Project Phases of an EPIC Contract

Pre Project Basic Eng Detailed Eng Typical EPIC Contract

E
Long Lead
Procurement
Items
Mechanical
Completion
P
MC MC
Prep
Installation
Execute I
Plant in
RFSU
Operation

PC Start Routine
PC and Commissioning Preparation
Execute Up Operation
C
 Commissioning Objectives
Safety
• The plant will be commissioned in such a manner that it ensures the safety of all personnel and
avoids damage to any part of the plant or equipment
Design Confirmation
• The commissioning of the plant will prove it functions according to the design intent and
within the specific system and equipment design parameters
Documentation
• The commissioning team will ensure they document all phases of the commissioning process
Auditable Trail
• Documentation will be kept in such a way as to provide auditable evidence of the completion
process both during commissioning and during the initial stages of operation
Budget and Schedule
• The commissioning process will be managed to ensure the project completion is within the
defined schedule and budget
Operational Acceptance
• Early operational acceptance criteria will be defined and included in the commissioning
process to ensure a smooth transition at both handover and acceptance between contractor and
client.
 General Preparation
General Completion Preparation
• Develop Commissioning Execution Plan and Strategy
• Define plant start up sequence
• Define list of systems and sub systems
• Develop and issue colored P&ID’s and SLD’s showing limits of sub system
• Compile equipment lists by sub system
• Develop comprehensive detailed commissioning schedule (believe in the schedule)
• Import relevant data into CMS tracking system
• Develop discipline check lists for both MC and PC

MC and PC Preparation
• Develop MC and PC check procedures
• Develop MC and PC Dossiers to be used as a handover document to hold all the relevant
completion information.
• Develop system based commissioning test procedures
• Develop a punch list management system
• Develop a handover and acceptance protocol procedure
 Project Breakdown

Systems and Sub systems

The standard Shell project completion strategy is

based on a breakdown of systems and sub systems Project

A system is a major sub-division of an installation that

performs a major operation function of a plant. The System
system testing is multi-disciplined
A sub system is a sub-division of the system that
performs a given operational function with no or little Sub-system
interference from the other parts of the plant. It also
contains the equipment and is usually checked and tested
as a single discipline Equipment
 The Sub-System Approach

Project Duration Without Sub System Approach

Project
Project Duration With Sub System Approach

System 1 TIME BENIFIT

System 2

System 3

MC PC Comm Start Up
 Sub-System Limit Definition

Sub-System Limits
 Discipline Breakdown Within Sub-System Limits

Discipline Breakdown
 Basic Tools Required

• Commissioning Execution Plan and • Equipment Lists with Tag Numbers

Strategy
• Instrument Index
• Project System Listing
• Pipe Line and Valve Listing
• Project Sub System Breakdown
• Loop Diagrams
• Colored System Based P&ID’s, SLD’s
• MC and PC Check Procedures
• Robust MC and Commissioning Schedule
• MC and Commissioning Dossiers
• Completions Management System
• SPDC Operations Acceptance Criteria
(tracking tool)
• System Based Commissioning Test
• Document Control Register System
Procedures
• Interface Between MC and PC Defined
• Punch list Management Strategy
between Daewoo and Kogas
• Handover Acceptance Protocol
• Cable Schedules (E&I)
 Developing Workable Systems and Sub-systems
Existing Project System Numbers Develop Sub-systems

0 General 58 Corrosion Inhibitor

2 Production 62 Diesel

4 Utilities 63 Instrument Air

5 Supply/ Disposal
Develop Sub-sub System Boundaries
7 Facilities/ Safety 63-01 Air Compression CCGP
8 Electrical/Control 63-02 Air Receivers CCGP
9 Civil/Structural 63-03 Air Dryers CCGP
63-04 Utility Air Dist CCGP
63-05 Inst Air Dist CCGP
Develop Workable System Limit and Create Create Work Pack Status
Multi-Disciplined Work Packs Assign Discipline Check Procedure
Electrical
Electrical Instrument
Instrument
MCWP
MCWP MCWP
MCWP MC
PCWP
PCWP PCWP
PCWP CP-A
6301-001 6301-002

CompAA
Comp CompBB
Comp Mechanical
Mechanical Piping
Piping
DryerAA
Dryer DryerBB
Dryer MCWP
MCWP MCWP
MCWP PC
PCWP
PCWP PCWP
PCWP CP-B
 MC to Commissioning and Acceptance Flow
Mechanical Completion Sub System Pre Commissioning Sub System
Discipline Check Procedures CP-A Discipline CP-B
6301-001 Discipline
M &Check
P Procedures
E&I CP-A 63-01-001 Discipline
M E CP-B I
6301-001
M&P E&I
63-01-001 M E I

MC Work Pack Pre-Comm Work Pack

MC Work Pack
(MCWP) Pre-Comm Work Pack
(PCWP)
(MCWP)
(PCWP)

CDAC CDAC CDAC

CDAC
M CDAC
E CDAC
I
DAC DAC DAC DAC M E I
DAC
M DAC
P DAC
E DAC
I
M P E I

Ready For Comm (RFC)

Ready For Comm (RFC)
Mech Comp Certificate (MCC) 63-01
Mech Comp Certificate (MCC) 63-01
6301-001
6301-001
Discipline CP-B
63-02-001 Discipline
M E CP-B
I
MCC from 6302-001 63-02-001 M E I

Pre-Comm Work Pack

Pre-Comm Work Pack
(PCWP)
(PCWP)
CTP
CTP
SAC
SAC System 63
System 63
CDAC
CDAC
M
CDAC
CDAC
E
CDAC
CDAC
I
Air M E I
Air

Commissioning Sub System RFC

RFC
63-02
63-02
 Typical Preparation Flow PC Documentation

Develop System and Sub system Mark up P&ID’s and SLD’s

Develop System and Sub system Mark up P&ID’s and SLD’s
Breakdown
Breakdown

By Discipline Develop PC Work Input System/subsystem Data

By Discipline Develop PC Work Input System/subsystem Data
Pack by Subsystem into Completions Database
Pack by Subsystem into Completions Database

Review PC Check Procedures Input Data into Completions

Review PC Check Procedures Input Data into Completions
and Adjust Content to Suit Database
and Adjust Content to Suit Database
Project Requirements
Project Requirements

By Discipline Assign Specific

Input Data into Completions By Discipline Assign Specific
Input Data into Completions Check Procedures to Each Piece
Database Check Procedures to Each Piece
Database of Equipment within Subsystem
of Equipment within Subsystem
Boundary to PCWP
Boundary to PCWP
Carry Out First Pass Review Adjust Data into Completions
Carry Out First Pass Review Adjust Data into Completions
Internally by Other Discipline Database as Final
Internally by Other Discipline Database as Final

Ready for Issue of PCWP

Ready for Issue of PCWP
 Gaps and Issues

• MC to PC interface and verification of completed construction works to enable

Mechanical Completion verification by Commissioning.(Daewoo/Kogas)
• MC Work pack development by sub system (Daewoo)
• PC Work pack development by sub system (Kogas)
• MC check procedure development and assignment to equipment (Daewoo)
• PC check procedure development and assignment to equipment (Kogas)
• Commissioning test procedure development by system (Kogas)
• Document control system development (Kogas)
• Schedule detail to be further developed to include, PC activities by sub system,
CTP activities by system, manpower histogram, system priority listing and
production of S curve and progress indication. (Kogas)