Best Practice Procedures in the transition from ...animp.it/animp_/images/PDF_archivio/METIN_KAYA.pdf · Best Practice Procedures in the transition from ... and/or facilities are

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

Milan. Italy, October 12, 2012

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Best Practice Procedures

in the transition from

Construction to Commissioning

Deniz Metin Kaya

Director of Construction Operations

Foster Wheler Italiana

© 2012 Foster Wheeler. All rights reserved.




• 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

Why transition from Construction to Commissioning is so

important?




• 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

What is Mechanical Completion ?




• 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)

What is Pre-Commissioning and

Commissioning?




Project Completion Data Base

En

gin

eering

Area Driven

Construction

System Completion

System Completion

System Completion

Area Driven Construction

System Completion

System Completion

Group of Systems

Completion

Group of

Systems

Completion

Rea

dy fo

r Pla

nt

Sta

rt-up

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

Completion & Turnover Map




Test

Pack

Punch

List TOD MC

Construction

Pre-Commissioning

Commissioning

Road Map for MC by Systems and

Handover to Commissioning

TOS

List Initial

Walkdown

Final

Walkdown

Punch List

Check-out

Testing




Construction 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




System

Process

Systems

Standard

Systems

Disciplines Disciplines

Sub-Systems Sub-Systems

Breakdown of Systems




BLACK UTILITIES TOS LIST

SYSTEM 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-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 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

Typical TOS List




Test Pack Identification




Punching and Walkdown




Punch List Management

PUNCH LIST RESUMING FOR

SUBCONTRACTOR

Punch List Register

WN158-11.23-LIS-0001

Date 28-apr-12

CONTRACTOR or

VENDOR

A B C NO GR. TOTAL

To Close To Close To Close To Close To Close Closed Hold

CONTRACTOR # 1 43 88 6 1 138 301 0

CONTRACTOR # 2 117 100 23 43 283 23 0

CONTRACTOR # 3 3 32 0 0 35 0 0

CONTRACTOR # 4 17 89 12 4 122 232 0

CONTRACTOR # 5 13 59 8 0 80 336 0

CONTRACTOR # 6 28 135 15 0 178 248 0

CONTRACTOR # 7 60 58 8 0 126 106 0

CONTRACTOR # 8 0 0 0 13 13 0 0

CONTRACTOR # 9 0 0 0 1 1 0 0

VENDOR #1 23 10 1 0 34 27 0

VENDOR #3 4 0 0 0 4 6 0

VENDOR #4 49 18 0 0 67 33 0

VENDOR #5 29 11 0 0 40 38 0

VENDOR #6 48 21 0 0 69 31 0

VENDOR #7 0 0 0 0 0 28 0

VENDOR #8 0 0 0 16 16 87 0

TOT 434 621 73 78 1206 1496 1

1180 1341 105 188 2814




Punch List by Discipline & Category




MC & Turnover Progress




Project 1 Project 2 Project 3 Project 4

Systems 350 340 140 250

Units 3 37 13 7

Isometrics 3,400 4,000 22,000 1,500

Test packs 1,000 1,500 7,000 600

Inst Tags 3,500 4,200 17,000 5,000

Loop Dossiers 600 850 4,750 2,000

Check Sheets 60,000 50,000 200,000 45,000

Typical Project Statistics




• Standardised preparation for mechanical completion and commissioning

• Maximization of electronic data transfer from engineering and project controls

• Continuous and auditable progress measurement (physical vs. QC achievements)

• Management of system-wise completion

• Structured and certified handover for all disciplines

• Controlling tool for the creation and management of all QC and MC forms

What is needed to administer this

Transition Phase




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)




Project 1st Level

2nd Level

3rd Level

4th Level

Systems

Sub-Systems

Disciplines

TAGs

Typical Project Tree for TAG ging




TAG s Engineering

Disciplines

Civil:

• Foundation List

• Steel Structure List

• Underground List (Pits,

Duct, Sewer, etc.)

• Building

Piping:

• Line List

• ISO List

• Hydro Test Pack

Equipment:

• Rotating

• Pressure Vessels

• Heat Exchanger

• More

Electrical:

• Cable List

• Equipment List

• Grounding

• More

Instrument:

• Instrument List

• Cable List

• Fire & Gas

• More

HVAC:

• Piping List

• Cable List

• Instrument List

• Equipment List

TOS

Assignment of Discipline TAGs




System

Sub

System

Disciplines

TAGs

Data Base INPUT OUTPUT

System

Acceptance

Certificate

System Ready

for Pre-

Commissioning

Mechanical

Completion

Certificate

Turnover Vision




Data Base

Data Flow & Interfaces




28

Engineering TAG List

Unit

Group of Systems

Group of Systems

System

System

Plant Area

Constr Area

Constr Area

Select Quality Pack Type Select Quality Steps

Commissioning Systems Construction Areas

Overview




• All stakeholders must be continuously kept up-to-date with the safety requirements of changing

site conditions

• Phased system-wise completion and turnover scheme requires very efficient planning and

scheduling

• 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

• The administration of voluminous turnover documentation necessitate the implementation of a

structured and tag oriented approach and application of software tools

Recommendations




THANK YOU…

www.fwc.com

[email protected]

© 2012 Foster Wheeler. All rights reserved.

http://www.fwc.com/

http://www.fwc.com/

Documents

Best Practice Procedures in the transition from ...animp.it/animp_/images/PDF_archivio/METIN_KAYA.pdf · Best Practice Procedures in the transition from ... and/or facilities are