionally, the sequence in which these subsystems are handed over is critical. Technical dependencies often dictate the order in which systems need to be completed. For example, you can’t energize a 230kV switchyard without first completing the transmission line that connects to it. Similarly, a plant process subsystem can’t be started if the incoming piping needed to deliver process fluids isn’t in place.
Pitfalls of Not Using a Systems-Based Approach
When commissioning teams are not involved from the beginning, systems and subsystems may not be defined early enough, leading to project WBS or construction sequences that don’t align with commissioning needs. This can result in out-of-sequence work, where completed construction doesn’t meet the technical requirements for commissioning to proceed.
For example, imagine a plant process subsystem is ready for startup, but the incoming header hasn’t even been ordered. This out-of-sequence completion causes significant delays while commissioning teams wait for critical components to arrive.
How to Implement a Systems-Based Approach
The best way to implement a systems-based approach is through early commissioning involvement. This doesn’t mean bringing in testing personnel early, as there is little to test at the beginning of a project. Instead, it means engaging the commissioning project manager from the outset. This individual works with design and construction teams to ensure that all three phases of the project—design, construction, and commissioning—are aligned from start to finish.
To implement a successful systems-based approach, engage your commissioning project manager early. They will help you prepare the project by aligning activities, systems, and documentation with the necessary sequence to ensure that commissioning and startup proceed smoothly.
For more information on how to adopt a systems-based approach to your projects, consider becoming a member of the Industrial Commissioning Association. Membership is free, and there are plenty of resources available to help you develop this approach early in your project.
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