When it comes to large, complex projects, commissioning is an essential activity to ensure that the project goals are achieved. It is the process of verifying that all project components have been designed, installed, and tested according to the project specifications, safety standards, and required regulatory criteria.
This process is an important way to ensure that equipment is fit for its intended use and purpose. In this article, we will explore the benefits of using commissioning experts for a project and the steps that companies go through when they enlist these services.
The Benefits of Commissioning
Commissioning has numerous benefits. To start, it helps ensure that the project is of high quality and meets all the required standards. It minimizes issues that may arise during the project's qualification and validation stages and helps to lower safety risks. The process helps ensure that all systems and equipment are functioning as intended and all user requirements are met. When executed correctly. the project is more likely to operate as designed, a meet project timelines and costs.
Steps in the Commissioning Process.
Planning:
This first stage is essential to ensure that all parties involved understand the project's scope, objectives, timelines, and resource requirements. The commissioning plan is created during this stage, defining the commissioning RACI, required documentation, and execution strategy. If you plan to leverage commissioning testing for qualification, then planning is critical to set yourself up for success.
Factory Acceptance Testing:
For some complex systems/pieces of equipment, a Factory Acceptance Testing (FAT) is critical to ensure equipment is designed per specification before leaving the factory. Taking the opportunity to complete testing and potentially discover major issues, allows for corrections prior to equipment leaving the factory, a point at which a significant payment is usually due.
Mechanical Completion:
The mechanical completion stage comes at the end of construction, and it confirms that equipment is installed per design. The construction and commissioning team inspect the installation in the field, against documents like piping and instrumentation diagrams (P&ID). In this stage, a punchlist is generated, with all critical issues being resolved prior to moving to full system testing.
Pre-commissioning:
At this stage, cleaning and flushing of pipes, pressure testing, and leak testing of mechanical systems are done, and continuity checks, loop checks, and verification of any wiring are done to ensure the electrical systems are up to standard. If any deficiencies are identified, they are categorized and rectified.
On-Site Testing:
The final stage is the on-site operational testing, which verifies that the equipment has not been damaged during shipping and operates per design. It is the stage to detect any issues caused by shipping, installation or operation, electrical and mechanical commissioningcommissioning, and minor updates since FAT. This step ensures that the equipment can communicate with all field devices, and all equipment is calibrated correctly.the system/equipment is ready to move to qualification activities.
Find a Team That Your Business Can Rely On
Bothwell Engineering is a network of expert engineering consultants who provide cutting edge solutions to pharmaceutical, biotech, cell, and gene therapy companies. If you are looking for support with commissioning one new piece of equipment or whole facility of equipment, we’re confident we have the team you need to help your project execution be completed on time and within budget.
If you need help with a new product line or set of procedures, you can learn more about the services we offer online, or you can subscribe to our free newsletter to stay on top of your industry’s latest trends.
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