The Acquisition of Modern Aluminum Extrusion Systems

Part 6: Commissioning and Start-up
Definition: To put in working order.
Key Words: Acceptance, performance.

by Roger A.P. Fielding, BENCHMARKS

Commissioning and start-up, or more properly: installation, commissioning and start-up are the culmination of a process which has moved from motivation to change or enhance manufacturing facilities and equipment, through understanding of what might be involved, to the specification, evaluation and selection of a modern aluminum extrusion system.

Modern aluminum extrusion systems integrate the operations of log heater, shear, taper quench, extrusion press, press quenches, saws, pullers, handling systems, stretchers, finish cut saws, stackers and aging ovens. Although a typical project may include only part of the extrusion production system, the project is always motivated by the desire to make improvements to the total system, and the process of acquisition is invariably the same.

Six discrete steps have been used to describe the process of acquiring modern aluminum extrusion systems. The performance specification, which describes what is expected of the system, has been shown to be the key to developing an effective relationship between customer and supplier, and to the ultimate success of the project. The performance specification describes in words and numbers what is expected from the system. The performance standards are the basis for accepting delivery of the installation from the supplier.

The selection process, which was discussed in the last article, is dependent on rigorous comparison of the alternative proposals. Additions (or deletions) are made to each supplier’s proposal to bring all their offers into line, so that a true comparison can be made.

There’s no room for personal preferences! The selection process depends on Cost-Benefit Analysis to understand what they (the extrusion system, the equipment, and any changes to the equipment) do to the performance of the extrusion business in terms of safety, operating performance and cost.

Having selected and ordered the best alternatives, the work of installation, commissioning and start-up can proceed. Whether a new "green-field" installation, the expansion to an existing facility, or modifications to an existing extrusion press system, preliminary engineering for the installation will have been part of selection process. The new equipment will require foundations, electrical power, water, and compressed air. The operation of the new equipment will often impact on a plant’s heating and ventilating needs, and on its safety arrangements: walkways, guarding and fire protection. All of these issues will have been addressed during the selection process. The necessary changes must now be put in place before the new equipment is delivered.

A properly engineered system will be simple to install. Because of the rigorous selection process, budgets are easy to track. Project management is transparent.

Because commissioning – "putting into working order"– proceeds throughout the installation, the customer’s start-up team of supervisor, operators and maintenance people should be getting their training and exposure to the new equipment throughout much of the commissioning phase of the project. Start-up and acceptance of the new aluminum extrusion system is complete when it has been shown to meet the agreed performance specification.