1. Commissioning Approach Integrated Service Solutions

2. Integrated operation & maintenance
- Dynamic simulation support
- Process data reconciliation
- etc.
Engineering
Side by Side
optimising maintenance costs
maximising plant productivity
preserving asset integrity
Conduct Plant operation
Technical assistance for O&M
Training
Integrated operation & maintenance
O&M
Procurement Construction
Plant Life Cycle
Hands-on
Classroom
Training
Training
IOP
Simplant®
- Spare Parts
- M.M.
(Material Management)
- I.P.O.S.
(Integrated Procurement outsourcing services)
- Turnover Management Methodology
- Pre-commissioning
- Commissioning / start-up
- High Tech. Support
- technical assistance
Commissioning

3. Integrated operation & maintenance
- Dynamic simulation support
- Process data reconciliation
- etc.
Engineering
optimising maintenance costs
maximising plant productivity
preserving asset integrity
Integrated operation & maintenance
O&M
Procurement Construction
Plant Life Cycle
Hands-on
Classroom
Training
Training
IOP
Simplant®
- Spare Parts
- I.P.O.S.
(Integrated Procurement outsourcing services)
- Turnover Management Methodology
- Pre-commissioning
- Commissioning / start-up
- High Tech. Support
- High tech. personnel
Commissioning

4. Turnover Management Methodology
Main Root
Main Activities
Certificates/Issues
Turnover management system operating manual check and preparation
Preparatory works
(Home office activities)
Tool for Mesurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc)
Interim Handover Certificate verification (P/L outstanding)
Mechanical Completion verification
Field inspections, documentation inspection (outstanding Item verification)
Inspections, Punch-list issueing, utilities comm, cleaning, flushing, blowing, chemical cleaning, non operating adjustment, motor run-in, catalyst, internal inspection, ...
Ready for Commissioning Certificate
Precommissioning
Ready for Start-up
Certificate
Commissioning
Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, ……..
Ready for performance test
Oil-In
Start-Up
Provisional Acceptance Certificate
Performance Tests
Conduct performance tests
End

5. Turnover management system operating manual check and preparation
Home Office Phase
(Preparatory work)
Turnover management system operating manual check and preparation
Preparatory works
(Home office activities)
Tool for Measurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc)
The Turnover Management System will allow to:
Manage QA/QC certificates
Manage Construction piping activities
Manage Construction electrical activities
Manage Construction instrument activities
Manage Construction machinery activities
Manage Construction punch lists
Have Construction progress per area
Have Construction overview progress
Have day by day reports
Manage the transaction between construction and commissioning activities
Manage pre-commissioning activities based on construction progress
Manage punch list outstanding items
Manage pre-commissioning and commissioning punch list
Manage Turnover progress and certificates
Manage mechanical completion progress, certificates and activities
Manage reinstatement progress, certificates and activities
Manage ready for pre-commissioning turnover progress, certificates and activities
Manage ready for commissioning turnover progress, certificates and activities
Manage performance test turnover progress, certificates and activities
Manage provisional acceptance turnover progress, certificates and activities
Dossiers management

6. Turnover Management System
System layout
SYSTEM START-UP
PASSWORD
USER'S AREA
PASSWORD
ADMINISTRATOR'S AREA
Construction
Commissioning
Piping
Electrical
Instrument
Machninery
Mechanical Completion
Flushing
Welding
Type 1
Preinst.
Type 1
Tighteness Test
Piping
Type 2
Installat.
Type 2
Performance Test
Hydrotest
Type 3
Operation
Type 3
Provisional Test
Reports &
Progress
Reinstat.
Type 4
Type 4
Acceptance Test
Loop Check
Dossier Filling
Punch List Management
Handover Management
Outstanding Item
management

7. Turnover Management System System detail pictures
2) Main Menu
3) Instrument management system
1) Main password
6) Punch List Out standing Item
4) Piping Menu
5) Punch List management system
9) Hydrotest Progress
7) Piping Construction management system
8) Equipment Management system

8. Pre-commissioning & Commissioning manuals
preparation & check
Pre-commissioning and Commissioning Manual
Operating Manual
Pre-commissioning and Commissioning Manual will be supplied as a collection of precommissioning procedures; these procedures are operating instructions for the activities to be carried out during the performing of precommissioning.
The list of the procedures of the pre-commissioning manual is the following:
    Mechanical Preparation
·                    Chemical Cleaning Instructions
·                    Physical Cleaning Instructions
·                    Mechanical Restoration
·                    Machinery Run in
·                    Tightness test
·                    Electrical testing/functional tests/energising
·                    Instruments calibration and functional test
·                    Loading of chemicals
·                    Loading of catalyst
·                    Heaters drying
·                    Chemicals boil out of steam generation facilities
·                    Verification of Mechanical Completion
·                    Performance Test
Operating Manual with the following contents:
Introduction
General
Basis of design
Duty of plant
Environmental conditions
Feedstocks and products specifications
Battery limit conditions
Specifications and consumption of utilities, chemicals catalysts
Process Description
Description of flow
Process Variables
Process Theory
Preparation for Initial Start-up
Plant Inspection
Cleaning of Piping and equipment
Specific pre-start-up operations
Start-up procedure
Normal Operation
Normal Shutdown Procedure
Emergency Shutdown
Analytical requirements
Attachments (P&ID’s, Class Specifications and other Project documents)

9. In order to optimize time and costs we will:
Interim Handover Certificate verification (P/L outstanding)
Mechanical Completion verification
Field inspections, documentation inspection (outstanding Item verification)
In order to optimize time and costs we will:
Verify the mechanical completion Punch list outstanding items via field inspections and certificates control and registration;
Plan the pre-commissioning and commissioning activities based on the real situation

10. utilities commissioning cleaning flushing blowing chemical cleaning
Inspections, Punch-list issueing, utilities comm, cleaning, flushing, blowing, chemical cleaning, non operating adjustment, motor run-in, catalyst, internal inspection, ...
Ready for Commissioning Certificate
Precommissioning
inspection
punch-listing
utilities commissioning
cleaning
flushing
blowing
chemical cleaning
non operating adjustment
motor run in
vessel loading
internals
catalyst
desiccant
resins
packing
drying
machinery alignment
instrument calibration
loopchecking
orifice plates installation
safety valves bench test
tightness test

11. Check all spring hangers
Ready for Start-up certificate
Commissioning
Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, ……..
Check all spring hangers
Start up cooling water system,which may include Chlorinator
Run in pumps on water,where possible, and establish Circulation
Start up compressors,where possible,on nitrogen and air
Activate the inert gas system
Light flare pilots, if used, and activate flare purges at the extremity of lines in the unit
Turn on the fuel gas system to process burners
Start up the fuel oil system to process burners
Boil out the steam generator (if it has not been chemically cleaned during pre-commissioning) Commission water treating facilities
Implement steam system andsteam trcing before insulation is checked
Activate condensate systems
Purge equipment, where required
Perform operational pressure test
Run required vcuum tests
Dry out refractories and heaters and special lines
Reactor system dry out
Check waste-treatment area for operation
Circulate chemical solutions where required
Activate catalysts where required
Prepare for and circulate test oil
Recheck all trip circuits and their bypasses
Practice normal and emergency shutdowns. If time allows, practice restarts

12. Introduce feed at low flow rate
Start-up
Oil-in
Ready for Performance test
Introduce feed at low flow rate
Adjust temperatures, pressures, levels and flows
Route off-specifications material to the designated areas
When the product reaches the specifications route it to storage
Increase slowly the feed rate to the Unit until the designed value.
Provisional Acceptance Certificate
Performance Tests
Conduct performance tests
Performance Tests Procedures preparation and validation
Systems preparation for performance tests
Conduct performance test in order to meet process guaranteed figures

13. Pre-commissioning & Commissioning typical organization chart
Comerint
Main Contractor

14. iop, sop....etc

15. iop, sop....etc

16. Simplant

17. Simplant

18. Comerint Organisation Chart

19. Comerint services during Plant Life Cycle
EPC CONTRACTORS
OWNERS
OPERATIONS
MAINTENANCE
CONSULTANCY SERVICES
TRAINING AND HRD (CTS)
ENGINEERING AND TECHNICAL DEPT.
SUPPORT SERVICES (SIMULATION)
COMMISSIONING
START-UP