Ipedex Commissioning Integrated Services - IPCIS

An overview of the capabilities,

methodology and software of IPCIS, for the
provision of integrated commissioning
services
Ipedex and Commissioning Services

Experience
Provision of commissioning
services worldwide since 1970
Extensive Reference List
Manpower
Experienced Project Managers,
Site Leaders, Superintendents,
Engineers, Technicians and
support personnel

Ipedex
Commissioning
Integrated
Services
IPCIS

Methodology Software
Commissioning methodology IPCIS Commissioning Software
based on OPERCOM for Planning, Management,
Ipedex licensed by TFE Execution and Documentation of
Commissioning Activities
 IPCIS Capabilities
• Provision of a complete Commissioning Service
• Commissioning planning
• Preparation and supply of Commissioning Dossiers
• Supply of experienced manpower
• Implementation and management of commissioning tests
• Logistical Assistance
• Vendor Assistance
• Materials Assistance

Ipedex Capabilities
• Supply of experienced manpower
• Operations and Maintenance for the Oil & Gas Industry
• Documentation Services
• Training Services
• Individual Development Programmes
Commissioning References – Worldwide Experience

Ipedex involved in Commissioning since 1970

Commissioning activities performed all over the world :

Algeria, Angola, Argentina, Cameroon, China, Congo, Egypt,

France, Gabon, Germany, Indonesia, Iraq, Iran, Ivory coast,
Malaysia, Morocco, Nigeria, Oman, Portugal, Russia, Saudi
Arabia, Senegal, Syria, Thailand, U.A.E., U.K., Uzbekistan,
…
Commissioning References – Plant Experience
Onshore oil recovery facilities
Onshore gas recovery facilities
Offshore oil recovery facilities
Offshore gas recovery facilities
Onshore gas treatment plant
Drilling platform
FPSO
Dehydration gas units
Gas terminal
Oil terminal
Oil depots
Gas compression units
Condensate stabilisation units
Refineries (including heavy oil
treatment, topping units, HDT,
HDS, catalytic reforming,
alkylation units, carbon Black
units, isomerisation, merox,
steam cracking, sulphur units,
viscoreducer, ..)
Ethylene / Polyethylene units
Polyols units
Solvent plants
Aromatics plants (Benzene,
paraxylene, orthoxylene)
Lube oil units
Dirty oil regeneration units
IPCIS Methodology – Plant Commissioning Activities
Phase Activities Milestone
Pre-commissioning Conformity checks Ready for Commissioning
Static tests (Mechanical Completion)
Hydrotests
Flushing & cleaning
Commissioning Energisation Ready for Start-up
Dynamic tests
Equipment running-in
Utilities start-up
Pre-start-up activities
Operational tests Commissioning
Start-up Feed in Provisional Acceptance Complete
Performance tests Plant in Operation
Bringing the plant on-line

Commissioning is the verification of construction activities and preparation of the plant for Startup
• Success of Startup (and hence the Provisional Acceptance) is dependant on a successful Commissioning
• An unsuccessful commissioning leads to problems in performance tests and delays Provisional Acceptance
• Commissioning involves many activities of short timescale. Even minor delays to these activities can have a
great impact on overall schedule
• Commissioning involves different parties – commissioning, vendors, operations, construction, engineering –
misunderstandings and ineffective organisation can lead to big delays in the overall schedule
• Commissioning needs careful planning and control to ensure that all activities are carried out effectively and
in a timely manner
IPCIS Methodology – Phasing of Activities

CONSTRUCTION
Plant

COMMISSIONING
COMMISSIONING STARTUP
START-UP
COMMISSIONING OPERATION
START-UP
OPERATION
COMMISSIONING

PRE-COMMISSIONING DOSSIERS

PREPARATION COMMISSIONING Commissioning

MANAGEMENT

PROCESS
STARTUP
Operations
UTILITIES PERFORMANCE
STARTUP TESTS

TIME
MECHANICAL COMPLETION
MECHANICAL COMPLETION

PLANT IN OPERATION

FINAL ACCEPTANCE
1st REQUEST FOR

OF FIRST SYSTEM

PROCESS READY
UTILITIES READY
COMMISSIONING

FOR START-UP
FOR START-UP
OF SITE
IPCIS Methodology – The System Hierarchy

As in the OPERCOM methodology a

Location project is subdivided into a hierarchy
of Systems and Subsystems by a set
of delimitation rules

These systems and subsystems

System 1 System 2 System n reflect autonomous plant areas and
divisions thereof

As a result of the rules, each

subsystem can be considered
functionally independent for
Subsys 1 Subsys 2 Subsys n
commissioning purposes

Each subsystem comprises a number

of disciplines (eg Instrumentation,
Electrical, Piping, Mechanical) which
Discipline Discipline Discipline relate to equipment included

In terms of the commissioning, each

discipline comprises the individual
items under it which require to be
Item 1 Item 2 Item n tested under the commissioning
activities
IPCIS Methodology – The System Approach

Mechanical Ready for Provisional

completion start-up acceptance
SYSTEMS

Time

USING SYSTEM APPROACH

SYSTEM APPROACH
Pre-commissioning
=
Commissioning
TIME SAVING
Start-up

Pre-commissioning
Commissioning
Start-up

WITHOUT SYSTEM APPROACH

 IPCIS Commissioning Software
• A multi-user software package developed by Ipedex for the planning, implementation, management
and documentation of Pre-Commissioning and Commissioning activities
• Based on the OPERCOM methodology, featuring the Systems Approach to Commissioning
• Includes a database to include all relevant information for items to be commissioned plus
management tools to implement the commissioning
• Used in the Preparation Phase to set up the database with engineering information
• Include all items to be commissioned into the database
• Assign test sheets and specifications (included within the software)
• Set up the format of Pre-Commissioning and Commissioning Dossiers
• Printout of Pre-Commissioning and Commissioning Dossiers
• Used in during the Commissioning Phase to implement and manage the commissioning activities
• Print out test sheets and specifications
• Entry of test results to the database
• Management of Certificates for Commissioning activities
• Viewing of status of activities and management of the commissioning
• Development and management of punchlists and materials / information requests
• Viewing and printout of Progress and Punchlist reports
• Automatic compilation of Pre-Commissioning and Commissioning Dossiers to include test
results
• Viewing and printout of Pre-Commissioning and Commissioning Dossiers
IPCIS Software – Managing Users
Users are defined as required for
each project and assigned
passwords
Levels of access and authority are
defined for each user
Throughout the commissioning,
users are recorded when
• Test sheets and certificates are
signed
• Punchlists are set and cleared
This ensures integrity of the
commissioning documentation and
allows auditing of the activities
Multiple users may operate the
software simultaneously using a
network of PC’s
IPCIS Software – Preparing for Commissioning – Database

Use the Design Module to:

• Set up the System hierarchy
- Systems
- Subsystems
- Disciplines
• Input the items to be commissioned
into the database
• Set up for multi-element loops (Global
Functions) and Operational Test
Procedures
• Assign Test Sheets and Specifications

Data can be entered using a variety of methods:

• Import from spreadsheets
• Manual data entry
• Selection of data from AutoCAD P&ID’s
IPCIS Software – Preparing for Commissioning – Dossiers

Use the Publishing Module to:

• View and edit the contents of the Pre-
Commissioning and Commissioning
Dossiers
• Print out individual sheets, sections or
the complete dossier

The basic contents structure of a dossier is

included within the software and may easily
be edited, as required

Database information is gathered

automatically by the software, to include
complete documents in the correct place

Additional documents may be linked into the

contents structure and viewed and printed
as a part of the dossier

A typical dossier is presented in a format

reflecting the System hierarchy and includes:
• Certificates
• Status sheets
• Test sheets
• Punchlist reports
• Other documents, as required
IPCIS Software – Carrying Out the Commissioning – Test Sheets

Use the Input Module to:

• View the Test sheets and
enter data relevant to the tests
• Print out individual sheets for
use by commissioning
personnel

Test sheets and specifications are

designed to make the maximum use
of check boxes to allow rapid entry
of results into the database

Test sheets include electronic

signature boxes. A suitably
authorised user may electronically
sign the sheet. Signatures and
dates are recorded by the software
IPCIS Software – Carrying Out the Commissioning – Punchlists
If any test on a test sheet is failed, a
punchlist is automatically identified
for the item concerned

One of four levels of punchlist must

be selected, remedial action is
assigned to a party, comments are
included and materials / information
requirements are identified.

To clear the punchlist, reasons for

the clear must be identified.

The software records the user when

the punchlist was generated and
when it was cleared, for reporting
and audit purposes. Cleared
punchlists are still held by the
software for audit purposes

For levels of punchlist which block

progress, the software automatically
prevents signature of test sheets
and certificates relevant until the
punchlist has been cleared
IPCIS Software – Carrying Out the Commissioning – Status Information

From the Input Module, status information is available in a variety

of formats

For each discipline, subsystem, system, and for the complete

location a status report is available showing the current status of
activities for the next hierarchical level down

These status displays provide extensive information for areas

completed and areas blocked.

Punchlist status displays are also available for each level showing
complete information for punchlist items for lower levels

Icons, and their colours, in the navigation window also give the
user overview information at a glance
IPCIS Software – Carrying Out the Commissioning – Certification

The IPCIS software includes

certificates for completion of pre-
commissioning and commissioning
activities for each subsystem,
system and the complete location

For a certificate to be signed it is

necessary for all activities lower in
the System hierarchy to have been
successfully completed and all
lower level certificates signed

The user management facilities of

the software ensure that it is only
possible for a suitably authorised
user to sign a certificate

Certificates are accessed through

the Input Module
IPCIS Software – Carrying Out the Commissioning – Progress Reporting

The IPCIS Software automatically

tracks progress of the commissioning
activities

Report generation facilities are

included, allowing progress to be
viewed and status reports to be
generated and printed out.

Progress information is extracted from

the database and analysed on Excel
spreadsheets – giving a very flexible
presentation

Progress information is easily available

and may be input into project
management software for effective
control of commissioning activities
IPCIS Software – Carrying Out the Commissioning – Progress Reporting

Progress reports allow presentation of

information in various formats

Punchlist Status reports give clear

summary information of deficiencies
found for appropriate remedial action to
be taken
IPCIS Software – Final Pre-Commissioning & Commissioning Dossiers

During commissioning activities the dossiers

are automatically updated as test
information is completed into that database.

The Publishing Module is used to:

• Print out test sheets for use by the
commissioning personnel
• View this development of the Pre-
Commissioning and Commissioning
Dossiers
• Include other documents into the
dossiers as required through the
commissioning activities
• Print out individual sheets, sections or
the complete dossier

A typical dossier is presented in a format

reflecting the System hierarchy and includes:
• Certificates
• Status sheets
• Test sheets
• Punchlist reports
• Other documents, as required
IPCIS Integrated Commissioning Services
• 30 years worldwide experience in commissioning activities
• IPCIS division dedicated to commissioning services
• Methodology based on OPERCOM
• IPCIS software for preparation, management, execution and documentation
of commissioning activities
• IPCIS can provide services at a variety of levels
• Preparation / supply of commissioning dossiers
• Commissioning planning, manpower analysis / schedules, review and
development of related documents (lists of consumables, spares,
temporary means; procedures; specifications….)
• Commissioning management
• Commissioning supervision
• Complete commissioning execution
• Additional support available from Ipedex including Training, Individual
Development Programmes, Documentation Services, Operations and
Maintenance, supply of experienced personnel