Unrestricted © Siemens AG 2019
Chapter:11
Site (Installation & Commissioning) ActivitiesSiemens Gas and Power Generation Business Management Course
10th May 2019,Hacettepe University
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Table of content
• Introduction 3
• Exercise - 1 6
• How to plan Site activites 7
• Site Organization 10
• EBoP Commissioning activities 13
• Process Commissioning 18
• What’s necassary for Site activities 21
• Project Sites 22
• Exersice – 2 27
• Wrap-Up & Questions 28
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Who we are?
Düzgün Arslan
1984-88 Yıldız, Electrical Engineering
1989-92 FHTE Esslingen,Information Eng.
1993- ... Siemens
Site Engineer & Site Manager
EFQM Quality
Bid and Sales Engineer
Senior Project Manager & Head of PM
Water, WasteWater, Irrigation
Paper, Metal, Cement , Automative
Energy (CFPP, CCPP, HES, RES )
Head of Field Service and Engineering
Gökhan Onar
1999-2004, ITU, Electrical Engineering
2004-2008, ITU, Control & Automation Eng.
2011- ... Siemens
Site Engineer & Site Manager
Offer & Order Execution
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PM@Siemens Site Activities«Puzzle to be completed»
Initiating Planning Executing&Controlling Closing
Project
Opening&
Clarification
Detailed
Planning
Purch.&Manu-
factureDispatch
Constr./Insta
llationCommission Acceptan.
Project
Closure
Project Execution @ SIEMENS
Site execution phase
Complete Installation & Commissioning activities in accordance to regulations,
standarts, requirement and contract.
Make the system properly working to handover operation team / customer.
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Siemens Power Generation Project in Turkey
Dinar WPP - 115 MW
Güriş Holding A.Ş
More then 50 wind turbine
Ambarlı CCPP – 1.350 MW (1988)
EÜAŞ
Biggest and most effective Natural
Gas Power Plant at 80’s in Turkey
Samsun CCPP – 600 MW (2016)
Cengiz Enerji A.Ş
Highest efficiency (%61) Power Plant
in Turkey
Silahtarağa CFPP – 13 MW (1913-83)
1st Fossile Power Plant in Turkey
ISKEN CFPP – 1.320 MW (2003)
Oyak & Steag
1st import Coal Power Plant in Turkey(ST, Geno, EBoP, Automation by Siemens)
Renewable Plants (Hydro, Wind, Geothermal
>80 Plant ~3,3 GW (@ 2017)
Fossile Power Plants
>50 Plants ~18 GW (@2017)
~%35 of Power Capacity in Turkey
used Siemens technology
(72 GW – December.2015)
Afsin Elbistan CFPP 1.355 MW (1984)
EÜAŞ ( privatized by Çelikler)
Door-opener lignite coal plant in
Turkey
YENI CCPP – 850 MW (2013)
YENI-AEN Energy
Turnkey completion within 30 month (All EBoP by Siemens Trk)
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How to plan site activities«Exercise-1 : How to re-arrange a class room »
Scope : Re-arrange class-room
Time : x min
Team1 : xx Person
Team2 : xx Person
WHAT
Team1: Built rectangle , use xx chairs
Team2: Built triangel , use xx chairs
Limited time ( 3 min preparation + 3 min execution)
Report resource & result ( 2 min)
What ?
How ?
What learned ?
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How to plan site activites «Bid engineering»«Survivor?»
• WHAT Scope at Site?
• WHICH Standard’s?
• HOW many Time ?
• WHAT resources do we need?
• HOW many resources?
• WHICH responsibilites ?
• WHICH Infrastructure needed ?
Timeline
Team
ISO, EN, TSE, ANSII
Contract
People
Equipment
Tool
Empowerent
Qualification
Quantity
Quality
Reports
Infrastructure
Organization
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Source Planning at offer stage Sample CCPP ManPower Chart
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Site Activity Cable Pulling
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Site Organization Site Org-chart according to offer study
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Sample Plants for Site Activities«Sample » Installation site photos
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Sample Plants for Site Activities«Sample » Installation site photos
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Site Tests - EBoP Commissioning Activities
The commissioning activities consist of all necessary checking and site tests before putting
the related plant section into operation in secure conditions.
What are the electrical commissioning scope of works?
-DC Systems
-LV Switchgear Systems
-MV AIS / GIS Switchgear Systems
-HV AIS/ GIS Switchgear Systems
-Excitation&protection&synchronisation systems of the generators
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Site Tests of HV Primary Equipments
Current Transformers
• Ratio test by primary injection
• Polarity test
• Saturation test
• Megger insulation test
• ….
Voltage Transformers
• Ratio test
• %pf power factor and cap. test
• Megger insulation test
• ….
Main Transformers
• Ratio control at all tap positions
• Winding resitance measurement
• Power loss test
• Megger insulation test
• Checking of fan controls
• ….
Circuit Breakers
• Open & Closing time measurement
• Main contact resistance measurement
• Power loss test
• Megger insulation test
• SF6 signal checks
• ….
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Site Tests - Secondary Protection
Machine
Protection
7UM... Series
Line
Protection
7SA... Series
Station
Protection
7SS... Series
Transformer
Protection
7UT.... Series
Medium Voltage
Protection
7SJ... Series
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Checking and testing of the secondary systems
Functional Tests
All the functional test of secondary
circuits will be done/checked
individually and highlighted in the
drawings. If there is any revision,
it will be shown with a red color pen
and revision remark.
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Site Activity Functional Tests
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Process / Plant Commissioning Activities
The process commissioning activities consist of all necessary checking and tests before
putting the related plant into operation in secure conditions.
What are the process commissioning scope ?
• CBoP - Civil systems ready and tested
• MBoP - Mechanical systems ready and tested
• EBoP – Electrical systems ready and tested
• Process & Interface tests
• Cold & Hot Tests of plant
• Performance Tests and Hand over
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Plant Automation Commissioning Steps
Commissioning of
I&C configuration
Receiving inspection
and preparation of
commissioning for DCS
Switching on the DCSCommissioning of 3rd
party interfacesInstallation
DCS
Testing safety instrumented functions
(authority, adviser, customer)
Commissioning under operating conditions
(higher-level open-loop and closed-loop controls)
Process commissioning: Functions (individual/
drive /sub-loop/sub-group control, drive switch over)
Alarm optimization,
load cability test
Commissioning of process technology
Conducttrial run Acceptance
Cold function testing
System commissioning
Field signal and
equipment
testing
Supply power for
auxiliary and special
cabinets (Field)
- Continuously motor- Open loop and closed loop actuator, Solenoid valve control- Binary transducer- Analog measurement- Black Box
Field commissioning
Site management &
commissioning
Calibration
Loop checks
Device checks
Installation
Hot commissioning
Installation
Site Management
Commissioning
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SMART Targets Everywhere
Specific = Anlaşılabilir
• İyi tanımla
• Herkesin anlayabileceği kadar açık
Measurable = Ölçülebilir
• Hedefin ne olduğunu ve ne koşulda tamamlanacağını bil
• Ne zaman ulaşabileceğini bil
Agreed Upon = Mutabık kalınan
• Hedefine ulaşman için paydaşlar hedefini bilmeli, anlamalı, kabul etmeli
Realistic = Gerçekçi
• Mevcut yetkinliklerine uygun, ulaşılabilir, zaman limitli olmalı
Time-Based = Yeterli zaman
• Hedefi gerçekleştirmek için yeterli zaman belirlemeli
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What’s necassary for Site Activities
Resource Management
Man-Power
Engineer
Foremans & Technicians
Helper
Tool & Consumables
Delivery Management
EBoP (Switchgear, Cubicles, Trafo’s,..)
MBoP (Turboset, Generator, Valves...)
Cable and accesories
Know-how
Contract, Regulations
Drawings
Instructions
Time Management
Schedule
KPI’s ( Start, critical paths, ends)
EHS Management
What skills make the best engineers so good?
1.Communication: listening, persuading, negotiating
2.Organizational: planning, goal-setting, analyzing
3.Team building: empathy, motivation, team spirit
4.Leadership: sets example, energetic, delegates, positive
5.Coping: flexibility, creativity, patience, persistence
6.Technical: experience, technical knowledge
Company & Management at Site
Key member of Project Organization
Keeping in touch with other members
Keeping in touch with external organizations
Keeping in touch with different cultures
High adrenalin & adventurous Life Style
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Sample Plants for Site ActivitiesInfrastructure, Public Transport
Orhangazi Highway Tunnels
Ankara-Eskişehir High-Speed Train Kayseray
Osmangazi Bay Bridge
Nefise Akçelik Highway Tunnel
Yavuz Sultan Selim Bridge
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Site Organization Sample CCPP Site Org-Chart
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Site CoordinationSample Schedule Milestones
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Site Activity GIS Installation
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Site CoordinationSample Daily Work Program
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How to plan site activities«Exercise-2 : How to re-arrange a class room »
Scope : Re-arrange class-room
Time : 8 min
Team1 : xx Person
Team2 : xx Person
WHAT
Team1: Built rectangle, use xx chairs
Team2: Built triangel, use xx chairs
Limited time ( 3 min preparation + 3 min execution)
Report resource & result ( 2 min)
HOW
Check resources
Manpower
Material
Check Condition ( Lay-out, drawing)
Communicate stakeholders
Customer
Team
other companies / teams
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Site EngineeringWrap-Up
Key Words of Site Activities (taken from Projekt
Management section)
Contract Schedule Stakeholder Team
Customer Subcontractor Owner Cost
Calc.
Supplier Risk Oppurtunity Claim
NegotiationMilestones Delay
Penalty Warranty PAC Bonds FAC
Satisfaction Complaint Budget
EHS Equipment Standards regulation
Warehouse Tools Site-Reports
Open Job Position@Siemens
We are looking for a Site Engineer with expertise on xxx.
Main responsibilities are described below
Coordination with the Engineering team to ensure proper execution and interfaces with other
parties.
Provide support on the submission of Design Documents
Ensure the availability of materials at Site in coordination with the Project Manager and
responsible colleagues
Supervise and update of specific programs for installation, test and commissioning.
Prepare daily/weekly /monthly reports of installation/test and commissioning
Control and monitoring progress of site execution
Provide evidence about deliveries, completion of the works for Project Manager
Technical support to QMiP and Project Manager for the closure of Non Conformance Reports
Required Experience / Knowledge:
• Bachelor Degree in Engineering
• Proven 3 years of experience on xxxx projects
• Knowledge of xxxx
• MS Office, AutoCAD, MS Project
• Very good command of English , xxxxx will be an asset
What else do I need to know?
• Military service should be completed for male candidates.
• Leadership
• Strong problem solving skills
• Excellent interpersonal communication skills
• Open minded and highly collaborative
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Wrap-Up & Questions
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References&SourcesReferences
PM@Siemens Guide
PM@Siemens
www.wikipedia.com
http://www.enerjiatlasi.com/
Project Management Chapter
Automation Engineering Chapter