Commissioning is complex, and to complete projects efficiently, a standardized approach is essential. The ICA Global Commissioning Standard is a framework designed for all industrial plant, process, and energy system projects, providing a method for efficiently completing complex projects. In a recent presentation, I discussed how to apply this standard to your projects to ensure efficient completion. Listen in as we dive into how you can use this standard to maximize project success.
Today, we’ll review how to implement the ICA Global Commissioning Standard on projects without needing to be a technical expert in every discipline. This presentation aims to empower you to execute world-class commissioning and become a global leader in the field.
My name is Paul Turner, and I work with professionals on industrial plant, process, and energy systems projects, helping them become commissioning leaders who can complete projects on time and within budget by applying ICA standards.
If this isn’t your first experience with commissioning and things haven’t gone smoothly in the past, don’t worry. Commissioning information is often scattered, confusing, and may not apply to your specific project type, making it challenging to succeed. However, with the right guidance and standards, commissioning can be manageable.
The ICA Global Commissioning Standard and Industry Misconceptions
A common misconception is that commissioning only occurs at the project’s end. But commissioning is more effective when planned throughout the project lifecycle, starting from design and construction phases. Unfortunately, outdated approaches contribute to projects being late and over budget. The Industrial Commissioning Association aims to change that by helping you meet cost, schedule, and quality objectives while becoming a global commissioning leader.
The ICA Global Commissioning Standard has been developed to avoid pitfalls like unstructured approaches that lead to delays and budget overruns. This framework helps you start with the end in mind, ensuring a clear vision for project success.
Framework for Success
Let’s break down the framework for successful commissioning, covering three core “secrets” to commissioning success:
- Scaling the ICA Global Commissioning Standard
Whether your project is large or small, starting with the end in mind is crucial. As Stephen Covey suggests in The 7 Habits of Highly Successful People, successful projects require a clear vision from the start. The ICA Standard emphasizes planning each project phase to align with your end goals, ensuring a streamlined and organized process.
- Managing Commissioning Across Disciplines
The ICA Standard outlines how to handle various disciplines involved in a project without needing to be a technical expert in each one. This structured approach keeps everyone aligned and working towards the same commissioning goals.
- Securing Management Buy-In Early On
Getting early support from management is key. The ICA Standard includes strategies to involve stakeholders from the outset, setting a clear pathway for project success and avoiding delays.
My Journey with Commissioning
In the past 25 years, I’ve worked on various complex projects, from building satellites and rockets to power generation and wastewater treatment. These experiences taught me the value of high-quality standards. On one specific mega project in Canada, I led commissioning for an enormous HVDC link project, spanning 1,400 kilometers and requiring the integration of four billion-dollar sub-projects. The ICA Global Commissioning Standard provided the structured approach we needed to meet our goals.
During that project, I saw two contrasting approaches to commissioning from different EPC contractors: one followed a structured, planned approach, while the other adopted a “cowboy” approach, with minimal planning and documentation. The latter contractor faced costly delays and setbacks due to a lack of thorough testing procedures, while the former stayed on schedule. These experiences solidified my commitment to structured commissioning, and I’m passionate about sharing these best practices with others.
Commissioning is more than just on-site testing; it’s an entire process, 80% of which occurs before on-site activities even begin. By following the ICA Global Commissioning Standard, project teams can implement a structured commissioning plan that prevents costly delays and delivers consistent success.
I hope this presentation helps you see the value of the ICA Global Commissioning Standard and motivates you to start your journey toward becoming a global commissioning leader.
The project involved a wastewater treatment plant with a budget ranging between $100 and $200 million. Though substantial, this was modest compared to the large-scale, multi-billion-dollar projects I had previously managed.
I joined the project when construction was approximately 60% complete. Due to the urgency, I had to cancel a planned trip to Italy to prioritize the commissioning, which was scheduled to begin in November — just two months after my September arrival. Upon arrival, I began preparing a commissioning plan. However, I quickly encountered a major obstacle. Despite the urgency, there would be no immediate commissioning on site. Significant issues had already arisen, rooted in the early stages of the project. Notably, there was no commissioning involvement in the design and procurement phases, leading to unqualified contractors being selected.
The pre-qualification process had allowed an inexperienced group to bid and win, which had long-term consequences. The team was underqualified and lacked essential quality management processes for commissioning, creating significant project challenges.
Consequences of Ignoring Commissioning Standards
The consequences were substantial. Due to the oversight in commissioning involvement, the project was delayed by three years and exceeded the budget by millions. Ironically, the “savings” from hiring a lower-cost contractor were far outweighed by these losses.
Despite my efforts to implement a structured commissioning approach, the contractor lacked the internal management processes and the skill sets needed for quality management. This costly mistake highlighted the importance of early commissioning involvement, even for projects of a smaller scale.
The Value of a Methodical Approach to Commissioning
This experience was a reminder that commissioning isn’t only for large-scale projects. A methodical approach, such as following the ICA Global Commissioning Standard, ensures every project starts with a clear end goal. Regardless of project size, early commissioning efforts align all project elements and reduce the need to reinvent processes for each new project. Otherwise, teams risk “cowboy commissioning,” where a lack of consistency leads to delays and increased expenses.
Types of Projects Requiring Commissioning
Commissioning generally falls into two categories:
- Building Commissioning: HVAC and life safety systems, following standards like ASHRAE, NEBB, and CSA.
- Industrial Commissioning: More complex, involving integrated systems with operational considerations. The ICA Global Commissioning Standard is ideal for these projects, as they include high-voltage substations, renewable energy, wastewater treatment, and other complex industrial facilities.
Managing Commissioning without Technical Expertise in All Disciplines
When starting with commissioning, it’s common to feel pressured to know the technical details of each discipline. However, effective commissioning is about managing a team of subject matter experts.
For instance, while commissioning a large 230 kV hydrogen-filled synchronous condenser, the contract required rigorous tests, including a short-circuit test at full speed. Lacking direct experience in this test, I brought in an expert to ensure safe and precise execution. This demonstrated that commissioning is more about coordination — guiding and integrating experts to create a cohesive, successful process.
Securing Management Buy-In for Commissioning
Management often views commissioning as an additional expense rather than a critical component of project success. They might assume it’s only necessary at the end or believe contractors can handle it without dedicated resources. To secure buy-in, it’s essential to present commissioning in terms of budget, timelines, and project success rather than technical jargon.
For example, in the Bipole III project in Canada, a proactive commissioning approach led to rigorous testing of control cubicles in the factory before installation. This saved considerable time on-site and minimized issues. In contrast, Muskrat Falls, a similar project, faced substantial delays and costs due to inadequate early testing. Public scrutiny and headlines highlighted the issues, and a subsequent inquiry documented these mistakes.
Securing Management Buy-In for Commissioning
Management often views commissioning as an additional expense rather than a critical component of project success. They might assume it’s only necessary at the end or believe contractors can handle it without dedicated resources. To secure buy-in, it’s essential to present commissioning in terms of budget, timelines, and project success rather than technical jargon.
For example, in the Bipole III project in Canada, a proactive commissioning approach led to rigorous testing of control cubicles in the factory before installation. This saved considerable time on-site and minimized issues. In contrast, Muskrat Falls, a similar project, faced substantial delays and costs due to inadequate early testing. Public scrutiny and headlines highlighted the issues, and a subsequent inquiry documented these mistakes.
When management sees the impact of commissioning in terms they value, they begin to appreciate it as an investment in success rather than an expense. Early and methodical commissioning is a proactive step that can safeguard timelines, budgets, and the long-term quality of a project.
When I started framing my discussions around risk reduction, cost savings, and efficiency—rather than just the technical aspects—I found that management was much more open to listening to these ideas. It turned out to be much easier than I thought. When the message is right, you can make all the difference. You can show management that commissioning isn’t an expense; it’s a safeguard.
What’s Next? Implementing the ICA Global Commissioning Standard
Now that we’ve covered the first two secrets of commissioning success, how do you actually start implementing the ICA Global Commissioning Standard on your projects?
Here’s how:
- Scale the Best Practices – Take the information I gave you in Secret #1 and scale the commissioning best practices in the ICA Global Commissioning Standard to the size of the projects you work on. Whether you’re dealing with massive, multi-billion-dollar projects or smaller, less complex projects, this standard can apply.
- Assemble Your Team – Use Secret #2 to assemble your commissioning team of subject matter experts (SMEs), so you don’t have to be an expert in everything yourself.
- Get Management Buy-In – Use Secret #3 to gain management buy-in for implementing these new commissioning processes on your projects. With management support, you’re more likely to achieve commissioning success from the start.
The Journey Toward Mastering Commissioning
Commissioning is a complex process, and it can feel overwhelming, like drinking from a fire hose, especially when you’re first starting. That’s why I recommend the Industrial Commissioning Association (ICA), which offers a progression path to help you along your commissioning journey.
The Stages of Your Commissioning Journey:
- Cowboy Commissioning – When you’re first starting out, commissioning may feel like a brute force method. Projects lose time, and commissioning is done reactively. At this stage, you’re likely losing money due to costly delays.
- Mission-Driven Commissioning – By around 60% completion of construction, you begin having a more structured approach, although still reactive. At this point, commissioning is being managed, but projects still suffer from delays due to last-minute planning.
- Proactive Commissioning – As you progress, you start planning commissioning at the beginning of the project. This is a much more active and focused approach, minimizing time and money wasted.
- Certified Excellence – The final stage is where you become a certified commissioning expert. You’ll be at the top of your game, planning and coordinating commissioning for complex projects, and you’ll be part of an elite group of commissioning professionals leading the industry.
ICA’s Programs for Every Stage of the Journey
The ICA offers training and resources for every stage of your commissioning journey, whether you’re just starting or are an experienced professional:
- Intermediate Planning Program – Designed for those who are at the mid-construction phase and need to refine their commissioning practices.
- Advanced Planning Program – For those who want to plan commissioning from the start, including during FEED (Front-End Engineering Design) and procurement.
- Certified CX PM Program – After gaining sufficient experience, you can become a Certified Commissioning Project Manager (CX PM), joining the top 1% of commissioning experts. This program certifies that you have mastered the art of commissioning and are ready to lead the most complex projects.
Please listen to this episode to learn more about ICA’s Program.
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