Transition From Construction To Commissioning PDF

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 F
Foster Wh
Wheeler.
l All rights
i h reserved.
d
Milan. Italy, Ooctober 12, 2012 THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Why 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
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

pre-commissioning
commissioning and commissioning
What is Pre
Pre-Commissioning
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)
Completion & Turnover Map
Project
j Completion
p Data Base
System Completion
Group of Systems
Reaady for Plaant

Area Driven Completion
System Completion
Construction
E
Engineering
Start-up
S
System Completion
System Completion Group of

Systems
y
g
Area Driven Construction Completion

System Completion
Perform (pre)
Preparation Perform
f iinspection
i andd Punch-Out
Punch-Out & commissioning
& Data Measure construction progress test requirement &
Acceptance inspection and test.
Validation Measure progress. Acceptance
Measure progress.
Road Map for MC by Systems and

Handover to Commissioning
Pre Commissioning
Pre-Commissioning
Construction Commissioning
Final
TOS Test Punch Initial Walkdown MC Check-out
List Pack List
i Walkdown Punch List TOD Testing
Construction Completion Milestones

• TOS Self-contained portion of a facility/system for hand over
(Turn Over System)

• 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


• P
Punch
h List
Li t F
Formal
l inspection
i ti and
d id
identification
tifi ti off remaining
i i outstanding
t t di works
k
& 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
readiness for
f turn 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
Breakdown of Systems
System
y
Process Standard
Systems Systems
Sub-Systems Sub-Systems
Disciplines Disciplines
Typical TOS List
BLACK UTILITIES TOS LIST
SYSTEM NUMBER
SYSTEM RUNNING DESCTRIPTION TOS SUBSYSTEM TOS DESCRIPTION AREA
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
05.41‐BS10/8/3 010 BLACK STEAM 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
TOS‐05.41‐BSC10‐001 CONDENSATE 10 BAR BASEMENT BASEMENT
05.41-BSC10/8/3 011 CONDENSATE 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
TOS‐05.41‐CAI‐001 CAI 10 BAR DISTRIBUTION BASEMENT BASEMENT
TOS‐05.41‐CAI‐002 CAI 10 BAR DISTRIBUTION BULK 1 BULK 1
05 41-CAI
05.41-CAI 012 CAI TOS‐05
TOS 05.41
41‐CAI‐003
CAI 003 CAI 10 BAR DISTRIBUTION BULK 2
CAI 10 BAR DISTRIBUTION BULK 2 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
Test Pack Identification
Punching and Walkdown
Punch List Management

Punch List Register
PUNCH LIST RESUMING FOR
WN158-11.23-LIS-0001
SUBCONTRACTOR
Date 28-apr-12
CONTRACTOR or A B C NO GR. TOTAL

VENDOR 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
434 621 73 78 1206 1496 1
TOT
1180 1341 105 188 2814
Punch List by Discipline & Category
MC & Turnover Progress
Typical Project Statistics
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
60,000 50 000
50,000 200 000
200,000 45 000
45,000
What is needed to administer this

Transition Phase
• S d di d preparation
Standardised i ffor mechanical
h i l completion
l i andd commissioning
i i i
• Maximization of electronic data transfer from engineering and project controls
• C ti
Continuous and
d auditable
dit bl progress measurementt (physical vs. QC achievements)
• Management of system-wise completion
• St t d and
Structured d certified
tifi d h
handover
d ffor allll disciplines
di i li
• Controlling tool for the creation and management of all QC and MC forms
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)
Typical Project Tree for TAG ging
1st Level Systems Project
2nd Level Sub-Systems
3rd Level Disciplines
4th Level TAGs
Assignment of Discipline TAGs

TOS
Civil:
Instrument:
• Foundation List
• Instrument List
• Steel Structure List
• Cable List
• Underground List (Pits,
• Fire & Gas
Duct, Sewer, etc.)
• More
• Buildingg
Piping: Equipment:
Engineering • Line List • Rotating
TAG s
Disciplines • ISO List • Pressure Vessels
• Hydro Test Pack • Heat Exchanger
• More
Electrical: HVAC:
• Cable List • Piping List
• Equipment List • Cable List
• Grounding • Instrument List
• More • Equipment List
Turnover Vision
System
System Acceptance
C tifi t
Certificate
S b
Sub
System
System Ready
INPUT OUTPUT for Pre-
Data Base Commissioning
Disciplines
Mechanical
TAGs Completion
Certificate
Data Flow & Interfaces
Data Base
Overview
Commissioning Systems Engineering TAG List Construction Areas
Unit Plant Area
Group of Systems Constr Area
G
Group off S
Systems
t Constr Area
System
System
Select Quality Pack Type Select Quality Steps
28
Recommendations
• 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
p
• The administration of voluminous turnover documentation necessitate the implementation of a

structured and tag oriented approach and application of software tools
THANK YOU…
www.fwc.com
Deniz_Metin_Kaya@fwceu.com
© 2012 Foster Wheeler. All rights reserved.

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PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Best Practice Procedures

Deniz Metin Kaya

Why transition from Construction to Commissioning is so

• Safety environment is complex and difficult to manage

• 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

What is Mechanical Completion ?

• Construction is completed in accordance with drawings, specifications, vendor instructions,

• All inspection, checking and testing works are completed

• System(s) and/or facilities are ready for pre

Completion & Turnover Map

Reaady for Plaant

System Completion Group of

Area Driven Construction Completion

Road Map for MC by Systems and

Construction Completion Milestones

Construction Completion Milestones

• Test Package Set of documentation demonstrating the MC of a system or its subsystems

Construction Completion Milestones

• Test Package Set of documentation demonstrating the MC of a system or its subsystems

• Punch List Formal inspection and identification of remaining outstanding works

Construction Completion Milestones

• Test Package Set of documentation demonstrating the MC of a system or its subsystems

• Punch List Formal inspection and identification of remaining outstanding works

Construction Completion Milestones

• Test Package Set of documentation demonstrating the MC of a system or its subsystems

• Punch List Formal inspection and identification of remaining outstanding works

Construction Completion Milestones

• Test Package Set of documentation demonstrating the MC of a system or its subsystems

Construction Completion Milestones

• Test Package Set of documentation demonstrating the MC of a system or its subsystems

• Punch List Formal inspection and identification of remaining outstanding works

Typical TOS List

Test Pack Identification

Punching and Walkdown

Punch List Management

CONTRACTOR or A B C NO GR. TOTAL

Punch List by Discipline & Category

MC & Turnover Progress

Typical Project Statistics

Project 1 Project 2 Project 3 Project 4

What is needed to administer this

• Maximization of electronic data transfer from engineering and project controls

• Management of system-wise completion

Basis of TAG Assignment

• shall be TAG ged

• shall belong to a family (Object Class)

Typical Project Tree for TAG ging

1st Level Systems Project

2nd Level Sub-Systems

3rd Level Disciplines

4th Level TAGs

Assignment of Discipline TAGs

Data Flow & Interfaces

Select Quality Pack Type Select Quality Steps

• The achievement of highest coordination standards between construction and commissioning

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

© 2012 Foster Wheeler. All rights reserved.

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