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THE OPERCOM METHODOLOGY

From TOTAL Company

Introduction

By T. R. D.
Technique & Régulation
Développement

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Index Introduction
Introduction
Project phases New Installation
System approach • Technically complex : Upstream, …
• Project dimensions : Platforms, FPSO, …
Precommissioning methodology
• Sophisticated data control and safety systems
Commissioning methodology • Aggressive environment
Technical preparation
Certificates and transfer of responsibility
F.A.T
O.T.P ; definition, preparation, principles …
Technical execution
Organisation
Conclusion
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Introduction Introduction

Requirements Specifications
• Higher efficiency, • Precomm. / Com. Guidelines
• Reliability, • GS EP EXP 101 Rev 4 - 09/05
• Safety, • Precomm. / Com Techn. Prep.
• Short planning, • GS EP EXP 103 Rev 4 - 09/05
• Precommissioning Execution
• GS EP EXP 105 Rev 3 - 09/05
• • Commissioning Execution
• GS EP EXP 107 Rev 3 - 09/05

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Introduction Introduction

Opercom Glossaire
• Project,
• To cover these requirements of new installations, • Discipline,
• Unit,
• Client, owner, company, operator,
• And reach these objectives
• Contractor EPSC, EPSCC, Turnkey,
• Project team, Contractor, Vendor,
• TOTAL has developed OPERCOM Methodology,
• Certifying authority.
• Based on know how and latest experiences.

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Project Phases

Basic engineering
Detail engineering
Construction & Precom. / item verif.
Project phases Commissioning / basic function verif.
Start-up
Routine operation.

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Project Phases PHASES

Typical Completion activities

• Consist of a series of various verifications carried out
BASIC
ENGINEERING
DETAILED
ENGINEERING Engineering prior to start-up of the plant.(just before the plant is
brought on line)
Long • The aim is to ensure that all equipments are built and
Lead
Items
PROCUREMENT Procurement Operate as per design.(last critical review before start-
up)
• Goals are to render the plant oil or/and gas in as safe
CONSTRUCTION Construction MECHANICAL
and without trouble, to get the routine production
PRECOMMISSIONING COMPLETION status as soon as possible.
READY FOR
COMMISSIONING • The completion activities are separated into two phases

COMMISSIONING
Commissioning (static)
COMMISSIONING PHASE READY FOR READY FOR (Dynamic)
OERATION
START-UP
• Followed by the
ROUTINE phase (introduction of hydrocarbon)
START-UP PHASE PVP
OPERATIONS

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PHASES Project Phases
Phases & Milestones
Start-Up activities
Construction
Commissioning
• The start-up activities are the final preparation to the Routine
introduction of the hydrocarbon into the plant. Utilities Start-Up Operations
• The start-up activities are prepared with the integration Start-Up
of specific Start-Up nad outine procedures (OPERGUID) Performance
Process
• These field activities consists of two sub-stages Precommissioning Start-Up
Test

Provisional
• Operate prior oil/gas in (PVP, safety tests, ) acceptance
• Operate after oil/gas in : bring the process in operation
with oil/gas in , water injection,.. + performance tests …. Mechanical
Mechanical
Completion Ready for Ready for Ready for Final acceptance
Commissioning Start-Up Operation EPC Contract

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Project Phases
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Project Phases
Summary of completion activities
Phases– Preparation, management, ...
CONSTRUCTION

COMMISSIONING
START-UP OPERATION
PRE-COMMISSIONING
DOSSIERS
Witness Precom

PREPARATION COMMISSIONING

MANAGEMENT involved

UTILITIES PROCESS PERFORMANCE

STARTUP START UP TESTS

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Project Phases System Approach

Classification of activities Completion constraints

• List of main completion & start-up activities by • Construction work progress is mainly planned by
discipline and major types of equipment, disciplines and areas,
• Checking and testing phases are long and complicated
• Classified per category:
processes,
• Precommissioning
• Commissioning • All parts of the plant never reach the same progress of
• Start-up completion at the same time.
• Operation
• Regarding the technical specificity of the project

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System Approach

Functional constraints
• Some areas or units are mechanically completed while
others are not,
• Start-up sequence of a new plant is directed by
operational constraints:
System Approach
• Safety equipment,
• Utility equipment (as power generation),
• Process equipment,
• Optimisation of the start-up phase needs the sequential
completion of multidiscipline units.

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System Approach System Approach

Others constraints Subsystem

• Optimisation of means and resources, • A Subsystem is a part of a system required for
commissioning purpose and start-up sequence,
• All tasks related to precom/com and start-up cannot
occur simultaneously, • Example:
• Fire water pump
• To start commissioning activities, it is impossible to • HV switchgear
wait the full mechanical completion of the plant. • Air compressor

• A3- Moho Subsystem list and modules lists rev3.xls

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System Approach System Approach

System Limits
• Project planning have to be optimised, considering that
completion activities are organised by system
INSTRUMENTS D
VESSEL
• A system is a subdivision of the plant that performs a &
PIPING
C
independent operational function. S

• Example:
• Fire water
• Power generation
• Instrument air ELECTRICAL

PUMP
SWB
MECHANICAL MOTOR LCS

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System Approach System Approach

Delimitation rules : Time benefit(2)

• Delimitation_OPERCOM_SS_Selection.ppt

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System Approach System Approach

Subsystem breakdown error sample: Example:

• sub system error.ppt

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Precommissioning

Specifications
• GS EP EXP 103: Precommissioning technical preparation,
• GS EP EXP 105: Precommissioning execution.

Precommissioning • All necessary technical procedures and support

document,

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Precommissioning Precommissioning

Index Scope of work

• Specification, • For all equipment items,
• Scope of work, • Systematic conformity checks,
• Status index, • Static tests
• Check lists, • Systematic pipes and vessels flushing and cleaning
• Test sheets,
• Punch list, • No spot or random checks and tests are allowed,
• Dossiers,
• Summary. • Prepared, carried-out and reported by subsystem.

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Precommissioning Precommissioning

Check Lists Status index (precommissioning database)

• Conformity checks as per check list forms, • The status index is the list of all tasks to be performed
• Forms available in GS EP EXP 105. (See examples in during precom. phase.
Appendix) • Created from engineering equipment list,
• Each check list defines the scope of the task on every • Arranged per subsystem, discipline and type of
item of equipment or package, equipment,
• Check list are used to record relevant check, • Defines the precommissioning scope of work,
• One check list is filled per subsystem and type of • The status index is a working document used to follow-
equipment. up the precommissioning work progress.

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Precommissioning Precommissioning

Test sheets Status index

• Test sheet forms are available in GS EP EXP 105 for • Example
every type of precommissioning test listed in the
classification of activities (examples in appendix)
• Static and de-energised tests as per technical
specifications and reported on test sheets,
• One test sheet is filled for each test performed.

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Precommissioning Precommissioning

Punch list Dossiers

• During precommissioning checks and tests, • Content of Precommissioning dossiers,
• Record and up-date of all discrepancies, damages, • Ready for Commissioning Certificate,
malfunctions, missing equipment / document, • Punch list,
• Sub-System Description and marked-up drawings,
• In subsystem punch lists,
• Status Index, by discipline,
• In order to have a precise status of each subsystem at • Check list, Test sheets, by discipline,
the Ready For Commissioning stage (RFC). • As-built drawings, by discipline,
• Vendor’s reports,
• Specific procedures and tests,
• List of modifications.

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Precommissioning Precommissioning

Methodology
Dossiers

• Specific dossier arranged by subsystem,

• Compilation of all the information required to

demonstrate that the subsystem has reached the
Ready For Commissioning status.

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Commissioning

Specifications
• GS EP EXP 103: Commissioning preparation,
GS EP EXP 107: Commissioning execution.
• All required technical procedures and support
Commissioning
documents,
• To prepare and carry out commissioning activities.

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Commissioning Commissioning

Index Scope of work,

• Scope of work, • The scope of works consists of:
• Preliminary check, • Dynamic verification of elementary process functions,
• Functional tests, • Actual online test of utilities and major equipment,
• Operational tests, • Oil or gas-in preparation activities,
• Pipe and Vessel Preparation activities, • The scope of work is divided into 4 separate activities:
• Technical data base, • Preliminary checks,
• Functional tests,
• Punch list, • Operational tests,
• Dossiers, • Piping and vessels preparation
• Summary. • and is organised by subsystem.

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Commissioning Commissioning

Preliminary check, Operational tests

• A verification that the subsystem is Ready for • Can be done when all basic functions of a subsystem
Commissioning, have been functionally tested,
• Carried out by discipline and formalised by a form • To bring a subsystem into operation with conditions as
available in GS EP EXP 107 (Form 2621) close as possible to running conditions,
• It consists of: • Follows an Operational Test Procedure (see later in
• Physical check of the subsystem installation, detail) established and approved during commissioning
• Review of the precommissioning dossier. preparation,
• Review of the precommissioning punch list • No standard procedure, a format is given in GS EP EXP
107 (example in Appendix)
• Witnessed and countersigned by operation team.

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Commissioning Commissioning

Functional tests Piping and vessels preparation

• Test of one item or group of items that perform an • Specific activities to prepare the oil or gas-in:
elementary function of the process, called • Leak test at pipework maximum operating pressure,
“Basic Function” • Drying-out,
• In GS EP EXP 107, list and definition of all possible types • Chemical loading,
of basic function per discipline are included, • Inerting.
• Tests are performed as per specification and recorded • Performed following procedures and reports included in
on Functional Test Sheets, GS EP EXP 107
• Test sheet forms are available in GS EP EXP 107 (see • May be related to more than a subsystem or system.
examples in appendix)

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Commissioning Commissioning

Technical data base Dossiers

• A list of all basic functions, grouped by subsystem, type
of basic function and discipline, • Specific dossier by subsystem,
• Established by commissioning team during preparation
phase,
• Compilation of all information required to demonstrate
• The database indicates the type of test required by to the operation that the subsystem has reached the
referring to the typical form number, “Ready for start-up” status

• Used for the follow-up of the commissioning activities.

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Commissioning Commissioning

Punch list Dossiers

• Updating the precommissioning punch list, by addition • Content:
• Ready for start-up certificate
of new found discrepancies and/or deletion of cleared • Subsystem definition drawings
ones, • Data base print-out
• Commissioning reports:
• Becomes the Ready for Start-up punch list, • Preliminary checks reports
• Gives a precise status of each subsystem when reaching • Functional test sheets
• Piping and Vessels Preparation reports
the Ready for Start-up condition. • Operational test procedures
• Vendors reports
• Mechanical reports
• Punch list
• As-built drawings
• List of modifications
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Commissioning Technical preparation

Methodology Index
• Policy
• General preparation
• Precommissioning preparation,
• Documents, Planning, Contracts.
• Commissioning preparation,
• Documents, Planning, Contracts, Supports.

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Technical preparation

Policy
• Precommissioning & commissioning activities have to
be done in a short period,
• Company policy is to thoroughly prepare long before
Technical
the beginning of completion activities, not only all
Preparation
precom and com tasks, but also all side activities, such
as organisation, documentation, spares,etc.
• So the organisation can be efficient right from day one.
• Company policy consists in a common approach from
end of construction until the start-up.

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Technical preparation
General
• General preparation activities are:
• Define list of systems and subsystems (refer to GS EP EXP
101)
• Define plant start-up sequence
• Issue marked-up PID’s and OLD’s showing limits of
subsystems,
• FPU PIDs Marked-Up rev99.pdf
• Compile equipment lists by subsystems,
• Define all tasks related to the partition of the plant into
systems and subsystems.
• These activities have to take place during the detailed
engineering phase
• These activities are an engineering contractor
responsibility.
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Technical preparation
Precommissioning
• Creation of the status index, arranged by subsystem,
discipline and type of item of equipment,
• Reviewing the set of precommissioning master forms,
adaptation or amendment the forms as required by the
distinctive features of the project,
• Filling out the Check lists and test sheets according to
the status index.
• Issuing the precommissioning dossier
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Technical preparation
Commissioning
• Preparation of the list of planned operational tests,
complemented for each test by a test summary,
schematics and Operational Test Procedures,
• Development of the task register, list by subsystem of
all elementary commissioning tasks to be carried out,
• Estimation of man-hours, manpower, duration of all
task,
• Development of the Commissioning network or
subsystem precedence diagrams,
• Development of the schedule by subsystem and type of
activity showing the duration, start and end of each
activity ( Planning level 2).
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Technical preparation
Commissioning
• Preparation of the schedule by system of the
commissioning activities ( Planning level 1),
• Preparation of the “Ready For Start-up” dates,
• Preparation of a commissioning progress calculation
method based on physical progress,
• Evaluation of overall man-hours, duration and
preparation execution histograms by discipline,
• Preparation of the field commissioning organisation and
deployment schedule,
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Technical preparation
Precommissioning
• Estimation of manpower and duration of the
precommissioning activities of each subsystem
• Preparation of the precommissioning planning showing
the beginning and end of the activities by subsystem
• Identification of the need for vendors, field equipment
spares, vendors special equipment and special tools
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Technical preparation
Commissioning
• Creation of the list of all instrument, electrical and
telecommunications basic functions by subsystem,
• Creation of the commissioning technical data base by
subsystem
• Reviewing the set of master functional test sheet forms
addition, adaptation or amendment of the forms as
required by the distinctive features of the project,
• Filling out the functional test sheets according to the
technical data base.
• Preparation of the list of Piping & Vessels preparation of
each subsystem with detailed procedures and support
documents.
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Technical preparation
Commissioning
• Compilation of the lists of spares, lubricants, chemicals
and special tools included in the various P.O.
• Preparation of the lists of tools, test equipment and
consumables required to carry out commissioning
operations,
• Definition of the temporary facilities (air, nitrogen,
power generation, ….), equipment and connections
necessary to carry out commissioning.
• Selection of the commissioning staff and execution
personnel with the personnel mobilisation schedule
• Preparation of the vendors representatives schedule and
relevant purchase orders
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Technical preparation
Commissioning
• Preparation of the documentation required for the
preparation and execution of the commissioning tests,
• Preparation of a cost control procedure in accordance
with project management procedures.
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Completion Activities :Technical A- Certificates and transfer of
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preparation and Execution responsibility
COMPLETION ACTIVITY COMPLETION ACTIVITY
PREPARATION EXECUTION
(GSEXP-103) (GSEXP-105 & GSEXP-107) Definition
A- GENERAL OPERCOM PREPARATION
(GSEXP-101-103)
D – PRECOMMISSIONING EXECUTION • Contractor shall issue for Company’s signature
(GSEXP-105) Certificates in order to attest that the facilities have
1- Subsystem Preparation
1- Conformity Checks reached predefined stages of Completion.
2- Start-Up Sequence Preparation
3- Coloured Marked-Up Drawing Preparation
2- Static Tests • After a full review of realisation on Work Site and
4- Subsystem Engineering List Preparation
3- Piping Tests through document evidence, Company agrees either
B- PRECOMMISSIONING PREPARATION totally (certificate), or partially (interim certificate), that
(GSEXP-103) E- COMMISSIONING EXECUTION the level of completion has been reached to pass to
1- Status Index Preparation (GSEXP-107) further stage.
2- Precomm. Dossier Preparation 1- Preliminary Checks
• A Punch list is raised with each certificate which details
2- Functionnal Tests
3- Precomm. Manpower Estimate Preparation exceptions, omissions in, or errors to the necessary
3- Operating tests
4- Long Precomm. Task Preparation completion level, agreed by all parties with priorities
4- Piping & Vessels Preparation
C- COMMISSIONING PREPARATION and dates identified for completion.
(GSEXP-103)
• The certificates are raised for each Subsystem up to the
1- Technical Database Preparation
Ready For Start Up certificate.
2- Commissioning Dossier Preparation
3- Comm. Manpower Estimate prepa
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Certificates (cont…)
What is involved
General Preparation These certificates are:
Establish Subsystem Boundaries and prepare coloured PID’s & SLD’s
Develop initial Start-up Sequence in conjunction with Construction
Build Equipment Lists from Engineering lists and schedules
Identify Spares, Temporaries and Specialist requirements
Prepare and issue Preservation Schedules
RFC Ready For Commissioning certificate
Precommissioning Preparation OT Operational Test certificate
Prepare and issue Precommissioning Procedures
Assign OPERCOM Check and Test sheets to each item of equipment
Develop the Precommissioning Status Index
Prepare Precommissioning (RFC) Dossiers for each Subsystem
RFSU Ready For Start Up certificate
Prepare Precommissioning planning and resource levels

RFO Ready For Operation

Commissioning Preparation
Prepare and issue Commissioning Procedures PAC Provisional Acceptance Certificate
Prepare and issue FAT and SAT Procedures
Generate Basic Functions for Instrument, Electrical & Telecoms circuits
Develop the Commissioning Technical Database
Develop the Preparation of Piping & Vessels required to start the Plant
FAC Final Acceptance Certificate
Prepare all the necessary Operational Test Procedures
Prepare Commissioning (RFHO) Dossiers for each Subsystem
Identify and organise all required tools, spares and temporaries
Arrange all Vendor and Specialist assistance as required

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1- Ready for commissioning

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Certificates … certificate

The issuance of these Certificates can be represented as follow: The Sub system will then be energised for further Commissioning
activities.
Conformity checks
Pre-Commissioning Static tests
Flushing, Cleaning &
hydrotest
RFC
The signature of these RFC certificates by the COMPANY
representative does not represent a hand over of the Pre
commissioned Sub system from CONTRACTOR to COMPANY.
Preliminary Checks
Energization
Commissioning Dynamic tests
Operational tests
The Certificate may be issued when the system is substantially
Leak test RFSU
complete and in such case is related to a Punch List including all
pending items.

Oil and Gas IN The Punch List shall indicate in regard of each listed item the
Last Operational tests RFO
Start Up Bring plant on line
Performance tests
scheduled date when it is to be corrected.

FAC time
Operation Performance tests

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1- Ready for commissioning

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certificate 2- Operationl test certificate

When the CONTRACTOR has performed the mechanical completion of a When the CONTRACTOR has brought into normal operation a given
given Sub system, i.e. all the components of such Sub system have been utility functional system, an Operational Test Certificate is issued for the
supplied, assembled and tested in accordance with the specifications, a system.
Ready For Commissioning Certificate is issued for such Sub system to
acknowledge such completion. This certificate is produced after the successful completion of the agreed
Operational Test. It states for each relevant subsystem of the PLANT
This certificate states the acceptance by CONTRACTOR commissioning that it has been brought into operational condition by CONTRACTOR and
team and COMPANY of MECHANICAL COMPLETION for each sub can be used by them for the needs of Commissioning activities with the
system of PLANT (with the exception of items listed on attached Punch exception of items listed on attached Punch List to be cleared in stated
List to be cleared in stated period). period.
Once agreed, this certificate states that the subsequent Sub system is The CONTRACTOR shall be responsible for the Operating and
ready for the performance of Commissioning activities by CONTRACTOR Maintenance of such utility functional system until the Hand Over of the
and particularly for its safe energisation. facilities is made to COMPANY.
Immediately following the signature of the RFC certificate, the Sub Where Operational tests cannot be performed before hand over because
system is placed under the responsibility of the CONTRACTOR hydrocarbons have to be introduced in order to carry out the Operational
Commissioning team for execution of the commissioning activities. test, they shall be performed under the control and supervision of the
COMPANY at a convenient time during Start Up phase with the
The Sub system will then be energised for further Commissioning CONTRACTOR Commissioning personnel.
activities.
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3- Operational tests done after
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OIL or GAS in
The Commissioning team cannot perform some tests, because of
HC requirement. In this case the sentence:
“Operational Test no: (test reference) to be performed Post
Oil or GAS IN”
shall be mentioned clearly on the Ready for Start-up Certificate,
and shall be also be added in the Punch List.
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4- Ready for Start-up certificate
When the CONTRACTOR has successfully commissioned a given Sub
system or sub system group, i.e. all relevant tests have been successfully
performed in accordance with the specifications, a Ready for start up
Certificate is issued for such Sub system or group to acknowledge its
status.
This certificate states the completion of Commissioning activities by
CONTRACTOR on the relevant Sub system or group with the exception
of items listed on attached Punch List to be cleared in stated period.
Similarly to the Ready For Commissioning Certificate, the Ready for Start
Up Certificate is issued related to a Punch List of the pending items with
their scheduled clearance date.
Once agreed, this certificate states that the subsequent Sub system is
ready for the performance of Start-up activities by Company.
Immediately following the signature of the RFSU certificate, the Sub
system is placed under the responsibility of the COMPANY Start-up team
for execution of the start-up activities.
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6- Ready for Hand over certificate
The installation must be formally transferred from CONTRACTOR to
COMPANY.
When the CONTRACTOR has successfully commissioned all the
functional systems and brought into normal operation all utility
functional systems, he is able to request the Hand Over status of the
facilities.
This certificate is issued when:
-The necessary Final Documentation has been transmitted, with the
exception of the as built drawings for which a copy of the full set of the
Discipline Master Dossiers with the red line mark up is acceptable.
- Completion of the formal Hand over of material such as:
- Set of keys and locking devices used during Construction and
Commissioning,
- Remaining Commissioning spare parts,
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6- Ready for Hand over certificate
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(cont…)
- Special tools, Miscellaneous consumables, etc….
- Completion of the formal Hand over of Commissioning Document
such as:
- Status of remaining Electrical isolation,
- Status of Inhibits and Overrides,
- Status of the current spading, etc…
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4- Ready for Start-up certificate
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(cont..)
The signature of these RFSU certificates by the COMPANY
representative represent a technical hand over of the
commissioned Sub system from CONTRACTOR to COMPANY
Start-up team.
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5- Ready for Operation certificate
When the Start-up team has successfully completed the start-up activities
on a given system or sub system group in accordance with the
specifications and procedures, a Ready for Operation Certificate is issued
for such System or subsystem group to acknowledge its status.
This certificate states the completion of Start-up activities on the relevant
system or sub system group with the exception of items listed on
attached Punch List to be cleared in stated period.
Similarly to the Ready For Commissioning Certificate, the Ready for Start
Up Certificate is issued related to a Punch List of the pending items with
their scheduled clearance date.
Once agreed, this certificate states that the subsequent system is ready
for the performance of Operation activities by Company.
Immediately following the signature of the RFO certificate, the system is
placed under the responsibility of the COMPANY Operation team for
execution of the Operation activities.
The signature of these RFO certificates by the COMPANY
representatives represent a technical hand over of the system from Start-
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7- Final acceptance certificate
• This certificate states the end of CONTRACTOR’s Warranty period after
The Provisional Acceptance Certificate agreement.
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B- Factory Acceptance Test
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General
A Pre commissioning and Commissioning scope of work is carried out on the
Construction Site for the packages that have been successfully tested at the
VENDOR’s facilities.
The list of packages to which the reduced scope of work applies shall be
mutually agreed between COMPANY and CONTRACTOR during the
preparation phase.
The detailed scope of work related to these selected packages shall also be
agreed between COMPANY and CONTRACTOR for the following:
Pre commissioning and Commissioning works at the VENDOR’s facility (FAT),
• - Pre commissioning scope on the Construction Site including spot checks of items
tested during the FAT,
• - Commissioning scope on the Construction Site,
• - Detailed definition of the Operational test.
For each package, an Inspection and Test Plan (ITP) shall be prepared by the
VENDOR and submitted to the CONTRACTOR / company for review.
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 Factory Acceptance Test OPERATIONAL TEST PROCEDURES
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(cont …) Definition

The Inspection Test Plan shall include Factory Acceptance Tests and reference
applicable detailed FAT procedures
The CONTRACTOR Commissioning team shall review these detailed FAT
procedures during the preparation phase held in the home office. COMPANY
shall have the right to review and approve all Procedures and add their
comments and witness involvement.
VENDOR shall not start work without full approval of the relevant Pre
commissioning and Commissioning procedures with CONTRACTOR /
COMPANY comments incorporated.
CONTRACTOR shall ensure that, all the Pre commissioning and Commissioning
activities performed on the package, are done in accordance with the same
OPERCOM procedures as those applied for the field equipment. CONTRACTOR
shall foreseen witnessing of the FAT by commissioning personnel at the vendor
premises.
Every item of equipment shall be checked by VENDOR for conformity with the
relevant checklist, and every item of the equipment that can be subject to a test,
shall be tested, and the tests reported on the relevant test sheets.
Technique & Régulation Développement 2008
Once all Basic Functions have been functionally tested, system, subsystem
or group of subsystem, is subject to an Operational Test, wherever
applicable.
It consists of bringing the system into operation under conditions as close
as possible to normal with inert fluids, not only to live test the automated
devices, controls, normal and shutdown sequences, but also to reveal
possible mechanical or electrical faults (water tightness, vibrations,
overheating, overloading, etc.) which may occur during prolonged normal
use.
Every operational test is a multi-discipline activity, conducted in accordance
with an Operational Test Procedure (OTP), which has been established
during the Commissioning preparation phase and approved by the
Operator. There is no standard OTP, since they vary with the plant.
Typical subsystems subject to an operational test are, but not limited to: fire
water pumps, air compressors, power generation, ESD system, export
pumps in recycle, process compressors in recycle (with air or nitrogen if
possible, under gas after Start-up if not), sub-sea equipments, freon or
propane packages, hot oil loop, etc.
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Factory Acceptance Test OPERATIONAL TEST PROCEDURES

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(cont …) Preparation

Unless the list of subsystems to be subject to operational testing is included in

The support of fully comprehensive test documentation shall avoid any
dispute on the Construction Site regarding the re testing of items.
the contractual documentation, and also when the Commissioning activities are
not covered by a contract, the Commissioning shall establish and submit for
approval to COMPANY the list of planned operational tests, not later than
five months before the start on site of physical commissioning works.
This list shall be established in accordance with the guidelines available in GS
EP EXP 107, chapter 8, paragraphs 8.1.2 and 8.2.1, and complemented, for
each test, by a test summary and schematics. Acceptance criteria shall be
defined at early stage and approved by COMPANY/Operator.
Once the list and key features of tests have been approved by COMPANY, the
Commissioning shall develop the Operational Tests Procedures and their
support documents, in accordance hwith the test guidelines and procedures
format given in GS EP EXP 107, chapter 8, paragraphs 8.2 and 8.3.
The OTP’s shall be submitted to COMPANY for approval, not later than
two months prior to the start on site of physical commissioning works.

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OPERATIONAL TEST PROCEDURES OPERATIONAL TEST PROCEDURES

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Principles : Equipments subject to Operational tests List of Operational tests

As a general rule, will be subject to an operational test:
• All subsystems including a major mechanical equipment.
Typical examples:
- Fire water pumps
- Air and process compressors
- Power generators.
- Sub-sea production/injection
A number of subsystems which, although they do not include major rotating
equipment,
perform a vital function of the plant.
Typical examples:
- ESD/F&G
- Hydraulics
- Deluges.
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OPERATIONAL TEST PROCEDURES OPERATIONAL TEST PROCEDURES

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Contents of the Operational tests and Procedures List of Operational tests Process and Utilities

The three phases of the operational test are :

• The test preparation

• The start-up and tuning
• The demonstration

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Subsystem 1870 Subsystem 1810

Functional analysis Attachments

Partial: only the subsystem diesel oil to main turbo • PID:
generators (A,B,C - Port side) • ….
• Shutdown diagram:
• ….

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Subsystem 1810

Set points
…
…
Technical
… Execution

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Technical execution Technical execution

Index Precommissioning
• Breakdown • Systematic conformity checks of equipment (transmitter,
• Precommissioning execution, motors, cables, …)
• Visual inspection
• Tasks, documents. • quality of installation
• Commissioning execution, • Compliance with project specifications, safety rules, standard, …
• Tasks, documents. • Static/de-energised tests of equipment
• Setting of instrument, setting of valves, machinery alignment,
pressure testing of tubing, de-energised tests of electrical or
instrument equipment
• Pipe works flushing & cleaning, pressure test grouped by test
pack
• Hydro test
• Gross leak tests

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Technical execution Technical execution
Breakdown
Preparation Phase Execution Phase Commissioning
Detail
Engineering
Preparation
Files
• Preliminary checks
Data Sub-system &
Process Test sheet System • Functional tests
Engineering
Data Tools, consumables TEST • Dynamic tests by basic function:
Preparation RFC • Electrical motors uncoupled runs, instrument loop tests,
analysis electrical breakers operation
Organisation Sub-system &
System
• Operational tests
/ Planning
• operation of a process equipment under condition as close
FUNCTIONAL
Start-up
TEST
as possible to operating condition
Sequence RFSU
Management
• Piping and vessels preparation
Support
Progress
System &
Process
• Piping dry out,
follow-up Files
Punch • Leak testing
TEST OPERATIONAL

Punch list
TEST
list
• Inerting
PROCEDURE RFO
clearance • Load of chemicals
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Organisation

Parties
• Company,
• Project team,
• Operations
Organisation • Engineering contractor
• Construction contractor
• Main contractor (EPSCC)
• Vendors
• Certifying authority

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Organisation Organisation

Index Contractual aspects

• Parties • The precommissioning activities are always performed
• Contractual aspects by the construction contractor or the main contractor,
• Commissioning team • The commissioning activities are performed by the
• Transfer of responsibility Company or project team in case of separate contracts
or EPSC schemes, by the main contractor in case of
EPSCC or turnkey contracts.
• The start-up activities are performed by the Company
or by the main contractor in case of turnkey contract

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Organisation Organisation

Commissioning team Responsibilities based on EPSCC contract

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Organisation Organisation
Commissioning team
Transfers of responsibility

102
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Organisation

Transfers of responsibility

EXAMPLES

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Samples

Precommissioning sheets
• A1- Precom sheets.xls
• A2- Com sheets.xls
Modules and SubSystems lists
Annexes
• A3- Moho Subsystem list and modules lists rev3.xls
• A4- FPO Module.xls
PID Mark-up’s
• A5- FPU PIDs Marked-Up.pdf

Precom, com tasks scema summary + organisation +

RFC, RFO, … milestones
• A6- pre-comm commissioning tasks schema, organisation
and RF milestones.doc

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AKPO FPSO WORK PACKAGES

Akpo décomposé.PDF

FPSO

Vendor packages

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Your contact
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PAZFLOR FPSO WORK PACKAGES

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