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Revision 1.0
Revision: 1.0
Petroleum Development Oman LLC Effective: Dec-10
This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part
of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
i Document Authorisation
Authorised For Issue – December 2010
ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
See Appendix 3
TABLE OF CONTENTS
1 Introduction........................................................................................................................... 6
1.1 Purpose........................................................................................................................... 6
1.2 Review and Improvement............................................................................................... 6
1.3 Step-out Approval............................................................................................................ 6
2 Strategy................................................................................................................................. 7
Figure 1 – RACI Overview........................................................................................................ 8
3 Flawless Project Delivery...................................................................................................... 9
4 Asset Ownership and Asset Management Transfer Strategy..............................................10
4.1 Asset Ownership............................................................................................................ 10
4.2 Asset Management Transfer..........................................................................................10
4.3 Final Asset Management Handover...............................................................................11
4.4 Acceptance criteria........................................................................................................ 11
5 Commissioning Management System & Completions Tools...............................................13
5.1 Commissioning Management system structure.............................................................13
5.1.1 Strategy................................................................................................................... 13
5.1.2 Control.................................................................................................................... 13
5.1.3 HSE......................................................................................................................... 13
5.1.4 Flawless Project Deliver (FPD)...............................................................................14
5.2 Certification and Completions Management System....................................................14
5.3 Systemisation................................................................................................................ 14
6 Organisation........................................................................................................................ 16
Figure 2 – CSU Organisation at Pre-Commissioning / Commissioning.................................16
Figure 3 – CSU Organisation Post RFU.................................................................................17
7 Competence........................................................................................................................ 18
Appendix 1 – Definitions and Terminology.................................................................................20
Appendix 2 – Abbreviations........................................................................................................ 22
Appendix 3 – Reference Material...............................................................................................23
1 Introduction
The Pre-Commissioning, Commissioning and Start-Up of facilities have been an area
of concern in PDO. The “Key Principles” detailed in this specification shall be used to
develop the “Commissioning and Start-Up Strategy” produced in the Select Phase.
IMPORTANT: The “Commissioning and Start-Up Strategy” is a DCAF deliverable.
The Key Commissioning and Start Up (CSU) Principles are aligned to the PDO
Procedure PR-1159 Engineering and Operations Commissioning and Start-Up
The Commissioning and Start-Up Phase of a Project is characterised by:
The risks of producing (toxic sour) oil and gas at pressure for the first time in
the life of a facility;
The requirement to utilise systems and procedures of the Operations
Management System (OMS) and Emergency Response (ER) system for the
first time;
The requirement to ensure that Process Safety and Asset Integrity are assured
at all times;
The complexity of operating a new facility where multiple parties are present
and multiple activities are being completed simultaneously;
For a brown field development: Integration of the new facilities into the existing
operation;
IMPORTANT NOTE: For High H2S (Sour) Project an extra phase may be needed
where the facility is gassed up with sweet Hydrocarbons. Only once the facility has
been tested on sweet hydrocarbons the Sour hydrocarbons will be introduced.
1.1 Purpose
The purpose of this specification is to ensure the Commissioning and Start-Up Strategy
is consistent throughout all projects and addresses the Key Principals detailed here in.
2 Strategy
The PDO CSU strategy for Pre-Commissioning and Commissioning shall be direct
supervision by a PDO lead CSU team, but may augmented by CSU staff from a
specialist CSU contractor.
Utilities systems shall normally be pre-commissioned / commissioned ahead of any
other system to supply energy to all systems. The Start-up shall be supervised by the
Operations Team supported by the CSU team (refer to remark 1 in Figure 1 and
Section 4.2).
IMPORTANT NOTE: Support services for Pre-Commissioning and Commissioning
shall be provided by the EPC and this shall be reflected in the contracting strategy.
Such support services may include:
Technician workforce
Scaffold
Riggers
Material Support & Management
Vendor call off
Consumables supply
First Fills
Admin assistance
Planners
Test Equipment
Tools
NOTE: Other strategies are possible, but they may place greater reliance on
contractor’s competence and capability to execute CSU activities. Recent experience in
PDO projects has shown major shortcomings in the EPC community.
The CSU strategy shall be part of the EPC Contract scope, roles and responsibilities.
The Scope shall include system milestone payments that meet optimum start up
sequence rather than area and commodity based payments.
Depending on the contract, the contractor may have little responsibilities post
start-up, e.g. warranty issues and defect management. It may be necessary for
the asset manager to take ownership / leadership of follow-on activities with
technical assistance taken from in-house engineering contractor or the project
engineering contractor under the direction of the CSU team.
These considerations shall be incorporated in the Project (EPC) contract.
5.1.1 Strategy
Commissioning Execution and Start Up Strategy (this document)
Handover Procedure
Systemization Procedure
Start Up Network
Commissioning Manual (PR-1159)
5.1.2 Control
Manpower Resource Plan including Vendor mobilisation plan
Level 4 Pre-Commissioning and Commissioning schedule
Spade / Blinds Management Procedure
Punch list Guidelines
Commissioning procedures
Commissioning Spares
First fills/Chemical register
System / Sub-system list
System marked up drawings (PEFS, Elec, Instr etc.)
Temporary equipment register
GU-623 - Project Completion Management System CMS Guideline
5.1.3 HSE
HSE plan and reporting system
Commissioning Emergency response Procedures
Journey Management Procedure
Emergency Response Plan
Waste Management Plan
Permit To Work Manual
5.3 Systemisation
Pre-Commissioning (sub system / discipline driven), Commissioning (system driven)
and Start-Up shall be ‘systems’ based. Early in the FEED phase of the project these
(sub) systems shall be defined and agreed, including all interfaces.
Systems shall be defined from a commissioning start-up point of view and be as ‘large
as possible’ parts of a unit to enable operations to make individual commissioning and
start-up progress.
A system shall be a composite assembly of hardware that has a singular purpose within
a unit, that can be commissioned and brought to Ready For Start Up (RFSU) status, to
a significant extent, without dependency on other systems.
The (sub) systemization approach must be applied not only to process (including utility)
systems, but also non-process systems i.e. civil and building works, and all supporting
electrical, telecom and instrument facilities.
The main reason for systemization shall be to achieve Mechanical Completion (MC)
followed by Ready For start UP (RFSU) in a structured way, thus enabling the
introduction of hydrocarbons.
6 Organisation
The Commissioning Process shall be a Project Deliverable hence the Project Manager
remains responsible for Commissioning and Start-Up until Final Handover. Start-Up i.e.
the Introduction of Hydrocarbons shall be effected by an Operations Team that is
competent in the operation of live hydrocarbon facilities.
Refer to Section 4.2 for a description of the responsibilities for the CSU manager and
the Operations Manager
The Commissioning Start-Up (CSU) Team shall start-up and operate the non-
hydrocarbon systems during commissioning activities until these systems are fully
proven and handover to Operations can be carried out. See Figures 2 & 3 below for
Organisation and Reporting relationships.
Oil And Gas Director
PDO Project
Engineer
PDO Project
Engineer
7 Competence
In the lifecycle of a facility the Commissioning and Start-Up period covers a relative
short period. The specific skills for the CSU process are difficult to build as staff tends
to be absorbed in the Operations organisation or if contract staff, will dissipate to a
next, possibly Non-PDO, project.
The CSU engineer shall show competence in the following:
1. Commissioning Organisation
Staff Experience requirements
Operator Involvement/ Integration
Key Positions
Functions and functional requirements
2. Commissioning Planning
Understanding CSU scope
Logic
Schedule
Commissioning Execution
Work Scope method statements
FPD methodology
3. Commissioning Deliverables
Systemisation
System Handover and punch listing
Commissioning procedures
CCMS
Administration procedures
(Vendor) Site support requirements
Vendor procedures and documentation
Training modules
Commissioning spares
First Fills
4. HSSE in Commissioning
Permit to Work
SIMOPS
Risk Assessment Methodology and Job Hazard Analysis
HSSE management and Operations HSSE Case
Regulatory requirements
Environmental Restriction (Flaring, water disposal etc)
ER requirements during CSU
Appendix 2 – Abbreviations
The following abbreviations have been used in this specification.