global completions and commissioning manager - · pdf filean overview of the commissioning...

01-Mar-13

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An Overview of the Commissioning Cycle

Presented 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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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




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

Pre–FEED - 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 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 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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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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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





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

Pre–FEED - 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

global completions and commissioning manager - · pdf filean overview of the commissioning...

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