MC and Commissioning Preparation

Safety

• The plant or facility will be commissioned in such a manner that it ensures the safety of all personnel and avoids damage to any part of the plant or equipment

Design Confirmation

• The commissioning of the plant or facility will prove it functions according to the design intent and within the specific system and equipment design parameters

Documentation

• The construction and commissioning groups will ensure they document all phases of the completion process

Auditable Trail

• Documentation will be kept in such a way as to provide auditable evidence of the completion process during construction completion / pre commissioning and through to system completion

Budget and Schedule

• The commissioning process will be managed to ensure the project completion is within the defined schedule and budget

Operational Acceptance

• Early operational acceptance criteria will be defined and included in the commissioning process to ensure a smooth transition at both handover and acceptance between contractor and client.

Typical Commissioning Objectives

General Completion Preparation

• Develop Commissioning execution plan and strategy

• Define plant start up sequence and set priorities

• Define list of systems, sub systems and sub sub systems

• Develop and issue colored P&ID’s and SLD’s showing limits of workable sub system

• Compile equipment lists by sub system and discipline

• Develop comprehensive detailed commissioning schedule (believe in the schedule)

• Align and import relevant engineering data into PWCOM tracking system

• Review and align discipline check procedures for both MC and PC

General Preparation

MC and PC Preparation

• Finalize and develop MC and PC check procedures

• Develop MC and PC dossiers to be used as a handover document to hold all the relevant completion information. • Develop system based commissioning test procedures • Develop a punch list management system and utilize PWCOM to track all activities

• Develop a handover and acceptance protocol procedure

A good completion strategy is dependant on early development of the correct structure and foundation thus allowing the establishment of system based activities

A system is a major sub-division of an installation that performs a major operation function of a plant or facility. The installation and commissioning of this system is multi-disciplined

A sub system is a sub-division of the system that performs a given operational function with no or little interference from the other parts of the plant. It also contains the equipment and is usually checked and pre-commissioned as a single discipline

Systems and Sub systems

Project

System

Sub-system

Equipment

Project Breakdown

Project Duration Without Sub System Approach

Project

MC PC Comm Start Up

Project Duration With Sub System Approach

TIME BENIFITSystem 1

System 2

System 3

The Sub-System Approach

Sub-System Limits

Typical Sub-System Limit Definition

Discipline Breakdown

Discipline Breakdown Within Sub-System Limits

Typical Project Numbers0 Wells/Sub-sea

1 Hull

2 Oil Process

3 Gas Process

4 Process Utilities

5 Utilities

6 Fire and safety

7 Electrical

8 Integrated Control

Develop Systems50 Instrument Air

51 Fresh Potable Water

52 Diesel

Develop Sub-System Boundaries

5201 Storage

5202 Purification

5203 Supply

5204 Transfer

Develop Workable Limits and Create Multi-Disciplined Work Packs

GeneralGeneral GeneratorGenerator Fire PumpFire Pump

5204-001 5204-002 5204-003

Create Work Pack Status Assign Discipline Check Procedure

MechanicalMCWPPCWP

MechanicalMCWPPCWP

PipingMCWPPCWP

PipingMCWPPCWP

InstrumentMCWPPCWP

InstrumentMCWPPCWP

ElectricalMCWPPCWP

ElectricalMCWPPCWP

MCCP-A

PCCP-B

Developing Workable Systems and Sub-systems

5204-0015204-001

MC Work Pack MC Work Pack

MCC5204-001

MCC5204-001

52-04-00152-04-001 CP-B

E M I

CP-BE M I

RFC5204-001

RFC5204-001

Pre-Comm Work PackPre-Comm Work Pack

Mechanical Completion Sub-sub System Pre Commissioning Sub-sub System

Commissioning System

CP-AM & P E & I

CP-AM & P E & I

52-04-00252-04-002 Discipline CP-B

E M I

Discipline CP-BE M I

RFC5204-002

RFC5204-002

Pre-Comm Work PackPre-Comm Work Pack

MC from 5204-002

MDAC

MDAC

MCDAC

MCDAC E

CDAC

ECDAC I

CDAC

ICDACP

DAC

PDAC E

DAC

EDAC I

DAC

IDAC

MCDAC

MCDAC E

CDAC

ECDAC I

CDAC

ICDAC

CTPSystem 52

Diesel

CTPSystem 52

DieselSACSAC

MC to Commissioning and Acceptance Flow

PWCOM Total Completions System

PreCommissioning

PreCommissioning

Mechanical Completion

Mechanical Completion

Check SheetCP-A

Check SheetCP-A

EngineeringEngineering

ConstructionConstruction

Check SheetCP-B

Check SheetCP-B

CommissioningCommissioning

AcceptanceAcceptanceHandoverHandover

OperationMaintenance

OperationMaintenance

Data

Data

Verification

Ve

rific

atio

n

Wo

rk p

ack

De

velo

pm

en

t

Work pack

Development

Verification

Pro

ced

ure

De

velo

pm

en

t

PWCOM Flow

PWCOM Preparation

• Develop system and sub system definition

• Mark up the relevant P&ID’ and SLD’s to suit the system definition into workable sub systems

• Align system and sub system definition into PWCOM

• Review check procedures CP-A and CP-B and adjust to suit project requirements

• Align engineering data externally to suit PWCOM input requirements including sub system and discipline alignment

• Import engineering tags into PWCOM

• Assign tags with the required CP-A and CP-B

• The MC and PC work packs are automatically developed within PWCOM

• Print out all draft MC and PC work packs and carry out first pass verification review of their content

• Ensure all the relevant data is captured and that the relevant checks have been correctly assigned

• Readjust MC and PC work packs to suit verification review and re print

• Carry out second pass review and adjust to suit

• Issue MC and PC work packs as final

• Print out and date MC and PC work packs including all relevant CP-A, CP-B’s

PWCOM Execution

• Issue and assign all MC work packs to field including CP-A’s

• On completion of CP-A sign off within PWCOM

• When all discipline CP-A’s are complete and signed off for specific MC work pack, issue discipline acceptance certificate DAC

• When all DAC’s are issued for that specific sub system, issue mechanical completion Certificate MCC

• Issue and assign all PC work packs to field including CP-B’s

• On completion of CP-B sign off within PWCOM

• When all discipline CP-B’s are complete and signed off for the specific PC work pack, issue commissioning discipline acceptance certificate CDAC

• When all CDAC’s are issued for that specific sub system, issue ready for commissioning certificate RFC

• The system is now ready for multi discipline commissioning via the commissioning test procedure CTP

PWCOM Main Menu

PWCOM is a Microsoft access 2000 based database with a visual basic software platform.

The system is designed to be very user friendly and flexible enough to suit any site condition and project quality requirements without the need

for corporate intervention.

System Development

The project system and sub systems are developed as the foundation of PWCOM and are further split into workable levels into sub sub systems

Internal MC and PC check procedures

PWCOM has a complete set of both construction and pre commissioning check procedures across all disciplines and can be easily adjusted and formatted

internally to suit any project requirement

Project Tag Register

The tag register is developed buy importing the relevant project engineering data and assigning specific sub systems to each tag which then forms the basis of the work pack

development . Engineering data of any format can be utilized and imported

Assigning check procedures to Tagged Items

Each tag will be assigned a specific check procedure to suit the project requirements and forms the basis of the verification process and auditable trail of

checks carried out during both construction and commissioning

Automatic Development of MC Workpacks

The Mechanical Completion work packs are automatically developed as each tag is assigned a sub system and specific check procedure CP-A

Automatic Development of PC Workpacks

The PC work packs are automatically developed as each tag is assigned a sub system and specific check procedure CP-B

Sign Off Completed check procedures

Signing off completed check procedures is an easy task and creates the final verification platform. It also allows progress reporting to be established at any

level required

Mass Update Ability

By using the mass update function, the assignment of checks procedures and revised data is by the click of a button

Automatic Development of Certification

The development of the relevant certification requirements is an automatic function. The certificates can be adjusted to suit the project QA/QC requirements

Discipline Acceptance Certificates

The standard issue of discipline acceptance certificates when the relevant work packs are complete is recommended but in some instances you may need to use

the added ability of being able issue partial completion which will include all outstanding activities listed on the certificate

Internal Development of check procedures

The development of the check procedures is carried out

internally therefore eliminating the need for external word

documents to be developed and allowing greater flexibility

should you need it on site

Internal Progress Reports Available

There are many reporting levels within PWCOM with it having the added ability of changing the reports to suit any project managers requirements. The reports are

generated by either discipline, system, subsystem or tag number. Each check procedure has an assigned hourly norm allocated therefore allowing the

calculation of man hours to be very accurate

Typical Progress Report

Bar Chart Type Progress Report

This report uses the reference of the total check procedures assigned as 100% therefore allowing the calculation of completed check procedures as a % to be

very accurate. Progress is achieved when the sheet is returned and signed off in PWCOM

Automatic Development of S Curve Reports

Internal Punchlist Capability

The punchlist is managed internally within PWCOM and encompasses both construction and commissioning activities consolidating as one punchlist

Punchlist Development

Each punchlist generic description is given a reference code therefore eliminating the need to for the site engineers to spend hours typing in the descriptions of the

punch

Typical Punchlist Summary Report

The reports are developed with as much detail as the project requires with each punchlist referenced back to a system and tag to enable accurate progress

reporting levels to be established

Typical CP-A and CP-B check procedures

MC and PC Workpack Forms