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Show More. No Downloads. Views Total views. Actions Shares. Embeds 0 No embeds. No notes for slide. Date Notes This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company. Reference documents Safety during activities Precommissioning and Commissioning methodology Start-Up methodology Offshore projects Specificity Surface package and Subsea equipments specificity Hand Over to Field Operation This specification shall be read as an introduction to the above Technical activities as, by giving the rationale and key principles of the Precommissioning and Commissioning, they will allow an easier approach to anyone having to prepare or carry out this kind of operations.
They will be referred to for any assistance on these matters. Reference documents The reference documents listed below form an integral part of this General Specification. Introduction The technical complexity of the new hydrocarbon installations is on the increase, as displayed by all recent large projects where sophisticated data, control, and safety systems prevail.
Moreover, the higher efficiency, reliability, and safety expected from the new plants, as well as the aggressive environments in which they are often built, those surrounding the offshore platforms and especially the deep offshore facilities, challenge the design and construction teams as never before.
Consequently, a number of techniques have been developed during the past years to overcome the problems that these demanding conditions create, among which are the tools required to conduct a project through its completion phases.
It should be noted that the above set of documentation does not cover all Quality Control activities achieved on a new plant: a number of inspection Tasks distinct from Precommissioning and Commissioning operations- such as the dimensional control of structures, the quality of welding, painting and materials, flange, gasket, will also be undertaken and available for any request from COMPANY.
This document is the property of Total. In particular "no economic priority shall overrule consideration of health and safety at work and respect of the environment". Phases 5. The aim of these verifications is to ensure, as thoroughly as practicable, that every piece of equipment are built and operate as per design. These verifications are also the last critical review of the design before start-up.
Their ultimate goal is to render the plant oil or gas in as safe and troublefree as possible. These completion activities are separated into two phases, Precommissioning and Commissioning, this split roughly corresponding to static and dynamic tests phases respectively.
The completion activities are followed by the Start-up phase itself, corresponding to the introduction of the hydrocarbon feedstock into the plant. This "cold" testing concerns all disciplines, e. Typical examples of such tests are electrical motors uncoupled runs, instrument loops tests, electrical breakers operation. The energization of the electrical distribution network is part of this activity.
Witnessing and assistance from Operator is required to allow a smooth transfer of the facilities from the Commissioning team to the Operator, in full confidence, and with all the required safety.
All those systems shall be finally commissioned after installation and hook-up and the commissioning and start-up may be carried out sequentially. In any case, tests to be carried out at the SUPPLIER premise shall demonstrate the correct design, manufacture and operation of the equipment and its performance in accordance with the specification. Lastly, those tests shall be witnessed by the Commissioning team s.
The aim of these tests is to ensure that all equipment operate normally and securely. The technical assistance for Start-up from Commissioning team may be required. In order to carry out a smooth transfer, the Start-Up team shall follow-up, assist, and check Site Acceptance Tests and appropriate Commissioning activities leak test, Running-in of the plant utilities, Oil or gas-in preparation, ESD demonstration, etc.
Precommissioning and Commissioning methodology The methodology described below in this chapter is compulsory, and shall be strictly applied. The tests to be carried out during Precommissioning and Commissioning activities shall be systematic and exhaustive, according to the methodology described below. No equipment or part of the installation shall be accepted without associated check and tests prior to energisation and Start-Up.
Each test shall be recorded through dedicated sheet, dated and signed by parties involved, according to the contractual organisation and the witnessing principle as per defined chapter The name of the representative of each party shall be clearly recorded.
Not all parts of the plant reach the same degree of completion at the same time, hence some areas or units may be mechanically completed while others are not. It would therefore be a waste of time to wait for the whole plant to be mechanically completed before starting commissioning activities.
The Start-up sequence of a new plant is driven by operational constraints where safety equipment and critical utilities are given the highest priority.
Other utilities and power generation are required earlier than the process equipment. Hence, contrary to the construction work progress, which is essentially planned by trades, areas and equipment tonnage, the optimisation of the start-up phase goes through the sequential completion of multi-trade operational units: fire pumps, power generation, etc. In addition, for reasons of optimisation of means and resources, not all tasks related to Precommissioning, Commissioning disciplines can be undertaken simultaneously.
Therefore, the Project planning shall be optimised if the completion activities are organised not as whole plant activities, but by Operational Systems and Subsystems. The system includes all the various equipment that allows it to operate. The firewater pumps, power generation, control systems, telecommunications, oil, gas, water processing, etc. Several equipment with the same function in the system, main packages are typical examples of subsystems.
The partition of a plant is a key preparation activity, that has a major impact on all aspects of completion operation. The subsystems must be defined so as to be as independent as possible, not too small, but of manageable size, and exactly adapted to the Start-Up sequence. The number of Sub-systems should not ideally be more than , but will depend on the size of the plant.
They provide all required procedures and support documents to prepare and carry out Precommissioning activities. Their key principles are as follows. These Check Lists define the exact scope of work that shall be systematically performed on every item of equipment or on selected packages, the same support being also used to record the checks. One check list is filled in per subsystem and per type of equipment for each discipline. One Test Sheet is filled in for each test performed.
The Tests pack may be carried out on lines included in different subsystem. The Test Packs breakdown may not fully match with a hierarchical sub-systems breakdown. Those Tests should be split according both phases Precommissioning prior to energisation and Commissioning after energisation.
The Status Index is a list of all equipment subject to one or several Precommissioning operations. The Status Index indicates for each item of equipment instrument, electrical cables, pumps, etc. Check Lists and Test Sheets numbers. The Status Index is therefore a summary of the Precommissioning scope of work. The completion data of each task is recorded on the Status Index so that it is a working document used to follow up the work progress. While the Precommissioning checks and tests are being performed, all discrepancies, damaged or missing equipment, malfunctions, missing documents, if not corrected immediately, are recorded in the subsystem Punch List.
At the Ready For Commisioning stage, an agreed punch List shall be issued for approval by the Commissioning team. See section 6. They contain all the information required to demonstrate that a subsystem has reached the "Ready for Commissioning" status. Figure 3 - Summary of Precommissioning methodology 6.
ICAPS© AND OPERCOM® TRAINING
On request, we also regularly organize training sessions at the Paris headquarters of COMSIP for experts wishing to develop their skills. Time saved by using this program in a project will definitely improve productivity and reduce cost. Thanks for all! A special thanks to organization team and trainer.
Explaining OPERCOM® methodology in commissioning
January 22, The methodology is used by the dedicated teams responsible for preparation during the engineering phase and for execution at the end of the project. Total has signed agreements with training organizations for providing them. Q: How long is the course? A: One week. It is a tool that ceases to be used at the end of the project.