Commissioning & Start-up Directory

1 Commissioning & Start-up Directory INTEGRATED SERVICE SOLUTIONS. Index 1. CHAPTER INTRODUCTION 4. 2. CHAPTER Commissioning & start UP SERVICE 5. Commissioning Standard Implementation Path 6. The Home Office Phase 7. (Pre-) Commissioning Engineering 8. (Pre-) Commissioning and Start-up Manuals 11. The Site Phase 14. Mechanical Completition Check & Interim Handover 14. Pre- Commissioning Period 15. Commissioning & Start-up Period 16. System Turnover Management 17. 3. CHAPTER DEDICATED TOOL 18. 1 2. CHAPTER Introduction CHAPTER Commissioning & Start-up Service ISS International is well experienced in Pre-Commis- The senior technicians and the engineers who make up The standard definitions used are as follows: sioning and Commissioning activities and can provide our staff have been all chosen on the basis of the pro- the in-deph experience, guidance and qualified per- fessionalism, versatility and ability to adapt themselves Pre- Commissioning Pre- Commissioning activities start when the plant, or system, achieves Mechanical Completion.

2 Fre- sonnel necessary to deliver a unit Safely prepared and to the different environment and industrial culture of our quently however, Pre- Commissioning activities overlap Mechanical Completion activities and for this ready to achieve a successful Start-up . customers covering both Home-Office and Site reason the plant should be separated into easily manageable system package, each system pack- phases providing specific services as well as the im- age will be Pre-Commissioned as a whole and isolations at the boundaries of the system package plementation of fully integrated projects even on a will be maintained until the completion of Pre- Commissioning activities. Turn-Key approach. Pre- Commissioning activities include: checking for design conformity, checking the status of elec- trical, mechanical and instrument installations, running-in of equipment, flushing and cleaning ac- tivities, drying, etc.

3 Commissioning Commissioning is the phase in a project when design process fluids are introduced to the process. Note that for hydrocarbon systems the Commissioning activities commence with inerting operations. Manage your business even before you turn the key . Commissioning activities normally consist of activities associated with running or operating the plant and include operating adjustments necessary for satisfactory operation of the plant or part thereof. Also included are Functional checks which are methods used to prove that an item of mechanical equipment or control system functions correctly. Start-up Start-up is the point in a project where process fluids and conditions are established with the intent of making products. System A section of the plant or facility that can be Pre-Commissioned and commissioned independently, but in parallel, with other sections of the plant or facility under construction.

4 Unit Ready for This is the point in a project where all utilities are commissioned and operational and the Commissioning unit is ready to accept the introduction of hydrocarbons. Unit Ready for This is the point in a project where the unit is ready to establish process conditions with Start-up the intent of making product. 4 Commissioning & Start-up Directory Commissioning & Start-up Directory 5. Commissioning STANDARD IMPLEMENTATION PATH THE HOME OFFICE PHASE. ISS International Standard Pre- Commissioning , Home Office Phase During this phase the preparation of Tool for measure- (Pre-) Commissioning & Start-up Manual Commissioning and Start-up Methodology is organized Preparatory Works ment and reporting of Pre- Commissioning & Commis- a. Development of (Pre-) Commissioning and start - considering the entire project frame and having in mind (Home office Activities).

5 Sioning activities Progress, project detailed plan, Up Manuals the following objective: TO CONDUCT THE PLANT IN Site Phase project detailed and operative deployment plan, prepa- b. Quality Manual OPERATION. Mechanical Completion Check ration of detailed procedures , etc. take place. Quality Control Plan (according to API 700 Sec. 3 & 4) During this phase the following activities will be carried Quality Control Forms The entire Commissioning Service process is devel- Pre- Commissioning out, but not limited to: oped according to the following phases: Commissioning & Start-up Performance Tests. (Pre-) Commissioning Engineering a. System/Subsystem definition The ISS International Standard implementation path Marked-up P&ID by System is shown in the following figure: b. Detailed Pre- Commissioning / Commissioning Ex- ecution Plan Organization Chart Deployment plan per activity c.

6 Generic Method Statement Preparatory Tool for Measurement and reporting of Turnover management system d. Commissioning Plan and Critical Path Network works (Home office Pre-Comm & Comm. Activities (CWPMS) operating manual Progress, preparation of details (planning, etc.) & Procedures check and/or preparation Activities to be performed by System activities). Mechanical API 700 sec. 3&4 Interim Handover Certificate e. Organisation Roles And Responsibilities f. Punch-listing method Statement Completion Filed inspections, documentation inspection verification (P/L oustanding). verification (outstanding Item verification). g. Commissioning input to the Design Process P&ID Review HazOp Reviews Precommissioning Inspections, Punch-list issuing, utilities comm, cleaning, Ready for Commissioning flushing blowing, chemical cleaning, non operating adjustment, Certificate h.

7 Commissioning Spare Parts & Consumables motor run-in, catalyst, internal inspection, .. i. Sample and Testing Schedule System Turnover Commissioning Cooling water Start-up , spring hangers check, Ready for Start-up j. Equipment Data Logging a. Handover: The Turnover Management System for operating adjustment, purging, pressure test, .. Certificate Start-up Commissioning (TMSCOM ). Tool implementation and configuration. Oil-In Ready for performance test Performance Conduct performance tests Provisional Acceptance Certificate Tests END. 6 Commissioning & Start-up Directory Commissioning & Start-up Directory 7. (Pre-) Commissioning Engineering Hydro-test boundaries should coincide with system A vendor schedule will be developed that identifies ven- Punch-Listing Method Statement boundaries, where possible. dor requirements for each item of equipment.

8 Support- A system will be developed to identify (see TMSCOM . ISS International Commissioning and technical person- Systems should be defined by colour coding a set of A3 ing documentation will provide information on required Para.), record and correct damaged, incomplete and nel will produce a number of deliverables. The docu- P&IDs. System boundaries should be flagged in RED vendor activities, support required and approximate du- incorrect installation and/or fabrication. Items which are ments will entirely fulfil the contractual requirements for and system numbers should be clearly marked at reg- ration of each major activity. inaccessible or unsafe will be incorporated into this sys- the pre- Commissioning , Commissioning , Start-up and ular intervals on the respective line-work and equip- tem. The system will be able to allow categorisation of initial operation of the complex as per customer docu- ment.

9 Generic Method Statements punch-list items as follows: ments. System summary sheets should be prepared which list Generic method statements is developed for each ac- Main activities of these phase can be summarized as the system content by line and equipment numbers. tivity type (Cleaning, Leak Test, Inerting, etc.). Each Category A Items that must be cleared prior to follows: statement will form the basis for the development of start of Pre- Commissioning Detailed Pre- Commissioning / Commissioning Ex- safe and efficient detailed procedures. The method Category B Items that can be cleared during System/Subsystem Definition ecution Plan statements will contain information on the methodol- pre- Commissioning To enable a smooth transition from construction to com- A plan is developed that identifies all of the major pre- ogy, acceptance criteria and HSE implications.

10 Category C Commissioning Items missioning it is required to complete construction work Commissioning activities by system. The plan will be de- in small packages (known as systems). This enables veloped in reverse and will clearly identify system Commissioning Plan and Critical Path Network The system will be able to track outstanding items by Pre- Commissioning work to progress from an earlier ready for pre- Commissioning milestones. A network is developed those indexes and identifies all system, category and discipline. point in the schedule, thus reducing the final pre-com- Commencement of system turnover from construction start up activities. missioning peak workload substantially. However, sys- to Commissioning should ideally commence at ap- Parallel and consecutive activities will be identified. Commissioning input to the Design Process temised turnover is more complex to co-ordinate and proximately 70% erection completion.