Transition From Construction To Commissioning

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 F
Foster Wh
Wheeler.
l All rights
i h reserved.
d
Milan. Italy, Ooctober 12, 2012 THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM
Why transition from Construction to Commissioning is so

important?
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
What is Mechanical Completion ?
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

pre-commissioning
commissioning and commissioning
What is Pre
Pre-Commissioning
Commissioning and
Commissioning?
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)
Completion & Turnover Map
Project
j Completion
p Data Base
System Completion
Group of Systems
Reaady for Plaant

Area Driven Completion
System Completion
Construction
E
Engineering
Start-up
S
System Completion
System Completion Group of

Systems
y
g
Area Driven Construction Completion

System Completion
Perform (pre)
Preparation Perform
f iinspection
i andd Punch-Out
Punch-Out & commissioning
& Data Measure construction progress test requirement &
Acceptance inspection and test.
Validation Measure progress. Acceptance
Measure progress.
Road Map for MC by Systems and

Handover to Commissioning
Pre Commissioning
Pre-Commissioning
Construction Commissioning
Final
TOS Test Punch Initial Walkdown MC Check-out
List Pack List
i Walkdown Punch List TOD Testing
Construction Completion Milestones

TOS Self-contained portion of a facility/system for hand over
(Turn Over System)

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


P
Punch
h List
Li t F
Formal
l inspection
i ti and
d id
identification
tifi ti off remaining
i i outstanding
t t di works
k
& Punch List
TOD Final dossier including all applicable as-built engineering documents and
(Turn Over Dossier) construction certificates as per Inspection & Test Plan attesting the
readiness for
f turn 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
Breakdown of Systems
System
y
Process Standard
Systems Systems
Sub-Systems Sub-Systems
Disciplines Disciplines
Typical TOS List
BLACKUTILITIESTOSLIST
SYSTEMNUMBER
SYSTEM RUNNING DESCTRIPTION TOSSUBSYSTEM TOSDESCRIPTION AREA
TOS05.41BS10001 BLACKSTEAM10BARBASEMENT BASEMENT
TOS05.41BS8001 BLACKSTEAM8BARDISTR.BASEMENT BASEMENT
TOS05.41BS3001 BLACKSTEAM3BARDISTR.BASEMENT BASEMENT
05.41BS10/8/3 010 BLACKSTEAM TOS05.41BS3002 BLACKSTEAM3BARDISTR.BULK1 BULK1
TOS05.41BS3003 BLACKSTEAM3BARDISTR.BULK2 BULK2
TOS05.41BS3004 BLACKSTEAM3BARDISTR.STERILEFILTRATION STERILEFILTRATION
TOS05.41BS3005 BLACKSTEAM3BARDISTR.CASA CASA
TOS05.41BSC10001 CONDENSATE10BARBASEMENT BASEMENT
05.41-BSC10/8/3 011 CONDENSATE TOS05.41BSC3002 CONDENSATE3BARBULK1 BULK1
TOS05.41BSC3003 CONDENSATE3BARBULK2 BULK2
TOS05.41BSC3004 CONDENSATE3STERILEFILTRATION STERILEFILTRATION
TOS05.41BSC3005 CONDENSATE3BARBULK2 CASA
TOS05.41CAI001 CAI10BARDISTRIBUTIONBASEMENT BASEMENT
TOS05.41CAI002 CAI10BARDISTRIBUTIONBULK1 BULK1
05 41-CAI
05.41-CAI 012 CAI TOS05
TOS 05.41
41CAI003
CAI 003 CAI 10 BAR DISTRIBUTION BULK 2
CAI10BARDISTRIBUTIONBULK2 BULK 2
BULK2
TOS05.41CAI004 CAI10BARDISTRIBUTIONCASA CASA
TOS05.41CAI005 CAI12BARGENER.ANDDISTR.CASA CASA
Test Pack Identification
Punching and Walkdown
Punch List Management

Punch List Register
PUNCH LIST RESUMING FOR
WN158-11.23-LIS-0001
SUBCONTRACTOR
Date 28-apr-12
CONTRACTOR or A B C NO GR. TOTAL

VENDOR 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
434 621 73 78 1206 1496 1
TOT
1180 1341 105 188 2814
Punch List by Discipline & Category
MC & Turnover Progress
Typical Project Statistics
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
60,000 50 000
50,000 200 000
200,000 45 000
45,000
What is needed to administer this

Transition Phase
S d di d preparation
Standardised i ffor mechanical
h i l completion
l i andd commissioning
i i i
Maximization of electronic data transfer from engineering and project controls
C ti
Continuous and
d auditable
dit bl progress measurementt (physical vs. QC achievements)
Management of system-wise completion
St t d and
Structured d certified
tifi d h
handover
d ffor allll disciplines
di i li
Controlling tool for the creation and management of all QC and MC forms
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)
Typical Project Tree for TAG ging
1st Level Systems Project
2nd Level Sub-Systems
3rd Level Disciplines
4th Level TAGs
Assignment of Discipline TAGs

TOS
Civil:
Instrument:
Foundation List
Instrument List
Steel Structure List
Cable List
Underground List (Pits,
Fire & Gas
Duct, Sewer, etc.)
More
Buildingg
Piping: Equipment:
Engineering Line List Rotating
TAG s
Disciplines ISO List Pressure Vessels
Hydro Test Pack Heat Exchanger
More
Electrical: HVAC:
Cable List Piping List
Equipment List Cable List
Grounding Instrument List
More Equipment List
Turnover Vision
System
System Acceptance
C tifi t
Certificate
S b
Sub
System
System Ready
INPUT OUTPUT for Pre-
Data Base Commissioning
Disciplines
Mechanical
TAGs Completion
Certificate
Data Flow & Interfaces
Data Base
Overview
Commissioning Systems Engineering TAG List Construction Areas
Unit Plant Area
Group of Systems Constr Area
G
Group off S
Systems
t Constr Area
System
System
Select Quality Pack Type Select Quality Steps
28
Recommendations
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
p
The administration of voluminous turnover documentation necessitate the implementation of a

structured and tag oriented approach and application of software tools
THANK YOU
www.fwc.com
Deniz_Metin_Kaya@fwceu.com
2012 Foster Wheeler. All rights reserved.

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PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Best Practice Procedures

Deniz Metin Kaya

Why transition from Construction to Commissioning is so

Safety environment is complex and difficult to manage

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

What is Mechanical Completion ?

Construction is completed in accordance with drawings, specifications, vendor instructions,

All inspection, checking and testing works are completed

System(s) and/or facilities are ready for pre

Completion & Turnover Map

Reaady for Plaant

System Completion Group of

Area Driven Construction Completion

Road Map for MC by Systems and

Construction Completion Milestones

Construction Completion Milestones

Test Package Set of documentation demonstrating the MC of a system or its subsystems

Construction Completion Milestones

Test Package Set of documentation demonstrating the MC of a system or its subsystems

Punch List Formal inspection and identification of remaining outstanding works

Construction Completion Milestones

Test Package Set of documentation demonstrating the MC of a system or its subsystems

Punch List Formal inspection and identification of remaining outstanding works

Initial Walkdown Identification and closure of all category A punch items

Construction Completion Milestones

Test Package Set of documentation demonstrating the MC of a system or its subsystems

Punch List Formal inspection and identification of remaining outstanding works

Initial Walkdown Identification and closure of all category A punch items

Construction Completion Milestones

Test Package Set of documentation demonstrating the MC of a system or its subsystems

Initial Walkdown Identification and closure of all category A punch items

Construction Completion Milestones

Test Package Set of documentation demonstrating the MC of a system or its subsystems

Punch List Formal inspection and identification of remaining outstanding works

Initial Walkdown Identification and closure of all category A punch items

Typical TOS List

Test Pack Identification

Punching and Walkdown

Punch List Management

CONTRACTOR or A B C NO GR. TOTAL

Punch List by Discipline & Category

MC & Turnover Progress

Typical Project Statistics

Project 1 Project 2 Project 3 Project 4

What is needed to administer this

Maximization of electronic data transfer from engineering and project controls

Management of system-wise completion

Basis of TAG Assignment

shall be TAG ged

shall belong to a family (Object Class)

Typical Project Tree for TAG ging

1st Level Systems Project

2nd Level Sub-Systems

3rd Level Disciplines

4th Level TAGs

Assignment of Discipline TAGs

Data Flow & Interfaces

Select Quality Pack Type Select Quality Steps

The achievement of highest coordination standards between construction and commissioning