Transition From Construction to Commissioning

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Best Practice Proceduresin the transition fromin the transition from

Construction to Commissioning

Deniz Metin KayaDirector of Construction OperationsFoster Wheler Italiana

© 2012 F Wh l All i h d

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012

© 2012 Foster Wheeler. All rights reserved.


Why transition from Construction to Commissioning is soWhy transition from Construction to Commissioning is so important?

• Safety environment is complex and difficult to manage

• Tight schedule: margins are usually eaten up by upstream project phases and little float to cope with unexpected events

• Major over-laps between various activities

• Number of participants are quite high compared to other project phases

• Stakeholders’ priorities sometimes conflict with each others

• Require very skilled and experienced personnel



What is Mechanical Completion ?What is Mechanical Completion ?

• Construction is completed in accordance with drawings, specifications, vendor instructions, applicable codes and regulations and authority requirements

• All inspection, checking and testing works are completed

• System(s) and/or facilities are ready for pre commissioning and commissioning• System(s) and/or facilities are ready for pre-commissioning and commissioning



What is Pre-Commissioning andWhat is Pre Commissioning and Commissioning?

• Non-operating adjustment adjustments and cold alignment checks (such as cleaning, drying and testing without introducing process and auxiliary fluids prior to equipment energization )

• Pre-startup, check-out, system adjustment, equipment and system activation activities to prepare system(s) and/or facilities for operation (by introducing auxiliary fluids and with equipment energization)



Completion & Turnover Map

Project Completion Data Base

Completion & Turnover Map

j p

E Area Driven Construction

System Completion

System Completion

Group of Systems Completion

ReaSE

ngineering

Construction

System Completion

System Completion Group of Systems

ady for PlaStart-up

g

Area Driven ConstructionSystem Completion

yCompletion

ant

f i i d Perform (pre)Preparation

& Data Validation

Measure construction progress Perform inspection and

test requirement

Measure progress.

Perform (pre) commissioning

inspection and test.

Measure progress.

Punch-Out &

Acceptance

Punch-Out &Acceptance



Road Map for MC by Systems and

Pre-Commissioning

Road Map for MC by Systems and Handover to Commissioning

Test Punch i TOD

MC

ConstructionPre Commissioning Commissioning

TOS Initial Final

Walkdown Check-out Pack List TODList Walkdown Punch List Testing



Construction Completion MilestonesConstruction Completion Milestones• TOS Self-contained portion of a facility/system for hand over

(Turn Over System)




• Test Package Set of documentation demonstrating the MC of a system or its subsystems or sections that can be isolated for test purposes





• Punch List Formal inspection and identification of remaining outstanding works






• Initial Walkdown Identification and closure of all category “A” punch items







• Final Walkdown Demonstration and acceptance of a pre-checked system for hand over & Punch List





P h Li t F l i ti d id tifi ti f i i t t di k• Punch List Formal inspection and identification of remaining outstanding works



• TOD Final dossier including all applicable as-built engineering documents and (Turn Over Dossier) construction certificates as per Inspection & Test Plan attesting the

fTHIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012

readiness for turn over







• TOD Final dossier including all applicable as-built engineering documents and construction certificates as per ITP attesting the readiness for turn over



Breakdown of Systems

System

Breakdown of Systems

y

Process

Systems

Standard

SystemsSystems Systems

Sub-Systems Sub-Systems

Disciplines Disciplines



Typical TOS List

BLACK UTILITIES TOS LISTSYSTEM SYSTEM NUMBER

RUNNING DESCTRIPTION TOS SUBSYSTEM TOS DESCRIPTION AREA

05.41‐BS10/8/3 010 BLACK STEAM

TOS‐05.41‐BS10‐001 BLACK STEAM 10 BAR BASEMENT BASEMENT

TOS‐05.41‐BS8‐001 BLACK STEAM 8 BAR DISTR. BASEMENT BASEMENT

TOS‐05.41‐BS3‐001 BLACK STEAM 3 BAR DISTR. BASEMENT BASEMENT

TOS‐05.41‐BS3‐002 BLACK STEAM 3 BAR DISTR. BULK 1 BULK 1

TOS‐05.41‐BS3‐003 BLACK STEAM 3 BAR DISTR. BULK 2 BULK 2

TOS‐05.41‐BS3‐004 BLACK STEAM 3 BAR DISTR. STERILE FILTRATION STERILE FILTRATION

TOS‐05.41‐BS3‐005 BLACK STEAM 3 BAR DISTR. CASA CASA

05.41-BSC10/8/3 011 CONDENSATE

TOS‐05.41‐BSC10‐001 CONDENSATE 10 BAR BASEMENT BASEMENT



TOS‐05.41‐BSC3‐002 CONDENSATE 3 BAR BULK 1 BULK 1

TOS‐05.41‐BSC3‐003 CONDENSATE 3 BAR BULK 2 BULK 2

TOS‐05.41‐BSC3‐004 CONDENSATE 3 STERILE FILTRATION STERILE FILTRATION

TOS‐05.41‐BSC3‐005 CONDENSATE 3 BAR BULK 2 CASA

05 41-CAI 012 CAI

TOS‐05.41‐CAI‐001 CAI 10 BAR DISTRIBUTION BASEMENT BASEMENT

TOS‐05.41‐CAI‐002 CAI 10 BAR DISTRIBUTION BULK 1 BULK 1

TOS‐05 41‐CAI‐003 CAI 10 BAR DISTRIBUTION BULK 2 BULK 205.41-CAI 012 CAI TOS 05.41 CAI 003 CAI 10 BAR DISTRIBUTION BULK 2 BULK 2

TOS‐05.41‐CAI‐004 CAI 10 BAR DISTRIBUTION CASA CASA

TOS‐05.41‐CAI‐005 CAI 12 BAR GENER. AND DISTR. CASA CASA



Test Pack IdentificationTest Pack Identification



Punching and Walkdown



Punch List ManagementPunch List ManagementPUNCH LIST RESUMING FOR

SUBCONTRACTOR

Punch List RegisterWN158-11.23-LIS-0001

Date 28-apr-12

CONTRACTOR orVENDOR

A B C NO GR. TOTALTo Close To Close To Close To Close To Close Closed Hold

CONTRACTOR # 1 43 88 6 1 138 301 0CONTRACTOR # 2 117 100 23 43 283 23 0CONTRACTOR # 3 3 32 0 0 35 0 0CONTRACTOR # 3 3 32 0 0 35 0 0CONTRACTOR # 4 17 89 12 4 122 232 0CONTRACTOR # 5 13 59 8 0 80 336 0CONTRACTOR # 6 28 135 15 0 178 248 0CONTRACTOR # 7 60 58 8 0 126 106 0CONTRACTOR # 8 0 0 0 13 13 0 0CONTRACTOR # 8 0 0 0 13 13 0 0CONTRACTOR # 9 0 0 0 1 1 0 0

VENDOR #1 23 10 1 0 34 27 0VENDOR #3 4 0 0 0 4 6 0VENDOR #4 49 18 0 0 67 33 0VENDOR #5 29 11 0 0 40 38 0VENDOR #5 29 11 0 0 40 38 0VENDOR #6 48 21 0 0 69 31 0VENDOR #7 0 0 0 0 0 28 0VENDOR #8 0 0 0 16 16 87 0

TOT 434 621 73 78 1206 1496 11180 1341 105 188 2814


1180 1341 105 188 2814


Punch List by Discipline & CategoryPunch List by Discipline & Category



MC & Turnover ProgressMC & Turnover Progress



Typical Project Statistics

Project 1 Project 2 Project 3 Project 4

Systems 350 340 140 250Units 3 37 13 7Units 3 37 13 7Isometrics 3,400 4,000 22,000 1,500Test packs 1,000 1,500 7,000 600

Inst Tags 3,500 4,200 17,000 5,000Loop Dossiers 600 850 4,750 2,000Check Sheets 60 000 50 000 200 000 45 000Check Sheets 60,000 50,000 200,000 45,000



What is needed to administer this

S d di d i f h i l l i d i i i

What is needed to administer thisTransition Phase

• Standardised preparation for mechanical completion and commissioning

• Maximization of electronic data transfer from engineering and project controls

C ti d dit bl t• Continuous and auditable progress measurement (physical vs. QC achievements)

• Management of system-wise completion

St t d d tifi d h d f ll di i li• Structured and certified handover for all disciplines

• Controlling tool for the creation and management of all QC and MC forms



Basis of TAG Assignment

At initial phase of engineering, each physical Object of the plant subject to a control:

• shall be TAG ged

• shall belong to a family (Object Class)

• shall be defined in case it does not represent an object (e.g: Hydrotest Circuit, Loop Folder, etc)



Typical Project Tree for TAG gingTypical Project Tree for TAG ging

Project1st Level Systems

2nd Level Sub-Systems

3rd Level Disciplines

4th Level TAGs



Assignment of Discipline TAGs

TOS

Assignment of Discipline TAGs

Civil:• Foundation List• Steel Structure List• Underground List (Pits,

Duct, Sewer, etc.)• Building

Instrument:• Instrument List• Cable List• Fire & Gas• More

TAG sEngineeringDisciplines

g

Piping:• Line List• ISO List• Hydro Test Pack

Equipment:• Rotating• Pressure Vessels• Heat Exchanger• MoreMore

Electrical:• Cable List• Equipment List• Grounding• More

HVAC:• Piping List• Cable List• Instrument List• Equipment ListMore • Equipment List



Turnover Vision

SystemSystem Acceptance C tifi t

Turnover Vision

S b

Certificate

Sub System

Data BaseINPUT OUTPUT System Ready for Pre-Commissioning

Disciplines

TAGsMechanical Completion Certificate



Data Flow & InterfacesData Flow & Interfaces

Data Base



Engineering TAG ListCommissioning Systems Construction Areas

OverviewEngineering TAG List

Unit

Group of Systems

G f S t

Plant Area

Constr Area

Commissioning Systems Construction Areas

Group of Systems

System

System

Constr Area

Select Quality Pack Type Select Quality Steps


Select Quality Pack Type Select Quality Steps


Recommendations

• All stakeholders must be continuously kept up-to-date with the safety requirements of changing site conditions

Recommendations

site conditions

• Phased system-wise completion and turnover scheme requires very efficient planning and schedulingscheduling

• The achievement of highest coordination standards between construction and commissioning teams is essential

• Construction contracts need to be structured with focus and incentives on system turn over and completion p

• The administration of voluminous turnover documentation necessitate the implementation of a structured and tag oriented approach and application of software tools



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© 2012 Foster Wheeler. All rights reserved.


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