Planner Role in Pre-Commissioning, Commissioning and Start-up

Pre-Commissioning, Commissioning and Start-up

Pre-Commissioning, Commissioning & Start-Up is the last visible and important step in an EPC project execution process. It moves the project from the “end of construction” to the “commercial operation” status. This phase covers initial and primary dynamic tests, including guarantee performance tests.

Some definition always used TnC stage are :

To enable a smooth transition from construction to commissioning it is required to complete construction work in small packages (known as systems). This enables Pre-Commissioning work to progress from an earlier point in the schedule, in return to reduce the final pre-commissioning peak workload substantially.

 

Systems should be defined by colour coding a set of A3 P&IDs. System boundaries should be “flagged” in RED and system numbers should be clearly marked at regular intervals on the respective line-work and equipment. System summary sheets should be prepared which list the system content by line and equipment numbers.

 

Detailed Pre-Commissioning / Commissioning Execution Plan
A plan is developed that identifies all of the major pre-commissioning activities by system. The plan will be developed in reverse and will clearly identify “system ready for pre-commissioning” milestones.
Commencement of system turnover from construction to commissioning should ideally commence at approximately 70% erection completion. From this point handover of systems should be made on a regular basis.

 

A method of pre-commissioning progress monitoring will be developed to allow progress to be monitored by:

• Overall pre-commissioning completion for the complex
• Pre-commissioning completion by Process Unit
• Pre-commissioning completion by system
• Discipline completion by system
• Vendor Schedule.

Some client would like to categorise the punch list in order to prioritise. Below is the example.
Category A : Items that must be cleared prior to start of Pre-commissioning
Category B : Items that can be cleared during pre-commissioning
Category C : Commissioning Items

Immediately prior to the hydrotest of each system, a Punch-List will be performed by an integrated Punch- List team consisting of construction, and EPC Commissioning Engineers (from relevant disciplines).

When all “A” type items have been cleared and a small but manageable amount of “B” type items are left, a handover can be progressed from the construction to the commissioning group. Since mechanical completion has been achieved with agreed exception items, it is classed as an interim handover to permit construction completion and Pre-Commissioning activities simultaneously.

Control and responsibility of work on the system rest with the commissioning group. Any construction work will require written permission from the Lead-commissioning Engineer of the particular Process Unit. Permission will be granted on a job by job basis.

This would involve a line-by-line detailed check of the actual physical installation against the latest P&I diagrams issue, job specifications, piping hanger and support drawings, vendor drawing, etc., for erection of the unit in accordance with all drawings and applicable specification. The systems would also be checked from an operating viewpoint for proper location and orientation of valves, vents, drains, steam tracing and traps, sample connections, etc.

Once the unit is precommissioned, the Commissioning Team will conduct the following main activities:

• Purging
• Leak Test / Tightness Test
• Spring Hanger Check
• etc

to start with initial Start-up operations assuring that every activity is accomplished smoothly and safely. The Commissioning Subcontractor Team would take care in troubleshooting any operating or process problems, should they arise, and would investigate any operating deviations as they occur.

 

Pre-Commissioning Complete
When the Pre-Commissioning work on each utility system is complete it can then be commissioned providing it is safe to do so. For non-utility systems the point at which the process Unit is considered to be “ready for Start-up” is when all non-hydrocarbon systems have been pre-commissioned. At this stage the Unit is presented as “Ready for Commissioning” This triggers several safety activities as follows:

• A final Punch-List to determine if the unit is ready to accept hydrocarbons
• A pre-start up safety review
• The introduction of a full permit to work and safety system.

Commissioning Complete
When all commissioning for a process unit is completed the unit is declared “Ready to Start-up”.

Role of a Planner

A planner need to be well aware of the whole Pre-Commissioning, Commissioning and Start-up flow in order to provide a realistic schedule. He or she should be able to advise not only the project manager but also the commissioning manager on the schedule impact in the area of commissioning.

A good knowledge in commissioning will help planners to maintain a full resources loaded schedule complete with commissioning activities.

My Experience.

In my experience I will work out with Process, QC, Commissioning manager and Project manager on each test package. Base on this test package, I will know which piping activities, electrical activities, instrument activities and etc that linked to each test package.

Below is the example of the piping scope where I will plan and link from Piping fabrication, tie-in and commissioning. This requires a good understanding in P&ID , tie-in and TnC knowledge and interpretation.

Hydrostatic pressure testing of the Unit shall be performed to prove strength of the materials and weld integrity after completion of the construction. The tests shall be made on new or repaired equipment and piping.

For this project, I would have to go in detail in order to create "activity code" for test medium, test-package number, tagging number or even job number.

 What was expected from us

Below are what my client expected from me especially during the commissioning and start-up planning. These can be details that can be useful for you as well.

• Prepare, update & maintain the relevant Commissioning schedules through contact with Company & Contractors Commissioning Teams, using logic network planning (Critical Path Method or CPM), and the Project WBS as appropriate
• Develop mini plans/schedules as necessary, including resource loading the commissioning plans/schedule.
• Participate as required in the integration of Commissioning schedule into the Overall Project schedule.
• Define & maintain the Work Breakdown Structure working closely with the Commissioning Site Leaders.
• Project lookahead plans and liaise closely with the CSU (Commissioning & Start Up) team to monitor and confirm that the necessary preparatory works (e.g. vendor mobilization, material availability, etc.) are in place.
• Monitor Contractors scheduling & perform analysis to validate Contractors dates