This document provides a brief review of commissioning and start-up activities. If you are not familiar with commissioning activities and find yourself in a situation where you need to provide some input on commissioning costs, this document will give you the basic understanding.

1. Cost Estimating Considerations

2. The Purpose of this Document

3. The Purpose of this Document
Is to assist the cost estimator in understanding of:

4. The Purpose of this Document
Is to assist the cost estimator in understanding of:
• Commissioning activities

5. The Purpose of this Document
Is to assist the cost estimator in understanding of:
• Commissioning activities
• Costs associated with commissioning activities

6. The Purpose of this Document
Is to assist the cost estimator in understanding of:
• Commissioning activities
• Costs associated with commissioning activities
• Costs allocation of commissioning activities

7. The Purpose of this Document
Is to assist the cost estimator in understanding of:
• Commissioning activities
• Costs associated with commissioning activities
• Costs allocation of commissioning activities
What this document it is not:
• A guide to commissioning and start-up cost estimating.

8. The Purpose of this Document
Is to assist the cost estimator in understanding of:
• Commissioning activities
• Costs associated with commissioning activities
• Costs allocation of commissioning activities
What this document it is not:
• A guide to commissioning and start-up cost estimating.
Commissioning and start-up cost estimate is developed by firms which
specialize in the field of commissioning.

9. Commissioning - Definition
Commissioning can be defined as:

10. Commissioning - Definition
Commissioning can be defined as:
Use of a systematic, pre-defined methodology, to convert a newly built industrial
facility into a fully integrated and operational unit, meeting the design
parameters.

11. Commissioning - Stages

12. Commissioning - Stages
1. Pre-commissioning

13. Commissioning - Stages
1. Pre-commissioning
• Consists of activities performed during the construction phase: installation and testing
of equipment.

14. Commissioning - Stages
1. Pre-commissioning
• Consists of activities performed during the construction phase: installation and testing
of equipment.
• This stage is also referred to as “mechanical completion”.

15. Commissioning - Stages
2. Commissioning

16. Commissioning - Stages
2. Commissioning
• During this phase, the various systems of the new facility are put into initial operation.

17. Commissioning - Stages
2. Commissioning
• During this phase, the various systems of the new facility are put into initial operation.
• Is performed in two steps:

18. Commissioning - Stages
2. Commissioning
• During this phase, the various systems of the new facility are put into initial operation.
• Is performed in two steps:
• Dry commissioning. This step includes tests and procedures performed before any process or safe
chemicals are introduced into the system. In this category we can include control system checks,
major motors initial running.

19. Commissioning - Stages
2. Commissioning
• During this phase, the various systems of the new facility are put into initial operation.
• Is performed in two steps:
• Dry commissioning. This step includes tests and procedures performed before any process or safe
chemicals are introduced into the system. In this category we can include control system checks,
major motors initial running.
• Wet commissioning. During this step, safe chemicals are introduced into the system and the whole
process in put through operating scenarios, to assess and achieve the normal operation of the
facility, as per design expectations.

20. Commissioning - Stages
3. Start-up

21. Commissioning - Stages
3. Start-up
a. The facility is brought into normal operation.

22. Commissioning – Step-by-Step
1. Appointment of commissioning team

23. Commissioning – Step-by-Step
1. Appointment of commissioning team
• Define the scope of commissioning

24. Commissioning – Step-by-Step
1. Appointment of commissioning team
• Define the scope of commissioning
• Appoint the commissioning manager

25. Commissioning – Step-by-Step
1. Appointment of commissioning team
• Define the scope of commissioning
• Appoint the commissioning manager
• Develop commissioning plan

26. Commissioning – Step-by-Step
1. Appointment of commissioning team
• Define the scope of commissioning
• Appoint the commissioning manager
• Develop commissioning plan
• Appoint commissioning team

27. Commissioning – Step-by-Step
2. Handover from construction team to commissioning team:

28. Commissioning – Step-by-Step
2. Handover from construction team to commissioning team:
• Check-out all installations, punch lists, labeling, packaging, factory acceptance testing,
etc.

29. Commissioning – Step-by-Step
2. Handover from construction team to commissioning team:
• Check-out all installations, punch lists, labeling, packaging, factory acceptance testing,
etc.
• Actual handout from construction team to commissioning team.

30. Commissioning – Step-by-Step
2. Handover from construction team to commissioning team:
• Check-out all installations, punch lists, labeling, packaging, factory acceptance testing,
etc.
• Actual handout from construction team to commissioning team.
• Implement system to manage scope change during commissioning.

31. Commissioning – Step-by-Step
3. Commissioning

32. Commissioning – Step-by-Step
3. Commissioning
• Equipment testing

33. Commissioning – Step-by-Step
3. Commissioning
• Equipment testing
• Systems testing

34. Commissioning – Step-by-Step
3. Commissioning
• Equipment testing
• Systems testing
• Dry commissioning

35. Commissioning – Step-by-Step
3. Commissioning
• Equipment testing
• Systems testing
• Dry commissioning
• Wet commissioning

36. Commissioning – Step-by-Step
3. Commissioning
• Equipment testing
• Systems testing
• Dry commissioning
• Wet commissioning
• Training and safety

37. Commissioning – Step-by-Step
3. Commissioning
• Equipment testing
• Systems testing
• Dry commissioning
• Wet commissioning
• Training and safety
• Adjust equipment and systems

38. Commissioning – Step-by-Step
4. Start-up

39. Commissioning – Step-by-Step
4. Start-up
• Introduce process chemicals

40. Commissioning – Step-by-Step
4. Start-up
• Introduce process chemicals
• Commissioning on process chemicals

41. Commissioning – Step-by-Step
4. Start-up
• Introduce process chemicals
• Commissioning on process chemicals
• Adjust equipment and systems

42. Commissioning – Step-by-Step
4. Start-up
• Introduce process chemicals
• Commissioning on process chemicals
• Adjust equipment and systems
• Develop operations and maintenance personal training program

43. Commissioning – Step-by-Step
5. Final verification against design parameters of:

44. Commissioning – Step-by-Step
5. Final verification against design parameters of:
• Equipment

45. Commissioning – Step-by-Step
5. Final verification against design parameters of:
• Equipment
• Process

46. Commissioning – Step-by-Step
5. Final verification against design parameters of:
• Equipment
• Process
• Product

47. Commissioning – Step-by-Step
6. Handover to Operations and Maintenance Team:

48. Commissioning – Step-by-Step
6. Handover to Operations and Maintenance Team:
• Commissioning documentation,

49. Commissioning – Step-by-Step
6. Handover to Operations and Maintenance Team:
• Commissioning documentation,
• Training and safety, operating procedures materials,

50. Commissioning – Step-by-Step
6. Handover to Operations and Maintenance Team:
• Commissioning documentation,
• Training and safety, operating procedures materials,
• Train operations and maintenance team to the final operating parameters of the new
facility.

51. Commissioning – Cost Estimate Considerations
1. Pre-commissioning

52. Commissioning – Cost Estimate Considerations
1. Pre-commissioning
• All associated costs are included in the equipment installation, therefore are part of the
construction costs,

53. Commissioning – Cost Estimate Considerations
1. Pre-commissioning
• All associated costs are included in the equipment installation, therefore are part of the
construction costs,
• Additional costs include the construction team to commissioning team handover.

54. Commissioning – Cost Estimate Considerations
2. Commissioning costs are comprised of:

55. Commissioning – Cost Estimate Considerations
2. Commissioning costs are comprised of:
• Commissioning team costs,

56. Commissioning – Cost Estimate Considerations
2. Commissioning costs are comprised of:
• Commissioning team costs,
• Contractor and vendor/manufacturer costs associated with its presence onsite to
perform any adjustments or interventions as required by the commissioning team,

57. Commissioning – Cost Estimate Considerations
2. Commissioning costs are comprised of:
• Commissioning team costs,
• Contractor and vendor/manufacturer costs associated with its presence onsite to
perform any adjustments or interventions as required by the commissioning team,
• Operations and Maintenance personnel training costs.

58. Commissioning – Cost Estimate Final
Considerations

59. Commissioning – Cost Estimate Final
Considerations
To properly determine the cost of commissioning and start-up, we require an
actual commissioning plan, specifically prepared for the project.

60. Commissioning – Cost Estimate Final
Considerations
To properly determine the cost of commissioning and start-up, we require an
actual commissioning plan, specifically prepared for the project.
Typically, the Project Owner will appoint the commissioning manager. Therefore,
the commissioning and start-up costs will be provided by the commissioning
manager.

61. Commissioning – Cost Estimate Final
Considerations
To properly determine the cost of commissioning and start-up, we require an
actual commissioning plan, specifically prepared for the project.
Typically, the Project Owner will appoint the commissioning manager. Therefore,
the commissioning and start-up costs will be provided by the commissioning
manager.
In the early stages of the project design, we can use factors to estimate
commissioning and start-up costs.

62. Commissioning – Cost Estimate Final
Considerations
To properly determine the cost of commissioning and start-up, we require an actual
commissioning plan, specifically prepared for the project.
Typically, the Project Owner will appoint the commissioning manager. Therefore, the
commissioning and start-up costs will be provided by the commissioning manager.
In the early stages of the project design, we can use factors to estimate commissioning
and start-up costs.
For most industrial facilities, the commissioning and start-up costs are approx. 3.5% of
the total capital cost of the project. Of course, this factor will vary depending on the
complexity of the new facility equipment, systems and processes.

63. Your turn now!
I hope you enjoyed flipping through these slides and thank you for your
curiosity.
What is your experience with commissioning and start-up cost estimating?
Please leave your comments below.
If you want to read more articles about cost estimating for construction projects,
please visit my blog: http://www.LearnCostEstimating.com