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
System Completion
System Completion
System Completion
Area Driven Construction
Group of
Systems
y
Completion
System Completion
Preparation
& Data
Validation
Measure construction progress
Perform
f
iinspection
i andd
test requirement
Measure progress.
Punch-Out &
Acceptance
Perform (pre)
commissioning
inspection and test.
Measure progress.
Reaady for Plaant

Start-up
S
E
Engineering
g
Area Driven
Construction
Group of Systems
Completion
Punch-Out
&
Acceptance
Road Map for MC by Systems and

Handover to Commissioning
Construction
TOS
List
Test
Pack
Punch
List
i
Initial
Walkdown
Pre Commissioning
Pre-Commissioning
Commissioning
Final
Walkdown
Punch List
MC
TOD
Check-out
Testing
Construction Completion Milestones
TOS
Self-contained portion of a facility/system for hand over
(Turn Over System)
TOS
Test Package
Set of documentation demonstrating the MC of a system or its subsystems

or sections that can be isolated for test purposes
TOS
Test Package

Punch List
Formal inspection and identification of remaining outstanding works
TOS
Test Package

Punch List
Initial Walkdown
Identification and closure of all category A punch items
TOS
Test Package

Punch List
Initial Walkdown
Final Walkdown
& Punch List
Demonstration and acceptance of a pre-checked system for hand over
TOS
Test Package

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
Initial Walkdown
Final Walkdown
& 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
TOS
Test Package

Punch List
Initial Walkdown
Final Walkdown
& 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
SYSTEM
SYSTEMNUMBER
RUNNING
05.41BS10/8/3
05.41-BSC10/8/3
05 41-CAI
05.41-CAI
010
011
012
DESCTRIPTION
BLACKSTEAM
CONDENSATE
CAI
TOSSUBSYSTEM
TOSDESCRIPTION
AREA
TOS05.41BS10001
BLACKSTEAM10BARBASEMENT
BASEMENT
TOS05.41BS8001
BLACKSTEAM8BARDISTR.BASEMENT
BASEMENT
TOS05.41BS3001
BLACKSTEAM3BARDISTR.BASEMENT
BASEMENT
TOS05.41BS3002
BLACKSTEAM3BARDISTR.BULK1
BULK1
TOS05.41BS3003
BLACKSTEAM3BARDISTR.BULK2
BULK2
TOS05.41BS3004
BLACKSTEAM3BARDISTR.STERILEFILTRATION
STERILEFILTRATION
TOS05.41BS3005
BLACKSTEAM3BARDISTR.CASA
CASA
TOS05.41BSC10001
CONDENSATE10BARBASEMENT
BASEMENT
TOS05.41BSC8001
BASEMENT
TOS05.41BSC3001
BASEMENT
TOS05.41BSC3002
CONDENSATE3BARBULK1
BULK1
TOS05.41BSC3003
CONDENSATE3BARBULK2
BULK2
TOS05.41BSC3004
CONDENSATE3STERILEFILTRATION
STERILEFILTRATION
TOS05.41BSC3005
CONDENSATE3BARBULK2
CASA
TOS05.41CAI001
CAI10BARDISTRIBUTIONBASEMENT
BASEMENT
TOS05.41CAI002
CAI10BARDISTRIBUTIONBULK1
BULK1
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 RESUMING FOR
SUBCONTRACTOR
Date
28-apr-12
TOTAL
CONTRACTOR or
VENDOR
NO GR.
To Close
To Close
To Close
To Close
To Close
Closed
Hold
CONTRACTOR # 1
CONTRACTOR # 2
CONTRACTOR # 3
CONTRACTOR # 4
CONTRACTOR # 5
CONTRACTOR # 6
CONTRACTOR # 7
CONTRACTOR # 8
CONTRACTOR # 9
VENDOR #1
VENDOR #3
VENDOR #4
VENDOR #5
VENDOR #6
VENDOR #7
VENDOR #8
43
117
3
17
13
28
60
0
0
23
4
49
29
48
0
0
88
100
32
89
59
135
58
0
0
10
0
18
11
21
0
0
6
23
0
12
8
15
8
0
0
1
0
0
0
0
0
0
1
43
0
4
0
0
0
13
1
0
0
0
0
0
0
16
138
283
35
122
80
178
126
13
1
34
4
67
40
69
0
16
301
23
0
232
336
248
106
0
0
27
6
33
38
31
28
87
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
434
621
73
78
1206
1496
1180
1341
105
188
TOT
Punch List Register

WN158-11.23-LIS-0001
2814
Punch List by Discipline & Category
MC & Turnover Progress
Typical Project Statistics
Project 1
Project 2
Project 3
Project 4
350
340
140
250
37
13
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
Systems
Units
What is needed to administer this

Transition Phase
S d di d preparation
Standardised
i ffor mechanical
h i l completion
l i and
d 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
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
vs. QC achievements)
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
2nd Level
Sub-Systems
3rd Level
Disciplines
4th Level
TAGs
Project
Assignment of Discipline TAGs

TOS
Civil:
Foundation List
Steel Structure List
Underground List (Pits,
Duct, Sewer, etc.)
Building
g
Engineering
Disciplines
Instrument:
Instrument List
Cable List
Fire & Gas
More
Piping:
Line List
ISO List
Hydro Test Pack
Equipment:
Rotating
Pressure Vessels
Heat Exchanger
More
Electrical:
Cable List
Equipment List
Grounding
More
HVAC:
Piping List
Cable List
Instrument List
Equipment List
TAG s
Turnover Vision
System
Acceptance
C tifi t
Certificate
System
S b
Sub
System
INPUT
Data Base
OUTPUT
System Ready
for PreCommissioning
Disciplines
TAGs
Mechanical
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

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

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

Milan. Italy, Ooctober 12, 2012

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

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

Milan. Italy, Ooctober 12, 2012

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Milan. Italy, Ooctober 12, 2012

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Completion & Turnover Map

Measure construction progress

Milan. Italy, Ooctober 12, 2012

Reaady for Plaant

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Road Map for MC by Systems and

Milan. Italy, Ooctober 12, 2012

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Construction Completion Milestones

Milan. Italy, Ooctober 12, 2012

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Construction Completion Milestones

Self-contained portion of a facility/system for hand over

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

Milan. Italy, Ooctober 12, 2012

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Construction Completion Milestones

Self-contained portion of a facility/system for hand over

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

Formal inspection and identification of remaining outstanding works

Milan. Italy, Ooctober 12, 2012

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM

PUSHING THE LIMITS OF ENGINEERING CONSTRUCTION

Construction Completion Milestones

Self-contained portion of a facility/system for hand over

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

Formal inspection and identification of remaining outstanding works

Identification and closure of all category A punch items

Milan. Italy, Ooctober 12, 2012

THIRD ANIMP CONSTRUCTION CONFERENCE & ECI AUTUMN FORUM