MC and Commissioning Preparation

Typical Commissioning Objectives 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.

General Preparation 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 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

Project Breakdown Systems and Sub systems Project System Sub-system A good completion strategy is dependant on early development of the correct structure and foundation thus allowing the establishment of system based activities Project 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 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 pre-commissioned 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

Typical Sub-System Limit Definition Sub-System Limits

Discipline Breakdown Within Sub-System Limits

Developing Workable Systems and Sub-systems Typical Project Numbers Develop Systems 0 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 50 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 Create Work Pack Status Assign Discipline Check Procedure Electrical MCWP PCWP Instrument MCWP PCWP MC CP-A 5204-001 5204-002 5204-003 General Generator Fire Pump Mechanical MCWP PCWP Piping MCWP PCWP PC CP-B

Mechanical Completion Sub-sub System Pre Commissioning Sub-sub System MC to Commissioning and Acceptance Flow Mechanical Completion Sub-sub System Pre Commissioning Sub-sub System 52-04-001 CP-B E M I 5204-001 CP-A M & P E & I MC Work Pack Pre-Comm Work Pack M CDAC E CDAC I CDAC M DAC P DAC E DAC I DAC RFC 5204-001 MCC 5204-001 52-04-002 Discipline CP-B E M I MC from 5204-002 Pre-Comm Work Pack SAC CTP System 52 Diesel M CDAC E CDAC I CDAC Commissioning System RFC 5204-002

PWCOM Total Completions System

PWCOM Flow Mechanical Completion Construction Check Sheet CP-A Work pack Development Check Sheet CP-A Work pack Development Verification Engineering Pre Commissioning Data Data Operation Maintenance Check Sheet CP-B Procedure Development Verification Commissioning Handover Acceptance Verification

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