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

Ipedex Commissioning

Integrated Services

IPCIS

ExperienceProvision of commissioning

services worldwide since 1970

Extensive Reference List

MethodologyCommissioning methodology

based on OPERCOM

Ipedex licensed by TFE

ManpowerExperienced Project Managers, Site Leaders, Superintendents,

Engineers, Technicians and support personnel

SoftwareIPCIS Commissioning Software

for Planning, Management, 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

Commissioning Complete

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

Phase Activities Milestone

Pre-commissioning Conformity checksStatic testsHydrotestsFlushing & cleaning

Ready for Commissioning(Mechanical Completion)

Commissioning EnergisationDynamic testsEquipment running-inUtilities start-upPre-start-up activitiesOperational tests

Ready for Start-up

Start-up Feed inPerformance testsBringing the plant on-line

Provisional AcceptancePlant in Operation

IPCIS Methodology – Phasing of Activities

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COMMISSIONING COMMISSIONINGSTARTUP START-UPCOMMISSIONINGOPERATION

COMMISSIONING

PRE-COMMISSIONING

PROCESSSTARTUP

UTILITIESSTARTUP

PERFORMANCETESTS

PREPARATION

MANAGEMENT

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Operations

IPCIS Methodology – The System Hierarchy

Location

System 1 System 2 System n

Subsys 1 Subsys 2 Subsys n

Discipline Discipline Discipline

Item 1 Item 2 Item n

As in the OPERCOM methodology a project is subdivided into a hierarchy of Systems and Subsystems by a set of delimitation rules

These systems and subsystems reflect autonomous plant areas and divisions thereof

As a result of the rules, each subsystem can be considered functionally independent for commissioning purposes

Each subsystem comprises a number of disciplines (eg Instrumentation, Electrical, Piping, Mechanical) which relate to equipment included

In terms of the commissioning, each discipline comprises the individual items under it which require to be tested under the commissioning activities

IPCIS Methodology – The System Approach

SYSTEM APPROACH=

TIME SAVING

Start-up

Commissioning

Pre-commissioning

Pre-commissioning

Commissioning

Start-up

USING SYSTEM APPROACH

WITHOUT SYSTEM APPROACH

Mechanicalcompletion

Ready forstart-up

Provisionalacceptance

TimeSY

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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 passwordsLevels of access and authority are defined for each userThroughout the commissioning, users are recorded when

• Test sheets and certificates are signed

• Punchlists are set and clearedThis ensures integrity of the commissioning documentation and allows auditing of the activitiesMultiple users may operate the software simultaneously using a network of PC’s

IPCIS Software – Preparing for Commissioning – Database

Data can be entered using a variety of methods:• Import from spreadsheets• Manual data entry• Selection of data from AutoCAD P&ID’s

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

IPCIS Software – Preparing for Commissioning – Dossiers

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

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

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

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

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

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