Commissioning Approach

Integrated Service Solutions

optimising maintenance costs

maximising plant productivity

preserving asset integrity

Conduct Plant operation

Technical assistance for O&M

Engineering

Commissioning

O&M Procurement ConstructionProcurement Construction

Plant Life Cycle

- Dynamic simulation support

- Process data reconciliation

- etc.

- Turnover Management Methodology

- Pre-commissioning

- Commissioning / start-up

- High Tech. Support

- technical assistance

- Spare Parts- M.M.(Material Management)- I.P.O.S.(Integrated Procurement outsourcing services)

TrainingTraining

Integrated operation & maintenance

IOP

Simplant®

ClassroomHands-on

Training

Side by Side

Engineering

Commissioning

O&M Procurement ConstructionProcurement Construction

Plant Life Cycle

- Dynamic simulation support

- Process data reconciliation

- etc.

- Turnover Management Methodology

- Pre-commissioning

- Commissioning / start-up

- High Tech. Support

- High tech. personnel

- Spare Parts- I.P.O.S.(Integrated Procurement outsourcing services)

TrainingTraining

optimising maintenance costs

maximising plant productivity

preserving asset integrity

Integrated operation & maintenance

IOP

Simplant®

ClassroomHands-on

Turnover Management Methodology

Preparatory works

(Home office activities)

Mechanical Completion verification

Precommissioning

Commissioning

End

Main Root Main Activities Certificates/Issues

Tool for Mesurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc)

Field inspections, documentation inspection (outstanding Item verification)

Inspections, Punch-list issueing, utilities comm, cleaning, flushing, blowing, chemical cleaning, non operating

adjustment, motor run-in, catalyst, internal inspection, ...

Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, ……..

Turnover management system operating manual check and

preparation

Interim Handover Certificate verification (P/L outstanding)

Ready for Commissioning Certificate

Ready for Start-up

Certificate

Performance Tests Conduct performance testsProvisional Acceptance

Certificate

Start-UpOil-In

Ready for performance test

Home Office Phase(Preparatory work)

The Turnover Management System will allow to:

• Manage QA/QC certificates• Manage Construction piping activities• Manage Construction electrical activities• Manage Construction instrument activities• Manage Construction machinery activities• Manage Construction punch lists• Have Construction progress per area• Have Construction overview progress• Have day by day reports• Manage the transaction between construction and commissioning activities• Manage pre-commissioning activities based on construction progress• Manage punch list outstanding items• Manage pre-commissioning and commissioning punch list• Manage Turnover progress and certificates• Manage mechanical completion progress, certificates and activities• Manage reinstatement progress, certificates and activities• Manage ready for pre-commissioning turnover progress, certificates and activities• Manage ready for commissioning turnover progress, certificates and activities• Manage performance test turnover progress, certificates and activities• Manage provisional acceptance turnover progress, certificates and activities • Dossiers management

Preparatory works

(Home office activities)

Tool for Measurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc)

Turnover management system operating manual check and

preparation

SYSTEM START-UP

PASSWORD

PASSWORD ADMINISTRATOR'S AREA

Construction

Reports &

Progress

Commissioning

Piping Electrical Instrument Machninery

Punch List Management

Mechanical Completion

Flushing

Tighteness Test

Performance Test

Provisional Test

Acceptance Test

Loop Check

Dossier Filling

Handover Management

Outstanding Item management

Preinst.

Installat.

Operation

Type 1

Type 2

Type 3

Type 4

Type 1

Type 2

Type 3

Type 4

Welding

Piping

Hydrotest

Reinstat.

Turnover Management SystemSystem layout

USER'S AREA

Turnover Management SystemSystem detail pictures

1) Main password

2) Main Menu 3) Instrument management system

4) Piping Menu 5) Punch List management system 6) Punch List Out standing Item

7) Piping Construction management system

8) Equipment Management system 9) Hydrotest Progress

• Pre-commissioning and Commissioning Manual will be supplied as a collection of precommissioning procedures; these procedures are operating instructions for the activities to be carried out during the performing of precommissioning.• The list of the procedures of the pre-commissioning manual is the following:

•    Mechanical Preparation                    Chemical Cleaning Instructions                    Physical Cleaning Instructions                    Mechanical Restoration                    Machinery Run in                    Tightness test                    Electrical testing/functional tests/energising                    Instruments calibration and functional test                    Loading of chemicals                    Loading of catalyst                    Heaters drying                    Chemicals boil out of steam generation facilities                    Verification of Mechanical Completion                    Performance Test

Operating Manual with the following contents:Introduction

•GeneralBasis of design

•Duty of plant•Environmental conditions•Feedstocks and products specifications•Battery limit conditions•Specifications and consumption of utilities, chemicals catalysts

Process Description•Description of flow•Process Variables•Process Theory

Preparation for Initial Start-up•General•Plant Inspection•Cleaning of Piping and equipment•Specific pre-start-up operations

Start-up procedureNormal OperationNormal Shutdown ProcedureEmergency ShutdownAnalytical requirementsAttachments (P&ID’s, Class Specifications and other Project documents)

Pre-commissioning and Commissioning Manual Operating Manual

Pre-commissioning & Commissioning manualspreparation & check

Mechanical Completion verification

Field inspections, documentation inspection (outstanding Item verification)

Interim Handover Certificate verification (P/L outstanding)

In order to optimize time and costs we will:

•Verify the mechanical completion Punch list outstanding items via field inspections and

certificates control and registration;

•Plan the pre-commissioning and commissioning activities based on the real situation

PrecommissioningInspections, Punch-list issueing, utilities comm, cleaning,

flushing, blowing, chemical cleaning, non operating adjustment, motor run-in, catalyst, internal inspection, ...

Ready for Commissioning Certificate

inspectionpunch-listing

utilities commissioningcleaningflushingblowing

chemical cleaningnon operating adjustment

motor run invessel loading

internalscatalyst

desiccantresins

packingdrying

machinery alignmentinstrument calibration

loopcheckingorifice plates installationsafety valves bench test

tightness test

Commissioning Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, ……..

Ready for Start-up certificate

Check all spring hangersStart up cooling water system,which may include Chlorinator

Run in pumps on water,where possible, and establish CirculationStart up compressors,where possible,on nitrogen and air

Activate the inert gas systemLight flare pilots, if used, and activate flare purges at the extremity of lines in the unit

Turn on the fuel gas system to process burnersStart up the fuel oil system to process burners

Boil out the steam generator (if it has not been chemically cleaned during pre-commissioning) Commission water treating facilities

Implement steam system andsteam trcing before insulation is checkedActivate condensate systems

Purge equipment, where requiredPerform operational pressure test

Run required vcuum testsDry out refractories and heaters and special lines

Reactor system dry outCheck waste-treatment area for operation

Circulate chemical solutions where requiredActivate catalysts where requiredPrepare for and circulate test oil

Recheck all trip circuits and their bypassesPractice normal and emergency shutdowns. If time allows, practice restarts

Performance TestsConduct performance tests

Provisional Acceptance Certificate

Performance Tests Procedures preparation and validation

Systems preparation for performance tests

Conduct performance test in order to meet process guaranteed figures

Start-upOil-in Ready for Performance test

Introduce feed at low flow rate

Adjust temperatures, pressures, levels and flows

Route off-specifications material to the designated areas

When the product reaches the specifications route it to storage

Increase slowly the feed rate to the Unit until the designed value.

Pre-commissioning & Commissioning typical organization chart

C o n s tru c tionO rg a n isa tion

S h iftS u p e rv iso rs

P a n e lO p e ra to rs

P ro ce ss U n itC o m m iss io n in gS u p erin te nd e n t

S h iftS u p e rv iso rs

P a n e lO p e ra to rs

U tility /O ffs iteC o m m iss io n in gS u p erin te nd e n t

In s trum e ntE le c trica l

M a ch in e ryM e ch a n ica l

L a b o ur

P ip ing

S u p e rv iso rs V e n d o r'sS p e c ia list

Q A /Q CM a n a g er

S afe tyM a n a g er

C o m m iss io n ingM a n a g er

S ite Re s id en t M an a g er O w n e r/M a n a g ingC o n trac t In te rfa ce

Comerint

Main Contractor

Comerint Organisation Chart

F O R IN DIn d u s tria l T ra in ing

E U C o nsu lta n cy

A V V IM PC o m m is s io n ing

S ta rt-upT e ch n ica l A s s is ta n ce

F O R P E TT ra in in g O il& G as

S IM P R OP ro ce ss S im u la tion

S E P C OS e rv ice s to E P C C o n tra c to rs

G E IM PP la n t O p era tion

T e ch n ica l A s s is ta n ce

A T T O PO p e ra tion

C o n tra c ting

B D ITIta ly

B D IN TIn te rn a tio n a l

B u s in e ss D e ve lo p m e nt

M a rke ting

S p a re P a rtsP ro cu re m e nt

C O M A PC o m m e rc ia l

A M M C OA d m in is tra tio n a n d C o n tro l

P E R O R GH u m a n R e s o u rce

T E C N OT e ch n ica l D e ve lo p m e nt

A D L

EPC CONTRACTORS OWNERS

OPERATIONSOPERATIONS

MAINTENANCEMAINTENANCE

CONSULTANCY SERVICES CONSULTANCY SERVICES

TRAINING AND HRD (CTS)TRAINING AND HRD (CTS)

ENGINEERING AND TECHNICAL DEPT. SUPPORT SERVICES (SIMULATION)

ENGINEERING AND TECHNICAL DEPT. SUPPORT SERVICES (SIMULATION)

COMMISSIONINGCOMMISSIONING

START-UPSTART-UP

Comerint services during Plant Life Cycle