The fundamental process to Successful Commissioning is the development of a solid Commissioning Philosophy. Our Commissioning Experts will use an integrated CCMS Completion & Commissioning Management System combined with a robust and trouble free execution philosophy that will ensure an on time and on budget start up every time. The key to this process is in the development of some of the following documents during the early stages of construction engineering.
An essential part of managing interfaces between the EPC Contractor and the Commissioning Experts Group is in the management of an independent and stand alone Completion Management System. Our Commissioning Experts are accustomed to work with a multitude of different software based systems, there are multiple systems on the market and although we also possess our own proprietary software we can work with any system providing the basic administration functions allow hierarchy searches and filtering. It is essential that the system is populated and the construction completion progress is monitored throughout the construction phase so documented Mechanical Completion Checks can be performed prior to Turn Over to the Commissioning Experts via MCR’s Mechanical Completion Report and CCR’s Commissioning Completion Reports which will form part of the system completion packs and project dossiers to be verified prior to final acceptance for plant Startup. The CCMS system will also support the Construction Build identifying Punch list carryover and as built record of the actual Plant Turnover Completion.
It is essential that all systems requiring Pre-Commissioning Services are undertaken in conjunction with approved processes and standards applicable to the type of plant being build, Our Commissioning Experts will review and develop project specific procedures for these activities.
Each system will have a Commissioning procedure which demonstrates that the system has been placed into operation within design parameters. Each Commissioning procedure will form part of the final Commissioning Manual, and become part of the respective system turnover package when the procedure is completed.
The Startup Manager reviews the project schedule to identify activities and milestone dates. Each System Turnover Package will be integrated into the project schedule. The Commissioning schedule will in most cases align to the Construction schedule with priority given to critical completion of those packages critical for an on time Startup. As construction completes a system, the turnover package is issued and the Commissioning work begins. The execution of Commissioning within the project schedule will have the same objectives as the Commissioning work where individual components are inspected and tested, sub-systems and systems are tested individually, then the plant is systematically brought live system by system according to the Startup philosophy then finally the entire plant is operated and tested.
Development of a Responsibility and Signatory Authority
Our Startup Manager will identify the specific responsibilities of each party in the project which will include members of the EPC Contractor, Client / Operations and Commissioning Experts in an approved matrix of responsibility and authority for the project. The Signatory Authority Matrix will form part of the compliance and sign off within the Commissioning Manual. Client or Operator will be responsible for reviewing and approving the Commissioning data and results. Our Startup Manager will identify the process for the review and approval.
Some equipment may require the assistance of vendor experts during the Commissioning to protect product warranties. The Startup Manager will review the vendor representative requirements and make recommendation for the vendors to arrive at the job at the correct time to minimalize costs. Some projects may have special equipment requirements, which necessitate a vendor expert, but other projects do not need the vendor. Our Experienced Commissioning Experts can Commission many pieces of equipment without the vendor assistance in turn reducing Vendor Costs and time during the Commissioning process.
Critical Path Review
Additional activities which the Commissioning Experts will review during office phase:
- Commissioning Water Management program
- Fuel specifications
- Fuel consumption
- EPC Construction support requirements
- Maintenance program, in accordance with the vendors literature
- Interface-points between the new plant, any existing plant
- Government or insurance company inspectors required for testing safety valves, fire detection/protection systems, etc.
CAPEX Purchases V’s Rental
Our Commissioning Experts will review and make suitable assumptions for the requisitions or rentals of the following as per contract requirements:
- Test equipment
- Chemical analysis equipment
- Storage Container for tools
- Storage Container for Equipment which has been temporarily removed from the plant
- Temporary pumps, hoses, plastic tubing, and fittings
- Spare parts (mechanical seals for pumps, DCS cards)
- Consumables (gaskets, packing, light bulbs, fuses, panel lenses, etc.)
- Solvents to dissolve grease or remove rust
- Truck(s) for hauling equipment and personnel on jobsite
- Office space, office equipment, furniture, supplies, telephones, fax machine
- Computers, printers, and software for the commissioning office
- Radios (and frequencies), antennas, base stations, and repeaters for onsite communication
- Transportation requirements for personnel (automobiles, vans, and drivers for international locations)
Our Commissioning Experts will determine who is responsible for supplying the various chemicals and lubricants. On many projects, the EPC Contractor is responsible for supplying the first fills of chemicals and/or lubricants this is an area where many EPC contractor have lost considerable margins when these costs have been underestimated. Our Commissioning Experts will be able in many cases through well-known companies produce a lubrication list for the project, as part of their scope of supply. It is considerably more cost effective to rent the more unusual test equipment for a limited time, and to purchase the normal, everyday type of test equipment. The schedule for the full-blown Commissioning effort occurs at a time when the construction team is winding down their manpower and equipment, so it is not advisable to rely on the support from construction in areas like tools and consumables. Our Commissioning Experts will plan on purchasing or renting a full package of tools. Some tools, like welding machines, rigging equipment, and scaffolding, may be supplied by the construction team, at least for the beginning of the Commissioning Phase. On many projects, considerable time is lost because the right gasket was not available, or maybe the pipefitters needed a special tool for access to plant, spare fuses not being accounted for the DCS input circuits. Our Commissioning Experts will prepare all the necessary consumables and tools to ensure there are no costly delays. Some seemingly insignificant tools can be very important during a startup.
Safety Procedures and Equipment
Safety equipment, should be ready for use during the System Commissioning, as conditions warrant. In many project the permanent safety equipment is not made available for project use so temporary equipment must be purchased or rented. Safety signs and warning barriers must be in place, and the workers in the area should be trained in the identification of safety hazards and the remedial actions in case of an incident or accident. Our Commissioning Experts will manage a strict Permit to Work system in order to have the proper controls and processes during the Construction and Commissioning interfaces. Permit to Work system is used to allow construction personnel to work within the boundaries of a system that has been turned over to Startup where special attention is placed on hot work permits, where any welding, cutting, or grinding will occur. An Isolation Tag and Lock Out System safety tagging program is always used and is the principle means of preventing injury to personnel or equipment when the systems have been energized. Material Safety and Data Sheets will be made be available onsite for all the hazardous chemicals used during the Startup.
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