When beginning a major capital project, it’s essential to have a clear vision of the project’s goals. In all cases, the primary objective is to meet your in-service date with successful commissioning and startup. This requires a clear definition of what success looks like during commissioning right from the start. Projects, like any endeavor, benefit from a well-defined goal—you wouldn’t start a marathon without knowing where the finish line is. Similarly, a project without a clear endpoint will lack direction and efficiency.
Understanding Commissioning
Today, we’re discussing why every project must start with commissioning. This approach can save time and money—without needing extra resources.
I’m Paul, and I guide organizations involved in industrial, process, and energy systems to become leaders in commissioning by applying ICA’s global standards. Commissioning is a critical, yet often misunderstood, phase in projects. Many organizations have had poor experiences with commissioning, which is understandable, given the lack of clear, standardized information on the topic. The right guidance is rare, which leads to avoidable challenges and unmet project goals.
The Myths and Realities of Commissioning
Contrary to common belief, commissioning should not be relegated to the end of a project. In fact, some industry groups benefit from projects running late or over budget. However, the ICA’s approach aims to ensure projects meet their cost, schedule, and quality targets. We’re here to help you consistently deliver successful projects.
Who Will Benefit
This presentation is designed for two types of organizations:
- Those new to commissioning: ICA provides best practices to implement world-class processes.
- Those needing advanced methods: ICA helps mature existing strategies for peak commissioning performance.
By following ICA’s global commissioning standards, organizations can achieve efficient and on-budget project completion.
My Journey in Commissioning
Over the last 25 years, I’ve had the privilege to work on various large projects, from satellite and rocket construction with the Canadian Space Agency to HVDC transmission and hydroelectric generation projects. My experiences have shown me the impact of high standards in project execution. For example, on a recent $5 billion mega project, we saw the difference between structured commissioning and a “cowboy” approach.
One contractor’s lack of structured planning resulted in a catastrophic failure, costing months and millions of dollars. Conversely, another contractor’s thorough documentation and planning led to an on-time project completion. This experience reinforced my belief in structured commissioning as the key to project success.
Why a Structured Approach Matters
In projects with complex systems, coordinating various groups with differing goals is challenging. Without a cohesive commissioning plan, projects can turn into costly messes. A structured approach helps align all teams toward the common goal, ensuring efficiency and reducing costs.
The Cost of Commissioning Mismanagement
Through my work on complex projects, I saw that a well-planned commissioning process prevents delays and cost overruns. For example, research from Professor Bent Flyvbjerg at the University of Oxford shows that 92.5% of projects run over time and budget, largely due to lack of structure. By following ICA’s standards, project teams can avoid these pitfalls and deliver on time and budget.
Key Takeaways
In the next half hour, we’ll discuss the “Three Secrets to Commissioning Success”:
- Scaling the ICA Global Commissioning Standard: Apply these standards to any project size.
- Starting with the End in Mind: Define your project’s end goals clearly.
- Using Commissioning as a Strategic Tool: Save time and money with a planned commissioning approach.
By establishing clear objectives and structured commissioning processes, you can transform project outcomes, saving both time and resources.
To achieve a successful project with an efficient in-service date, a methodical commissioning process is essential. This approach aligns with the ICA Global Commissioning Standard, which defines the necessary steps and requirements throughout the stages of a project—from front-end engineering design (FEED) to procurement, construction, and commissioning—to ensure that projects are completed seamlessly.
Framework for Commissioning Success
- Front-End Engineering Design (FEED) and Procurement
- The ICA Global Commissioning Standard emphasizes that commissioning considerations must start early, during FEED and procurement. Key elements include incorporating commissioning requirements into construction contracts and ensuring that commissioning input is part of design reviews. This guarantees that lessons learned from past projects are applied effectively, aligning early efforts with the end goal of project completion.
- Early Construction Process
- Defining mechanical completion packages, an integrated construction and commissioning schedule, and conducting factory acceptance testing (FAT) are all critical steps during early construction. These steps ensure that equipment is tested and validated before being shipped to the project site, significantly reducing the chance of issues during onsite testing.
- Construction Completions and Onsite Testing
- Once construction concludes, a series of rigorous pre-commissioning, commissioning, and startup activities verify that all systems operate as intended. Performance verification and trial operation ensure optimization of these systems, preparing them for seamless integration into operational use.
- Final Stages and Handover
- During the last phase of the project, systems are transferred to operations. This transition involves training operating teams on maintaining and managing the new facilities, as well as completing all required commissioning closeout tasks.
Case Study: Lessons Learned from a Wastewater Treatment Project
One project I worked on—a wastewater treatment plant—highlighted the consequences of insufficient commissioning planning. I was brought into the project when construction was 60% complete, and commissioning was intended to begin immediately. However, fundamental project flaws became evident. Due to a lack of commissioning involvement during FEED and procurement, the project had awarded work to an unqualified group, resulting in delays, quality issues, and cost overruns.
The Importance of Starting with the End in Mind
Commissioning only during the final stages is just the tip of the iceberg. Onsite testing comprises just 20% of the commissioning process, yet it often receives disproportionate attention. The remaining 80% of commissioning tasks—those “below the surface”—are what ultimately make onsite testing successful. When these tasks are neglected, projects face delays, budget overruns, and compromised quality.
Two Types of Commissioning Processes
- Building Commissioning
- This process, often used in typical construction projects, includes systems like HVAC and life safety systems.
- Industrial Commissioning
- The ICA Global Commissioning Standard specifically addresses industrial commissioning, which is crucial for more complex systems that require integration across electrical, mechanical, and automation components. Projects such as substations, LNG plants, and data centers require this rigorous, coordinated approach due to the interdependent nature of their systems.
Case Study Comparison: Bipole III vs. Muskrat Falls
The contrasting outcomes of two similar power projects—Bipole III and Muskrat Falls—demonstrate the impact of proactive commissioning. Bipole III prioritized extensive offsite testing, which streamlined onsite testing and reduced issues. In contrast, Muskrat Falls suffered costly delays and budget overruns due to deferred and inadequate commissioning, resulting in public scrutiny and lessons learned the hard way.
Using Commissioning as a Strategic Tool
Rather than viewing commissioning as an end-stage expense, organizations should adopt commissioning as a proactive tool for reducing project risks. A commissioning-led approach saves both time and money by identifying potential issues early, allowing for more efficient project completion.
Conclusion: The Path Forward
To improve project outcomes, organizations should integrate the ICA Global Commissioning Standard into their delivery strategies. By adopting a proactive, structured commissioning approach, projects can achieve significant cost and time efficiencies. The Industrial Commissioning Association offers resources, training, and certifications like the CxPM to enhance project teams’ commissioning capabilities, guiding them toward successful, on-time project completions.
For more information on incorporating commissioning best practices and standards into your projects, reach out to the Industrial Commissioning Association at info@ixa.net.
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