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01-Mar-13
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An Overview of the Commissioning CyclePresented by Norman
Kirwan-WardGlobal Completions and Commissioning Manager
Sponsored by the IICA and EA
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Agenda
Completions and Commissioning
Systems Completion
A Framework for Completions and Commissioning
Systems Commissioning Database
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01-Mar-13
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Completions
The management, development, planning and preparation for the
final stages of a project, when new or upgraded plant and equipment
is checked, tested, commissioned and started up to first time
operational status.
Completions begin during the early stages of a project where
budget and schedule, organisational structure, general
documentation and information requirements, supplier deliverables
and site requirements are identified. It continues through all the
other stages culminating in the completed and first time
operational facility being turned over to the Operator for care,
custody and control.
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Commissioning
The checks, tests and demonstration that prove the plant and
equipment have been built to the plans and specifications and
perform to the design intent. Commissioning can also be described
as the field tasks of the completions process.
Field commissioning commences during the construction phase
(Commissioning Stage 1 - Mechanical Completion Constriction
Verification etc.) and culminates with the facility started up to
first time operational status.
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A Framework for Completions
Failure to PLAN is a plan for Failure
A framework for Completions (and Commissioning) is in effect a
master plan for completions
Lets walk through a Completions Framework
This master plan aligns with most of the global top shelf
Operators expectation for a structured and considered commissioning
process
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Systems Completion Concept
An important part of successful commissioning is to break down
the plant into System and Sub-systems with clearly defined boundary
limits directly related to the start-up sequence
System Completions facilitates the progressive early start up in
planned stages.
This is a proven methodology that introduces inherent
efficiencies into the commissioning process.
The greatest hurdle to Systems Completions is the transition by
the constructor from Area Build to System Delivery
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Completions Framework
Identify Evaluate Define
Detail
Engineering &
Procurement
Stage 1
Mechanical
Completion
Stage 2
Function
Testing
Stage 3
System
Commissioning
Stage 4
Start Up &
Ramp Up
Operation &
Performance
Testing
Interim
Facility
Turnover
IDENTIFY EVALUATE DEFINE EXECUTE OPERATE
IDENTIFY
(Pre-feasibility
studies)
EVALUATE
(Conceptual
Engineering)
DETAIL
ENGINEERING
& DESIGN
DEFINE
(Front End Eng
& Design; Cost
Estimating &
Execution Plan)
CONSTRUCTION / COMPLETIONS ENGINEERING SUPPORT
Dry Commissioning Wet/Live Commissioning
Early Procurement
ActivityProcurement
Early FAT
Activity
CONSTRUCTION DEVELOPMENT &
PREPARATIONS
Factory Acceptance Testing
CONSTRUCTION
CONTRIBUTION
Early Construction
Activity
FABRICATION , INSTALLATION
& CONSTRUCTION
COMPLETIONS
CONTRIBUTION
COMPLETIONS DEVELOPMENT &
PREPARATIONS
Commissioning STAGE 1
Commissioning STAGE 2
Commissioning STAGE 3
Commissioning STAGE 4
Attend to Punch Lists
Operation &
Performance Testing
Facilities TurnoverCompletions Manpower
Opportunity to Manage Risk
COMPANY PROJECT PHASES Support across all project delivery
phases
COMPLETION FRAMEWORK STAGES
COMPLETION FRAMEWORK RELATIONSHIPS
PreFEED - input
to scope
development,
strategies and
budget and
schedule
FEED - Input into HSE strategies and plans
Input to project scope development & strategies
Contribution to budget and schedule
First Pass Systemisation & start up sequence
Coordinate data requirements from engineering
Risk and Constructability reviews
Develop the Completions Strategy and Management Plan(s)
Identify Completions Interfaces (including 3rd parties)
Identify REQ needing Commissioning input(including FAT)
Identify field commissioning opportunities for modular units
Identify a CMT
DETAIL DESIGN & PROCURE
interfacing with engineering and design
finalise collection of engineering data,
commence CMT population,
complete completions documentation,
finalise site preparations
Issue the Field Commissioning Documentation.
Special attention will be given to selected engineering
requisitions that require FAT.
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Commissioning - stages
Commissioning Stage 1 (MC) - Field checking and testing of
individual items of equipment to confirm compliance with drawings,
instructions and specifications- single discipline activity,
carried out on un-energised static
tagged items (device by device)- transition from Area Build to
System Delivery- Controlled by A Check sheets; managed by CMT
Commissioning Stage 2 (FT) - live testing- PTW comes into play
introduction of energy- verification equipment and loops are
functional - Controlled by B Check sheets; managed by CMT
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Commissioning - stages
Commissioning Stage 3 (SC) - multi-discipline- Tests and
measurements to prepare systems to ready for start
up or introduce product- Operations participation mandatory-
Controlled by purpose written procedures; managed by CMT
Ready for Start Up Milestone (RFSU) Confirmation facility is
ready for start up- Commissioning complete- Operator ready- PSSRs
undertaken and pre-start walk downs completed- Controlled by
purpose written procedures; managed by CMT
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Commissioning - stagesCommissioning Stage 4 (SU) - Introduction
of product, start up and steady, controlled ramp up to first time
operation- Controlled by purpose written procedures; managed by CMT
- Undertaken by Operator; guidance from commissioning team
Operation and Performance Tests defined tests and demonstrations
to confirm the facility meets the contract and design parameters. -
Controlled by purpose written procedures- Undertaken by Operator
using their operating procedures
Interim Facility Turnover - Formal turn over of the facility to
the Operator for care, custody and control pending the formal close
out of the project
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Completions Framework
SUMMARY Enables a structured approach Provides the opportunity
to minimize risk Can be adapted and applied to different types of
WorleyParsons
projects. Segregates a project into identifiable and
measurable
completions stages Identifies the tasks, control documents,
deliverables and risks for
each stage Provides guidance for managing the completions
and
commissioning activities during each stage Identifies the
transition from one stage to another Promotes cooperation and
collaboration
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Systems Commissioning Database- SCDB or CMT -
FUNCTION Systematic technical assurance approach to completing
projects Repository of all Completion data Supports the Completions
Framework Provides comprehensive turnover packages
VALUES Improves technical assurance Complete electronic
documentation speeds up system turnover Customized turnover
packages Equipment preservation management
MOST POPULAR SYSTEMS WinPCS; PIMS-CMS; QEDI-GoCMS; ORBIT
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Completions Framework
Identify Evaluate Define
Detail
Engineering &
Procurement
Stage 1
Mechanical
Completion
Stage 2
Function
Testing
Stage 3
System
Commissioning
Stage 4
Start Up &
Ramp Up
Operation &
Performance
Testing
Interim
Facility
Turnover
IDENTIFY EVALUATE DEFINE EXECUTE OPERATE
IDENTIFY
(Pre-feasibility
studies)
EVALUATE
(Conceptual
Engineering)
DETAIL
ENGINEERING
& DESIGN
DEFINE
(Front End Eng
& Design; Cost
Estimating &
Execution Plan)
CONSTRUCTION / COMPLETIONS ENGINEERING SUPPORT
Dry Commissioning Wet/Live Commissioning
Early Procurement
ActivityProcurement
Early FAT
Activity
CONSTRUCTION DEVELOPMENT &
PREPARATIONS
Factory Acceptance Testing
CONSTRUCTION
CONTRIBUTION
Early Construction
Activity
FABRICATION , INSTALLATION
& CONSTRUCTION
COMPLETIONS
CONTRIBUTION
COMPLETIONS DEVELOPMENT &
PREPARATIONS
Commissioning STAGE 1
Commissioning STAGE 2
Commissioning STAGE 3
Commissioning STAGE 4
Attend to Punch Lists
Operation &
Performance Testing
Facilities TurnoverCompletions Manpower
Opportunity to Manage Risk
COMPANY PROJECT PHASES Support across all project delivery
phases
WORLEYPARSONS COMPELTION FRAMEWORK STAGES
COMPANY COMPELTION FRAMEWORK RELATIONSHIPS
PreFEED - input
to scope
development,
strategies and
budget and
schedule
FEED - Input into HSE strategies and plans
Input to project scope development & strategies
Contribution to budget and schedule
First Pass Systemisation & start up sequence
Coordinate data requirements from engineering
Risk and Constructability reviews
Develop the Completions Strategy and Management Plan(s)
Identify Completions Interfaces (including 3rd parties)
Identify REQ needing Commissioning input(including FAT)
Identify field commissioning opportunities for modular units
Identify a CMT
DETAIL DESIGN & PROCURE
interfacing with engineering and design
finalise collection of engineering data,
commence CMT population,
complete completions documentation,
finalise site preparations
Issue the Field Commissioning Documentation.
Special attention will be given to selected engineering
requisitions that require FAT.
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SCDB Structure
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CMT Screen ShotDynamic System
readiness display
SubSystem
Summary
SubSystem
Details Tab
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CMT Reports