Limestone RNG Commissioning – Overcoming Challenges for Project Success

The Challenge

Our client had embarked on a Renewable Natural Gas (RNG) recovery project in the Lorraine Basin, aimed at harnessing methane from a landfill gas field. However, they encountered significant challenges that jeopardized the project’s success. At the time of our intervention, the project was already 80% complete, yet it suffered from severe delays, cost overruns, and operational inefficiencies. Several key issues plagued the project:

1. Schedule Delays: The project was well behind schedule, leading to deferred production and increased costs.
2. Budget Overruns: The project had exceeded its budget, causing financial strain for the client.
3. Inventory Management: There was no organized system in place for locating spare parts and equipment on-site, leading to operational disruptions and downtime.
4. Lack of Continuity: Multiple managers had overseen the project, resulting in a lack of consistent leadership and project direction.
5. Absence of Systemization: There was no structured systemization process in place, and construction activities were not aligned with commissioning activities.

The Solution

To address these complex challenges and get the project back on track, our commissioning services team devised a comprehensive solution:

1. Early Systemization Process: We introduced a specialized early systemization process that was integrated into the project from the moment we took control. Instead of postponing systemization until the end of construction, we ensured that it was a concurrent and integral part of the project plan.
2. Inventory Management System: We established an efficient inventory management system, enabling the client to easily locate spare parts and equipment when needed. This significantly reduced downtime and operational disruptions.
3. Streamlined Project Management: Our team provided consistent and effective project management, eliminating the challenges associated with multiple managers and ensuring a unified project direction.
4. Alignment of Schedules: We correlated the project’s P6 schedule with the commissioning schedule, ensuring that construction and commissioning activities were synchronized. This alignment played a pivotal role in reducing delays and increasing project efficiency.

The Outcome

Our proactive approach and tailored solutions yielded remarkable results:

• Time and Cost Savings: By integrating systemization early in the project and aligning schedules, we saved over 5 months of deferred production and helped the client regain control over their budget.
• Inventory Efficiency: The implementation of an inventory management system reduced downtime, enabling smoother operations.
• Enhanced Continuity: Our project management approach provided consistent leadership, reducing confusion and enhancing project continuity.
• Future-Ready Systemization: The client received a robust systemization framework that can be applied in future operations, enhancing long-term operational efficiency.

In conclusion, our strategic intervention not only saved the Limestone RNG Commissioning project from further delay, but also positioned the client for future success in renewable natural gas ventures. By connecting construction and commissioning activities, we revitalized the project’s profitability and delivered results that exceeded expectations.

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