10_completion, Commissioning, Start-up.pptx

Management of Medium-Size / Revamping Projects Oil & Gas Downstream Projects 10. Completion, Commissioning, Start-up

RC - PR GES - 08176_A_A - Rev. 1 - 18/07/2013

Management of Medium-Size / Revamping Projects: course content I.

Introduction

II.

Preliminary Studies

III. Basic Engineering (or FEED)

IV. EPC Contracting V.

Organization and Engineering

VI. Procurement VII. HSE, Quality and Risk Management

VIII. Project Control (cost/schedule) X.

Completion / Commissioning / Start-up / Closure

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IX. Construction and Fabrication Management

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Scope and objectives

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Scope: • Completion of all construction activities • Transfer to Owner Operating staff (who normally assures start-up) • Remaining activities until dismantling of the project team

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Objectives: • Assure complete and satisfactory execution of project scope • Verify that Operations agree to take Ownership, and transfer it • Identify and implement post-completion project activities Technical (punch-list items resolution) Documentary (as built documents) Financial (claim settling, invoice payment) Managerial (feedback lessons)

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− − − −

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Completion activities

Provisional Acceptance

Routine operation START-UP COMMISSIONING EXECUTION PRECOMMISSIONING EXECUTION

CONSTRUCTION & PROCUREMENT

DETAILED ENGINEERING BASIC ENGINEERING

Preliminary and conceptual studies

Perf. Tests Ready for StartUp Mechanical Completion

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Commissioning activities through Project phases and completion activities

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Operations

PROJECT Pre-Project

General preparation

Completion activities

PHASE

ACTIVITIES

MILESTONE

CONFORMITY CHECKS PRECOMMISSIONING

STATIC TESTING

MECHANICAL COMPLETION

FLUSHING & CLEANING ENERGIZATION DYNAMIC TESTS COMMISSIONING

EQUIPMENT RUNNING-IN

READY FOR START - UP

START UP OF UTILITIES TESTS OF SAFETY SYSTEMS

START – UP

BRINGING PLANT ON LINE PERFORMANCE TESTS

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PROVISIONAL ACCEPTANCE

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OIL & GAS IN

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Completion activities Precommissioning - Commissioning 

PRECOMMISSIONING or mechanical completion (unit non energized): • • • •

Visual inspection of equipment (Power Generation, motors, cables...). Quality of installation. Compliance with Project drawings and specifications. “Cold testing”: calibration of instruments, machinery alignment, setting of safety valves, pressure testing of piping... (De-energized tests). • Pipes and vessels air or water flushing and cleaning. 

Normally, Project Team responsibility stops there (transfer to Ops)



COMMISSIONING: all activities carried-out before start-up (energized systems)

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• Electrical motors uncoupled runs, instrument loops tests, electrical breakers operation... • Running-in and on-line tests of plant utilities, and main process equipment in closed loop (wherever applicable). • Piping drying out and leak testing, inerting or loading of various chemicals. • Tests of all safety systems (gas detection, fire water…).

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System approach “From TRADE to SYSTEM approach” 

CONSTRUCTION: organized and split by Trades, disciplines (Civil work, structural, piping, electricity, mechanical…).



Commissioning Activities & Start-up: by system function A system is a part of an Installation (built of various trades) that performs a given operational function such as: Safety system Instrument air Fire water Oil separation

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• • • •

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System approach Projet without system approach

Project Projet with system approach

TIME BENEFIT

System 1 System 2

System 3

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Pre-Comm Comm Start-Up

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System approach

Oil

Utility Water

Fuel Gas

Oil to Utilities

ExchA

ExchB

ExchC Heat A

Heat B

Drain

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Sub-system break-down

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System approach

VESSELS & PIPING INSTRUMENTS

ELECTRICAL PUMP

MOTOR

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MECHANICAL

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Precommissioning methodology

TASK

DISCIPLINE

NUMBER - 1 per item of equipment ( Field )

Conformity Checks

SUPPORT DOCUMENT - 1 Check List per type of equipment & subsystem (Field)

All - 1 Check List per package - 1 per package

- 1 List of checks in the Status Index

Static Tests

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Process

- 1 per subsystem or Network or TestPack

- 1 Test Sheet per test - List of tests in the Status Index - Specific procedure & report

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Flushing & Cleaning

All

- 1 test per specified item ( Field ) - 1 test per safety item ( Package )

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Precommissioning methodology

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Piping hydrotest sequence

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Commissioning methodology

TASK

DISCIPLINE

Preliminary Checks

All

NUMBER - 1 per subsystem

- 1 per package

Functional Tests

Operational Tests

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Test:multi-discipline

Process

- 1 test per Basic Function

- 1 task report form per subsystem + punch list items in Precomm. dossier

- 1 Functional Test Sheet List of tests in Technical Data Base

- 1 per subsystem or Network

- 1 operational Test Procedure by Subsystem, specific to the installation

- 1 per subsystem, or level of pressure, or main circuit

- Leak test, Inerting... reports, specific to the Installation

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Pre-Start up Activities

Electrical Instruments Telecommunication

SUPPORT DOCUMENT

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Commissioning methodology



System component: Basic Function • Item or group of items that performs an elementary function of the plant (ex: a pump) • It is the smallest item which can be submitted to energization in a Commissioning operation (ex: a switch) • e.g.: Switchboards, transformers, heaters, process control loops, loudspeaker loops, pumps, vessels, etc.



System: made of subsystem, themselves made of system component (ex: electrical power distribution) © 2013 - IFP Training

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Commissioning Organization

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Commissioning organization chart

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Commissioning Organization EPCC contract

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Split of Responsibility between Company and Contractor (TOTAL sample)

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Commissioning Revamping Projects: specific aspects When several S/D: package-wise construction completion, precommissioning and commissioning and acceptance



At ea. main S/D facilities built during pre-shutdown & S/D will be started

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Objective: as for construction, pre-commission / commission to largest extent before S/D in order to minimize S/D time

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Job Cards system (refer construction section) define “systems” for ea. JC which are part of commissioning sub-systems: a commissioning sub-system includes several JCs.



Very detailed preparation & planning of commissioning together by Company / Contractor/ Sub-Contractors, and together with construction is necessary.

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Commissioning Revamping Projects: specific aspects 

Overall commissioning schedule packages-wise according to completion requirements & available S/Ds



Shut-Down commissioning schedule will include broadly 3 sequential stages, detailed by sub-systems: • Step 1 (normally all by Company Operations): decommissioning, emptying, inerting, install blinds, venting (as required) • Step 2 (by Contractor, with work duration guaranteed by him): works detailed by JCs including construction / pre-com (and, in parallel for maintenance works, by Company and /or possibly by S/D or Maintenance Contractor)

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• Step 3 (normally all by Company Operations): inerting, remove blinds, filling, circulations as required (e.g. adsorbents), commissioning tests

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Acceptance of Facilities

Construction and precommissioning

Ready for commissioning (mechanical completion)

Start-up and operation tests

commissioning

Ready for start-up

Performance tests

warranty period To Gas Injection Wells

Ready for performance tests

Provisional acceptance Provisional certificate acceptance

Final acceptance

Performance guarantees (capacity, products, utilities, global operability, possibly some packages and/or equipment…)



Performance Tests duration will depend on work scope



Mechanical Guarantee will start as soon as facilities are operated

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Completion, Commissioning, Startup, Closure Key points to keep in mind 

Medium-size and Revamp projects: Project Team stops at Completion



Problems at the Mechanical Completion stage may lead to trouble: • • • • •

Inadequate or incomplete scope execution Unknown needs of operational staff Absence of some As Built Documentation Lack of Start-Up spare parts Communication deficiencies

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Commissioning and Start-up are normally done by Operations



The project is only complete when all financial matters are solved



Feedback lessons are important for Continuous Improvement

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• Invoices • Claims

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Attachments I. Integrated Commissioning

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Commissioning tool sample: ICAPS

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Commissioning tool ICAPS PREPARATION

EXECUTION

PUNCH LIST

OPERCOM

FORMS

PROGRESS

ENGINEERING

REPORTING

Total use ICAPS … but some other software are used like WINPCS, … RC - PR GES - 08176_A_A - Rev. 1 - 18/07/2013

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POPULATION

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Overall Sequence

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RC - PR GES - 08176_A_A - Rev. 1 - 18/07/2013

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Sequence & dossiers Precommissioning dossier Combined RFC Certificate

RC - PR GES - 08176_A_A - Rev. 1 - 18/07/2013

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One Dossier Per Sub-System

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Sequence & dossiers Commissioning dossier RFSU Dossier Index

RFSU Certificate

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One Dossier Per Sub-System

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Sequence & dossiers Hand-over dossier

RC - PR GES - 08176_A_A - Rev. 1 - 18/07/2013

One Dossier Per Hand Over Unit

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SUB SYSTEM ZZ

SUB SYSTEM YY

SUB SYSTEM XX

RFHO Certificate

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Sequence & dossiers Overall dossiers

308m

273m

206 HOU Dossiers 849 RFSU Dossiers 891 RFC Dossiers 1,946 Dossiers © 2013 - IFP Training

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