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MC and Commissioning Preparation
Safety
• The plant or facility will be commissioned in such a manner that it ensures the safety of all personnel and avoids damage to any part of the plant or equipment
Design Confirmation
• The commissioning of the plant or facility will prove it functions according to the design intent and within the specific system and equipment design parameters
Documentation
• The construction and commissioning groups will ensure they document all phases of the completion process
Auditable Trail
• Documentation will be kept in such a way as to provide auditable evidence of the completion process during construction completion / pre commissioning and through to system completion
Budget and Schedule
• The commissioning process will be managed to ensure the project completion is within the defined schedule and budget
Operational Acceptance
• Early operational acceptance criteria will be defined and included in the commissioning process to ensure a smooth transition at both handover and acceptance between contractor and client.
Typical Commissioning Objectives
General Completion Preparation
• Develop Commissioning execution plan and strategy
• Define plant start up sequence and set priorities
• Define list of systems, sub systems and sub sub systems
• Develop and issue colored P&ID’s and SLD’s showing limits of workable sub system
• Compile equipment lists by sub system and discipline
• Develop comprehensive detailed commissioning schedule (believe in the schedule)
• Align and import relevant engineering data into PWCOM tracking system
• Review and align discipline check procedures for both MC and PC
General Preparation
MC and PC Preparation
• Finalize and develop MC and PC check procedures
• Develop MC and PC dossiers to be used as a handover document to hold all the relevant completion information. • Develop system based commissioning test procedures • Develop a punch list management system and utilize PWCOM to track all activities
• Develop a handover and acceptance protocol procedure
A good completion strategy is dependant on early development of the correct structure and foundation thus allowing the establishment of system based activities
A system is a major sub-division of an installation that performs a major operation function of a plant or facility. The installation and commissioning of this system is multi-disciplined
A sub system is a sub-division of the system that performs a given operational function with no or little interference from the other parts of the plant. It also contains the equipment and is usually checked and pre-commissioned as a single discipline
Systems and Sub systems
Project
System
Sub-system
Equipment
Project Breakdown
Project Duration Without Sub System Approach
Project
MC PC Comm Start Up
Project Duration With Sub System Approach
TIME BENIFITSystem 1
System 2
System 3
The Sub-System Approach
Sub-System Limits
Typical Sub-System Limit Definition
Discipline Breakdown
Discipline Breakdown Within Sub-System Limits
Typical Project Numbers0 Wells/Sub-sea
1 Hull
2 Oil Process
3 Gas Process
4 Process Utilities
5 Utilities
6 Fire and safety
7 Electrical
8 Integrated Control
Develop Systems50 Instrument Air
51 Fresh Potable Water
52 Diesel
Develop Sub-System Boundaries
5201 Storage
5202 Purification
5203 Supply
5204 Transfer
Develop Workable Limits and Create Multi-Disciplined Work Packs
GeneralGeneral GeneratorGenerator Fire PumpFire Pump
5204-001 5204-002 5204-003
Create Work Pack Status Assign Discipline Check Procedure
MechanicalMCWPPCWP
MechanicalMCWPPCWP
PipingMCWPPCWP
PipingMCWPPCWP
InstrumentMCWPPCWP
InstrumentMCWPPCWP
ElectricalMCWPPCWP
ElectricalMCWPPCWP
MCCP-A
PCCP-B
Developing Workable Systems and Sub-systems
5204-0015204-001
MC Work Pack MC Work Pack
MCC5204-001
MCC5204-001
52-04-00152-04-001 CP-B
E M I
CP-BE M I
RFC5204-001
RFC5204-001
Pre-Comm Work PackPre-Comm Work Pack
Mechanical Completion Sub-sub System Pre Commissioning Sub-sub System
Commissioning System
CP-AM & P E & I
CP-AM & P E & I
52-04-00252-04-002 Discipline CP-B
E M I
Discipline CP-BE M I
RFC5204-002
RFC5204-002
Pre-Comm Work PackPre-Comm Work Pack
MC from 5204-002
MDAC
MDAC
MCDAC
MCDAC E
CDAC
ECDAC I
CDAC
ICDACP
DAC
PDAC E
DAC
EDAC I
DAC
IDAC
MCDAC
MCDAC E
CDAC
ECDAC I
CDAC
ICDAC
CTPSystem 52
Diesel
CTPSystem 52
DieselSACSAC
MC to Commissioning and Acceptance Flow
PWCOM Total Completions System
PreCommissioning
PreCommissioning
Mechanical Completion
Mechanical Completion
Check SheetCP-A
Check SheetCP-A
EngineeringEngineering
ConstructionConstruction
Check SheetCP-B
Check SheetCP-B
CommissioningCommissioning
AcceptanceAcceptanceHandoverHandover
OperationMaintenance
OperationMaintenance
Data
Data
Verification
Ve
rific
atio
n
Wo
rk p
ack
De
velo
pm
en
t
Work pack
Development
Verification
Pro
ced
ure
De
velo
pm
en
t
PWCOM Flow
PWCOM Preparation
• Develop system and sub system definition
• Mark up the relevant P&ID’ and SLD’s to suit the system definition into workable sub systems
• Align system and sub system definition into PWCOM
• Review check procedures CP-A and CP-B and adjust to suit project requirements
• Align engineering data externally to suit PWCOM input requirements including sub system and discipline alignment
• Import engineering tags into PWCOM
• Assign tags with the required CP-A and CP-B
• The MC and PC work packs are automatically developed within PWCOM
• Print out all draft MC and PC work packs and carry out first pass verification review of their content
• Ensure all the relevant data is captured and that the relevant checks have been correctly assigned
• Readjust MC and PC work packs to suit verification review and re print
• Carry out second pass review and adjust to suit
• Issue MC and PC work packs as final
• Print out and date MC and PC work packs including all relevant CP-A, CP-B’s
PWCOM Execution
• Issue and assign all MC work packs to field including CP-A’s
• On completion of CP-A sign off within PWCOM
• When all discipline CP-A’s are complete and signed off for specific MC work pack, issue discipline acceptance certificate DAC
• When all DAC’s are issued for that specific sub system, issue mechanical completion Certificate MCC
• Issue and assign all PC work packs to field including CP-B’s
• On completion of CP-B sign off within PWCOM
• When all discipline CP-B’s are complete and signed off for the specific PC work pack, issue commissioning discipline acceptance certificate CDAC
• When all CDAC’s are issued for that specific sub system, issue ready for commissioning certificate RFC
• The system is now ready for multi discipline commissioning via the commissioning test procedure CTP
PWCOM Main Menu
PWCOM is a Microsoft access 2000 based database with a visual basic software platform.
The system is designed to be very user friendly and flexible enough to suit any site condition and project quality requirements without the need
for corporate intervention.
System Development
The project system and sub systems are developed as the foundation of PWCOM and are further split into workable levels into sub sub systems
Internal MC and PC check procedures
PWCOM has a complete set of both construction and pre commissioning check procedures across all disciplines and can be easily adjusted and formatted
internally to suit any project requirement
Project Tag Register
The tag register is developed buy importing the relevant project engineering data and assigning specific sub systems to each tag which then forms the basis of the work pack
development . Engineering data of any format can be utilized and imported
Assigning check procedures to Tagged Items
Each tag will be assigned a specific check procedure to suit the project requirements and forms the basis of the verification process and auditable trail of
checks carried out during both construction and commissioning
Automatic Development of MC Workpacks
The Mechanical Completion work packs are automatically developed as each tag is assigned a sub system and specific check procedure CP-A
Automatic Development of PC Workpacks
The PC work packs are automatically developed as each tag is assigned a sub system and specific check procedure CP-B
Sign Off Completed check procedures
Signing off completed check procedures is an easy task and creates the final verification platform. It also allows progress reporting to be established at any
level required
Mass Update Ability
By using the mass update function, the assignment of checks procedures and revised data is by the click of a button
Automatic Development of Certification
The development of the relevant certification requirements is an automatic function. The certificates can be adjusted to suit the project QA/QC requirements
Discipline Acceptance Certificates
The standard issue of discipline acceptance certificates when the relevant work packs are complete is recommended but in some instances you may need to use
the added ability of being able issue partial completion which will include all outstanding activities listed on the certificate
Internal Development of check procedures
The development of the check procedures is carried out
internally therefore eliminating the need for external word
documents to be developed and allowing greater flexibility
should you need it on site
Internal Progress Reports Available
There are many reporting levels within PWCOM with it having the added ability of changing the reports to suit any project managers requirements. The reports are
generated by either discipline, system, subsystem or tag number. Each check procedure has an assigned hourly norm allocated therefore allowing the
calculation of man hours to be very accurate
Typical Progress Report
Bar Chart Type Progress Report
This report uses the reference of the total check procedures assigned as 100% therefore allowing the calculation of completed check procedures as a % to be
very accurate. Progress is achieved when the sheet is returned and signed off in PWCOM
Automatic Development of S Curve Reports
Internal Punchlist Capability
The punchlist is managed internally within PWCOM and encompasses both construction and commissioning activities consolidating as one punchlist
Punchlist Development
Each punchlist generic description is given a reference code therefore eliminating the need to for the site engineers to spend hours typing in the descriptions of the
punch
Typical Punchlist Summary Report
The reports are developed with as much detail as the project requires with each punchlist referenced back to a system and tag to enable accurate progress
reporting levels to be established
Typical CP-A and CP-B check procedures
MC and PC Workpack Forms