Transcript No Slide Title

Project Phases of an EPIC Contract
Pre Project
Basic Eng
Detailed Eng
Typical EPIC Contract
E
Long Lead
Items
Procurement
Mechanical
Completion
P
MC
Prep
Installation
MC
Execute
I
RFSU
PC and Commissioning Preparation
PC
Execute
C
Plant in
Operation
Start
Up
Routine
Operation
Commissioning Objectives
Safety
• The plant 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 will prove it functions according to the design intent and
within the specific system and equipment design parameters
Documentation
• The commissioning team will ensure they document all phases of the commissioning process
Auditable Trail
• Documentation will be kept in such a way as to provide auditable evidence of the completion
process both during commissioning and during the initial stages of operation
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.
General Preparation
General Completion Preparation
• Develop Commissioning Execution Plan and Strategy
• Define plant start up sequence
• Define list of systems and sub systems
• Develop and issue colored P&ID’s and SLD’s showing limits of sub system
• Compile equipment lists by sub system
• Develop comprehensive detailed commissioning schedule (believe in the schedule)
• Import relevant data into CMS tracking system
• Develop discipline check lists for both MC and PC
MC and PC Preparation
• 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
• Develop a handover and acceptance protocol procedure
Project Breakdown
Systems and Sub systems
The standard Shell project completion strategy is
based on a breakdown of systems and sub systems
Project
A system is a major sub-division of an installation that
performs a major operation function of a plant. The
system testing is multi-disciplined
System
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 tested
as a single discipline
Sub-system
Equipment
The Sub-System Approach
Project Duration Without Sub System Approach
Project
Project Duration With Sub System Approach
TIME BENIFIT
System 1
System 2
System 3
MC
PC
Comm
Start Up
Sub-System Limit Definition
Sub-System Limits
Discipline Breakdown Within Sub-System Limits
Discipline Breakdown
Basic Tools Required
• Commissioning Execution Plan and
• Equipment Lists with Tag Numbers
Strategy
• Instrument Index
• Project System Listing
• Project Sub System Breakdown
• Colored System Based P&ID’s, SLD’s
• Robust MC and Commissioning Schedule
• Pipe Line and Valve Listing
• Loop Diagrams
• MC and PC Check Procedures
• MC and Commissioning Dossiers
• Completions Management System
(tracking tool)
• SPDC Operations Acceptance Criteria
• Document Control Register System
• System Based Commissioning Test
Procedures
• Interface Between MC and PC Defined
between Daewoo and Kogas
• Punch list Management Strategy
• Cable Schedules (E&I)
• Handover Acceptance Protocol
Developing Workable Systems and Sub-systems
Existing Project System Numbers
Develop Sub-systems
0 General
58 Corrosion Inhibitor
2 Production
62 Diesel
4 Utilities
63 Instrument Air
5 Supply/ Disposal
7 Facilities/ Safety
Develop Sub-sub System Boundaries
63-01 Air Compression CCGP
8 Electrical/Control
9 Civil/Structural
63-02 Air Receivers CCGP
63-03 Air Dryers CCGP
63-04 Utility Air Dist CCGP
63-05 Inst Air Dist CCGP
Develop Workable System Limit and Create
Multi-Disciplined Work Packs
6301-001
6301-002
Comp A
Dryer A
Comp B
Dryer B
Create Work Pack Status
Assign Discipline Check Procedure
Electrical
MCWP
PCWP
Instrument
MCWP
PCWP
MC
CP-A
Mechanical
MCWP
PCWP
Piping
MCWP
PCWP
PC
CP-B
MC to Commissioning and Acceptance Flow
Mechanical Completion Sub System
6301-001
Discipline Check Procedures CP-A
M&P
E&I
Pre Commissioning Sub System
63-01-001
MC Work Pack
(MCWP)
DAC
M
DAC
P
DAC
E
Discipline CP-B
M E I
Pre-Comm Work Pack
(PCWP)
CDAC
M
DAC
I
CDAC
I
Ready For Comm (RFC)
63-01
Mech Comp Certificate (MCC)
6301-001
Discipline CP-B
M
E
I
63-02-001
MCC from 6302-001
CDAC
E
Pre-Comm Work Pack
(PCWP)
SAC
CTP
System 63
Air
Commissioning Sub System
CDAC
M
CDAC
E
RFC
63-02
CDAC
I
Typical Preparation Flow PC Documentation
Develop System and Sub system
Breakdown
Mark up P&ID’s and SLD’s
By Discipline Develop PC Work
Pack by Subsystem
Input System/subsystem Data
into Completions Database
Review PC Check Procedures
and Adjust Content to Suit
Project Requirements
Input Data into Completions
Database
Input Data into Completions
Database
By Discipline Assign Specific
Check Procedures to Each Piece
of Equipment within Subsystem
Boundary to PCWP
Carry Out First Pass Review
Internally by Other Discipline
Adjust Data into Completions
Database as Final
Ready for Issue of PCWP
Gaps and Issues
• MC to PC interface and verification of completed construction works to enable
Mechanical Completion verification by Commissioning.(Daewoo/Kogas)
• MC Work pack development by sub system (Daewoo)
• PC Work pack development by sub system (Kogas)
• MC check procedure development and assignment to equipment (Daewoo)
• PC check procedure development and assignment to equipment (Kogas)
• Commissioning test procedure development by system (Kogas)
• Document control system development (Kogas)
• Schedule detail to be further developed to include, PC activities by sub system,
CTP activities by system, manpower histogram, system priority listing and
production of S curve and progress indication. (Kogas)