Commissioning teams are small compared with a peak construction workforce, but they are harder to staff. The people are specialists, they are needed for a defined window, and timing is unforgiving. Arrive too early and they sit idle while construction finishes. Arrive too late and completed systems wait for them. Building a commissioning workforce plan comes down to three things: defining the roles, sizing the team and timing mobilization against system turnover.
What is a commissioning workforce plan?
A commissioning workforce plan defines the roles, numbers, competencies and mobilization dates of the people needed to commission a facility, based on the systems to be commissioned and the order in which they will be turned over. It sits within overall workforce planning but follows its own logic.
Typical commissioning roles
| Role | Main responsibility |
|---|---|
| Commissioning manager | Overall commissioning plan and interfaces with construction and operations |
| System or area leads | Driving specific systems from turnover through commissioning |
| Discipline commissioning engineers | Mechanical, electrical, instrumentation and control, process |
| Commissioning technicians | Tests, run-ins, loop checks and functional checks |
| Completions coordinator | Tracking checks, punch items and system status in the database |
| Document controller | Test records and turnover packages |
| Vendor representatives | Package equipment checks and warranty requirements |
| Operations personnel | Running the plant during commissioning and startup |
The wider set of project positions is covered in technical roles needed for oil and gas projects.
Step 1: Start from the system list
List every system and subsystem with its planned turnover date, complexity and discipline content. A utility air system and a compressor train do not need the same effort, and a headcount built without this list is a guess.
Step 2: Estimate effort per system
Count the work: loops, motors, valves, interlocks and procedures per system. Productivity data from earlier projects helps, adjusted for the client’s documentation and witnessing requirements, which can add a surprising amount of time.
Step 3: Build the histogram against turnover dates
Commissioning manpower should rise as systems are turned over, not before. The early team is small: the manager, system leads and completions staff building the database and procedures. Technicians build up as turnovers accelerate, and the peak usually comes with the main process systems and startup.
Step 4: Plan shift coverage for startup
Startup often runs around the clock. A plan that only covers day shift fails exactly when it matters most. Build night coverage and relief rotations into the plan from the start, especially for long startups.
Step 5: Manage the overlap with construction
Late in construction, both workforces are on site. Some construction personnel, particularly E&I technicians who installed the systems, can move into commissioning roles and bring useful system knowledge with them. Plan construction demobilization so that knowledge is not lost by accident.
Competency and selection
Commissioning roles need verified experience on similar systems. A CV that lists “commissioning” can mean anything from leading a startup to filling in test sheets. Structured technical interviews and reference checks are worth the time. Apex Core Engineering can assess candidates for commissioning roles through its manpower selection services, against the technical requirements of each position.
The team’s work begins at the gate described in the commissioning readiness checklist. For the overall scope, see industrial commissioning services.
Frequently asked questions
When should commissioning personnel be mobilized?
Leads and completions staff early in construction, technicians as system turnovers begin, with the peak around the main process systems and startup.
Can construction workers move into commissioning roles?
Some can, especially E&I technicians who installed the systems, provided they meet the competency requirements for the role.
How large should a commissioning team be?
It depends on the number and complexity of systems, the turnover schedule and the client’s documentation requirements, so it should be built up from the system list.
Plan your commissioning team with Apex Core Engineering.