transition from construction to commissioning
DESCRIPTION
CommissioningTRANSCRIPT
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.
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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)
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Construction Completion MilestonesConstruction Completion Milestones• TOS Self-contained portion of a facility/system for hand over
(Turn Over System)
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Construction Completion MilestonesConstruction 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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Construction Completion MilestonesConstruction 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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Construction Completion MilestonesConstruction 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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Construction Completion MilestonesConstruction 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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Construction Completion MilestonesConstruction 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
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
• 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
fTHIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
readiness for turn over
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Construction Completion MilestonesConstruction 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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Breakdown of Systems
System
Breakdown of Systems
y
Process
Systems
Standard
SystemsSystems Systems
Sub-Systems Sub-Systems
Disciplines Disciplines
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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‐BSC8‐001 CONDENSATE 8 BAR BASEMENT BASEMENT
TOS‐05.41‐BSC3‐001 CONDENSATE 3 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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Test Pack IdentificationTest Pack Identification
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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Punching and Walkdown
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
1180 1341 105 188 2814
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Punch List by Discipline & CategoryPunch List by Discipline & Category
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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MC & Turnover ProgressMC & Turnover Progress
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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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)
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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Typical Project Tree for TAG gingTypical Project Tree for TAG ging
Project1st Level Systems
2nd Level Sub-Systems
3rd Level Disciplines
4th Level TAGs
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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Data Flow & InterfacesData Flow & Interfaces
Data Base
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
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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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 201228
Select Quality Pack Type Select Quality Steps
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUMMilan. Italy, Ooctober 12, 2012