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