Commissioning

An integrated project team (IPT) is a multidisciplinary group of people who work with transparency and are collectively responsible for delivering a defined product or process.

The objective of the IPT is focusing significant attention on fully understanding the needs and desires of each stakeholder.

Operations

• The operating personnel must live with the plant once it is built.  Their timely input can result in a design that is most logical for operator utilization by identifying operating concepts so that control rooms and key control stations are located on the same level, placing instruments and associated manual controls in logical proximity, allowing space for working storage and have recently operated similar types of plants and can therefore contribute innovation, based on practical experience.
• Incorporating operator requirements, can improve startup and “commitment” by these key personnel.  Conducting careful reviews with operating personnel can result in considerable savings during startup and mechanical completion.
• Commissioning Procedures that can be easily carried onto Operational, Maintenance  and Preventive Maintenance  Procedures.

Maintenance

• Meaningful reviews by maintenance personnel have a much more subtle and longer range impact.  Maintenance costs and often more importantly, shutdown time for turnarounds, can be minimized if proper access, drop-out areas and monorails can be incorporated into the design.  The method of handling equipment for maintenance can best be defined by the plant maintenance personnel, based on their experience, proposed philosophy and available or planned mobile and rigging equipment.

• Contractors, Subcontractors & Vendors

• Integrated work scope planning, interfaces with construction and has a much more subtle and longer range impact when leveling resources.
• Time to complete is as important as cost.

• Construction will coordinate with IPT after 80% completion of systems/subsystems using systems not areas as Critical Path.
• P1, P2 and P3 Priorities are systems critical path.
• Priority 1, Quarters Habitable (QH)  • all QH systems commissioned with exception of Interface Connections

 Mechanical Spools, Electrical Cables, Control & Network Cables

• Priority 2, Certificate of Inspection

(COI)

• all COI system/subsystems shall be made as ready as possible

• Pre-commissioning of  subsystems
• Every Loop Shot on Deck
• All Safety Logic Tested  Planned Carryover Work

• Priority 2.5, Hook Up &

Commissioning (HUC) Preparations

• All Interface Connections Readied for Offshore HUC
• Hydro Test Spools & Piping
• Meggar & Hi-Pot Feeds, Power
• Laser Test Fiber-Optic Network, SIS
• Continuity Test Hardwires, F&G
• Priority 3, Ops Readiness (OR)
• Unplanned Carryover Work

• Start-up and Shutdown Logic Test
• Start-up and First Oil Operations
• System/Subsystem Based
• Fabrication during procurement done using test sheets similar to normal fabrication (Completed at Vendor Shop, Part of the Manufacturer Data Records)

• FAT (Factory Acceptance Test) – Final Inspection Test prior to leaving shop.
• SAT (Site Acceptance Test) – Vendor reviews the Fabrication quality.  The test will ensure that no damage was done during shipping and will test integration points to the remaining facility.
• Sub-system completion – Confirmation that all fabrication work has been done to the latest design
• Pre-Commissioning Test
• SIT Procedure
• Automation & Network Systems
• FAT Test
• SAT Test

Controls  Objective The objective is to ensure that system components are commissioned and tested in a safe and controlled manner while confirming compliance with the design intent and the criteria for system and equipment performance.

• Construction Completion, when referring to IPT means that Construction , Commissioning and Operations work together and agree:

• Provided erection is in accordance with drawings, specifications, vendor instructions, applicable codes and regulations and authority requirements.
• IPT will work with construction completing all inspections, checking and testing work as listed in the checklist for mechanical completion, applicable to the specific project.
• It is recognized that structural, decking, piping, painting, insulation, ect., along with final clean up and removal of temporary facilities must be completed by Williams before facilities completion is achieved.  However, at the time of mechanical completion of facility, a system or an area, this work need not be totally complete, but should be in a sufficiently advanced state of completion, as not to interfere with subsequent activities such as precommissioning and commissioning.
• The IPT will note all exceptions, as stated above should be agreed upon and included in the punch-list attached to the certificate of mechanical completion.

Mechanical Completion

• means that  Construction has provided and Commissioning has approved that erection in accordance with drawings and specifications and other items referred to in the definition of mechanical completion, plus pre-commissioning and commissioning, if applicable to the specific project and other items not completed when mechanical completion was reached.  When plant completion is reached and accepted as such by IPT and Operator is deemed to have fulfilled all his obligations under the construction part of the contract.

Pre-Commissioning

• is defined as energized pre-start up check out, system adjustment, equipment and system activation, required to allow IPT members  to prepare the facility for operations.

Start Up Operations and Systems/Subsystem Commissioning

• Support work to bring the facility in production readiness.
• Running of equipment, motors, instrumentation, etc. by IPT
• Introducing into the plant of process liquids and gasses with Ops
• By agreement specialized subcontract services, as required to assist IPT in commissioning and start up of the facility but it should be recognized that Operator has responsibility.

Structural

• Infill deck plates
• Stairs
• Replacement of any tertiary steel from Installation
• Mechanical
• Welding of tie in spools (c/w NDE andHydro)

• Gross Leak Testing
• Equipment Installs
• Reinstatements
• Electrical
• Interconnect Tray Assemblies
• Interconnect cables to Hull (c/w Test Sheets)

• Phase Rotation Testing and motor run tests
• Automation and Business Networks
• Integration testing with network systems
• Full Shut-down test after Start-up sequence simulation

FEED & Engineering/Design

• Commissioning Manager
• Project Specifications, 26 weeks

• Operational Readiness, 26 weeks
• Engineering/Design Coordination and Collaborations,

78 weeks Planning & Scheduling

• IPT Supervisors & Ops
• Engineering, Contractors , Subcontractors and

Vendors Integrating scopes, 52 weeks Onshore Commissioning Scope

• IPT  System Commissioning Procedures, 26 weeks
• Construction Completions to Mechanical Completions 26 weeks

• IPT Operations/Maintenance
• Full time  Mechanical Completions to PreCommissioning 16 weeks
• IPT Leads/Commissioning Tech support
• P2 & P3, Pre-Commissioning  to Onshore Commissioning 16 weeks
• IPT Specialty Vendors support
• P1, Commissioning to complete 16 weeks  Offshore Scope, HUC
• CC, MC, Pre-Com and Com 16 weeks after structural Hook Up
• P1 goal is Quarters Habitable availability in less than 8 weeks after Topsides is set on Hull
• P2 goal is COI available in less than 12 weeks after QH

• P3 goal is First Oil available in less than 6 weeks after COI