Best Practice Procedures in the transition from...
Transcript of Best Practice Procedures in the transition from...
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
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 Foster Wheeler. All rights reserved.
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
• 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
Why transition from Construction to Commissioning is so
important?
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
• 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-commissioning and commissioning
What is Mechanical Completion ?
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
• 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)
What is Pre-Commissioning and
Commissioning?
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Project Completion Data Base
En
gin
eering
Area Driven
Construction
System Completion
System Completion
System Completion
Area Driven Construction
System Completion
System Completion
Group of Systems
Completion
Group of
Systems
Completion
Rea
dy fo
r Pla
nt
Sta
rt-up
Preparation
& Data
Validation
Measure construction progress
Perform inspection and
test requirement
Measure progress.
Perform (pre)
commissioning
inspection and test.
Measure progress.
Punch-Out
&
Acceptance
Punch-Out &
Acceptance
Completion & Turnover Map
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Test
Pack
Punch
List TOD MC
Construction
Pre-Commissioning
Commissioning
Road Map for MC by Systems and
Handover to Commissioning
TOS
List Initial
Walkdown
Final
Walkdown
Punch List
Check-out
Testing
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Construction Completion Milestones
• TOS Self-contained portion of a facility/system for hand over
• 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
• TOD Final dossier including all applicable as-built engineering documents and
construction certificates as per ITP attesting the readiness for turn over
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
System
Process
Systems
Standard
Systems
Disciplines Disciplines
Sub-Systems Sub-Systems
Breakdown of Systems
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
BLACK UTILITIES TOS LIST
SYSTEM SYSTEM NUMBER RUNNING DESCTRIPTION TOS SUBSYSTEM TOS DESCRIPTION AREA
05.41-BS10/8/3 010 BLACK STEAM
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
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
05.41-BSC10/8/3 011 CONDENSATE
TOS-05.41-BSC10-001 CONDENSATE 10 BAR BASEMENT BASEMENT
TOS-05.41-BSC8-001 CONDENSATE 8 BAR BASEMENT BASEMENT
TOS-05.41-BSC3-001 CONDENSATE 3 BAR BASEMENT BASEMENT
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
05.41-CAI 012 CAI
TOS-05.41-CAI-001 CAI 10 BAR DISTRIBUTION BASEMENT BASEMENT
TOS-05.41-CAI-002 CAI 10 BAR DISTRIBUTION BULK 1 BULK 1
TOS-05.41-CAI-003 CAI 10 BAR DISTRIBUTION 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
Typical TOS List
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Test Pack Identification
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Punching and Walkdown
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Punch List Management
PUNCH LIST RESUMING FOR
SUBCONTRACTOR
Punch List Register
WN158-11.23-LIS-0001
Date 28-apr-12
CONTRACTOR or
VENDOR
A B C NO GR. TOTAL
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
TOT 434 621 73 78 1206 1496 1
1180 1341 105 188 2814
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Punch List by Discipline & Category
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
MC & Turnover Progress
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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 50,000 200,000 45,000
Typical Project Statistics
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
• Standardised preparation for mechanical completion and commissioning
• Maximization of electronic data transfer from engineering and project controls
• Continuous and auditable progress measurement (physical vs. QC achievements)
• Management of system-wise completion
• Structured and certified handover for all disciplines
• Controlling tool for the creation and management of all QC and MC forms
What is needed to administer this
Transition Phase
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
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)
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Project 1st Level
2nd Level
3rd Level
4th Level
Systems
Sub-Systems
Disciplines
TAGs
Typical Project Tree for TAG ging
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
TAG s Engineering
Disciplines
Civil:
• Foundation List
• Steel Structure List
• Underground List (Pits,
Duct, Sewer, etc.)
• Building
Piping:
• Line List
• ISO List
• Hydro Test Pack
Equipment:
• Rotating
• Pressure Vessels
• Heat Exchanger
• More
Electrical:
• Cable List
• Equipment List
• Grounding
• More
Instrument:
• Instrument List
• Cable List
• Fire & Gas
• More
HVAC:
• Piping List
• Cable List
• Instrument List
• Equipment List
TOS
Assignment of Discipline TAGs
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
System
Sub
System
Disciplines
TAGs
Data Base INPUT OUTPUT
System
Acceptance
Certificate
System Ready
for Pre-
Commissioning
Mechanical
Completion
Certificate
Turnover Vision
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
Data Base
Data Flow & Interfaces
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
28
Engineering TAG List
Unit
Group of Systems
Group of Systems
System
System
Plant Area
Constr Area
Constr Area
Select Quality Pack Type Select Quality Steps
Commissioning Systems Construction Areas
Overview
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
• 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
• The administration of voluminous turnover documentation necessitate the implementation of a
structured and tag oriented approach and application of software tools
Recommendations
THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Milan. Italy, October 12, 2012
PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION
THANK YOU…
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© 2012 Foster Wheeler. All rights reserved.