Best Practice Procedures. Construction to Commissioning

Transcription

1 Best Practice Procedures in the transition from Construction to Commissioning Deniz Metin Kaya Director of Construction Operations Foster Wheler Italiana 2012 Foster Wheeler. All rights reserved.

2 Why 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

3 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

4 What 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)

5 Completion & Turnover Map Project Completion Data Base Engineering g Area Driven Construction Area Driven Construction System Completion System Completion System Completion System Completion System Completion Group of Systems Completion Group of Systems Completion Rea ady for Pla ant Start-up Preparation & Data Validation Measure construction progress Perform inspection i and test requirement Measure progress. Punch-Out & Acceptance Perform (pre) commissioning inspection and test. Measure progress. Punch-Out & Acceptance

6 Road Map for MC by Systems and Handover to Commissioning Pre-Commissioning Construction Commissioning Final TOS Test Punch Initial Walkdown MC Check-out List Pack List Walkdown Punch List TOD Testing

7 Construction Completion Milestones TOS Self-contained portion of a facility/system for hand over (Turn Over System)

8 Construction Completion Milestones TOS Self-contained portion of a facility/system for hand over Test Package Set of documentation demonstrating the MC of a system or its subsystems or sections that can be isolated for test purposes

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

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

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

12 Construction Completion Milestones TOS Self-contained portion of a facility/system for hand over 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 i outstanding t 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 TOD Final dossier including all applicable as-built engineering documents and (Turn Over Dossier) construction certificates as per Inspection & Test Plan attesting the readiness for turn over

13 Construction Completion Milestones TOS Self-contained portion of a facility/system for hand over 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 TOD Final dossier including all applicable as-built engineering documents and construction certificates as per ITP attesting the readiness for turn over

14 Breakdown of Systems System Process Systems Standard Systems Sub-Systems Sub-Systems Disciplines Disciplines

15 Typical TOS List BLACK UTILITIES TOS LIST SYSTEM SYSTEM NUMBER RUNNING DESCTRIPTION TOS SUBSYSTEM TOS DESCRIPTION AREA TOS BS BLACK STEAM 10 BAR BASEMENT BASEMENT TOS BS8 001 BLACK STEAM 8 BAR DISTR. BASEMENT BASEMENT TOS BS3 001 BLACK STEAM 3 BAR DISTR. BASEMENT BASEMENT BS10/8/3 010 BLACK STEAM TOS BS3 002 BLACK STEAM 3 BAR DISTR. BULK 1 BULK 1 TOS BS3 003 BLACK STEAM 3 BAR DISTR. BULK 2 BULK 2 TOS BS3 004 BLACK STEAM 3 BAR DISTR. STERILE FILTRATION STERILE FILTRATION TOS BS3 005 BLACK STEAM 3 BAR DISTR. CASA CASA TOS BSC CONDENSATE 10 BAR BASEMENT BASEMENT TOS BSC8 001 CONDENSATE 8 BAR BASEMENT BASEMENT TOS BSC3 001 CONDENSATE 3 BAR BASEMENT BASEMENT BSC10/8/3 011 CONDENSATE TOS BSC3 002 CONDENSATE 3 BAR BULK 1 BULK 1 TOS BSC3 003 CONDENSATE 3 BAR BULK 2 BULK 2 TOS BSC3 004 CONDENSATE 3 STERILE FILTRATION STERILE FILTRATION TOS BSC3 005 CONDENSATE 3 BAR BULK 2 CASA TOS CAI 001 CAI 10 BAR DISTRIBUTION BASEMENT BASEMENT TOS CAI 002 CAI 10 BAR DISTRIBUTION BULK 1 BULK CAI 012 CAI TOS CAI 003 CAI 10BAR DISTRIBUTION BULK 2 BULK 2 TOS CAI 004 CAI 10 BAR DISTRIBUTION CASA CASA TOS CAI 005 CAI 12 BAR GENER. AND DISTR. CASA CASA

16 Test Pack Identification

17 Punching and Walkdown

18 Punch List Management PUNCH LIST RESUMING FOR SUBCONTRACTOR Punch List Register WN LIS-0001 Date 28-apr-12 CONTRACTOR or VENDOR A B C NO GR. TOTAL To Close To Close To Close To Close To Close Closed Hold CONTRACTOR # CONTRACTOR # CONTRACTOR # CONTRACTOR # CONTRACTOR # CONTRACTOR # CONTRACTOR # CONTRACTOR # CONTRACTOR # VENDOR # VENDOR # VENDOR # VENDOR # VENDOR # VENDOR # VENDOR # TOT

19 Punch List by Discipline & Category

20 MC & Turnover Progress

21 Typical Project Statistics Project 1 Project 2 Project 3 Project 4 Systems Units Isometrics 3,400 4,000 22,000 1,500 Test packs 1,000 1,500 7, Inst Tags 3,500 4,200 17,000 5,000 Loop Dossiers ,750 2,000 Check Sheets 60, , , ,000

22 What is needed to administer this Transition Phase Standardised di d preparation for mechanical completion and commissioning i i Maximization of electronic data transfer from engineering and project controls Continuous and auditable progress measurement (physical vs. QC achievements) Management of system-wise completion Structured t and certified handover for all disciplinesi Controlling tool for the creation and management of all QC and MC forms

23 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)

24 Typical Project Tree for TAG ging 1st Level Systems Project 2nd Level Sub-Systems 3rd Level Disciplines 4th Level TAGs

25 Assignment of Discipline TAGs Civil: Foundation List Steel Structure List Underground List (Pits, Duct, Sewer, etc.) Building TOS Instrument: Instrument List Cable List Fire & Gas More Engineering Disciplines Piping: Line List ISO List Hydro Test Pack Equipment: Rotating Pressure Vessels Heat Exchanger More TAG s Electrical: Cable List Equipment List Grounding More HVAC: Piping List Cable List Instrument List Equipment List More Equipment List

26 Turnover Vision System System Acceptance Certificate t Sub System INPUT Data Base OUTPUT System Ready for Pre- Commissioning Disciplines TAGs Mechanical Completion Certificate

27 Data Flow & Interfaces Data Base

28 Commissioning Systems Unit Group of Systems Overview Engineering TAG List Construction Areas Plant Area Constr Area Group of Systems Constr Area System System Select Quality Pack Type Select Quality Steps 28

29 Recommendations All stakeholders must be continuously kept up-to-date with the safety requirements of changing site conditions Phased system-wise completion and turnover scheme requires very efficient planning and scheduling 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 The administration of voluminous turnover documentation necessitate the implementation of a structured and tag oriented approach and application of software tools

30 THANK YOU Foster Wheeler. All rights reserved.