Commissioning Engineering Execution Plan
Commissioning Engineering Execution Plan
Commissioning Engineering Execution Plan
Commissioning
Engineering & Execution Plan
HYUNDAI
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Nasr Full Field Development Project – Package2 ADMA OPCO
Contents
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Nasr Full Field Development Project – Package2 ADMA OPCO
HYUNDAI
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Nasr Full Field Development Project – Package2 ADMA OPCO
PROJECT MANAGER
S.I. Chang
COMMISSIONING
MANAGER
G.W.Kim
Coordinator of
Comm. and
Precomm.
S.U.Jeong
COMMISSIONING CONSTRUCTION
QM DEP'T PROCESS DEP'T HSE TEAM CONSTRUCTION 4
DEP'T ENG. DEP'T
Head Head Head Head
Head Head
S.B.Kang S.C.JUNG D.G.Ha J.Y.Kim J.T.Kim J.H.Pyun
PRE-
COMMISSIONING COMMISSIONING CONSTRUCTION
QA/ QC MANAGER HSE MANAGER COMMISSIOING
ENGINEERING MANAGER ENG. DEP'T
MANAGER
O.J.Jeon K.H.Joung N.C.Sung G.W.Kim J.Y.Lim S.U.Jeong
4 HYUNDAI
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Nasr Full Field Development Project – Package2 ADMA OPCO
PTW Coordinator Mech. Comm. Lead Engr E&I Comm. Lead Engr Engineering Coordinator
Mech. Comm. Engr Mech. Comm. Engr E&I Comm. Comm. Engr INST. Comm. Engr
Process Foreman Mechanical Foreman Electrical Foreman Instrument Foreman Telecom Foreman
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Nasr Full Field Development Project – Package2 ADMA OPCO
2. Commissioning Engineering
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PROJECT SCOPE
Nasr Full Field OF WORK
Development Project – Package2 ADMA OPCO
Final commissioning for the entire NASR field and facilities performed by EPC Pkg-
2 with support Pkg-1, Pkg -2 and ADMA
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PROJECT SCOPE
Nasr Full Field OF WORK
Development Project – Package2 ADMA OPCO
COMPANY SPECIFICATIONS
AD177-NSG-G-SOW-00165 :
Scope of Work
AD177-NSG-G-PHY-00133 :
Precommissioning and Commissioning Philosophy
GDL – 006 :
Guideline For Pre-commissioning, Commissioning And
Handover Of Projects
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ORGANIZATION CHART
Nasr Full Field Development Project – Package2 ADMA OPCO
V. DIVAKAR
divakar15@hhi.co.kr
202-1069
K. ASTAYA
astaya76@hhi.co.kr
202-1096
B. Ghosal
bamdeb.ghosal@hhi.co.kr
202-1096
A. J. KIM
aejeongislove@hhi.co.kr
202-1096
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PROJECT SCOPE
Nasr Full Field OF WORK
Development Project – Package2 ADMA OPCO
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DELIVERABLES & PLAN
Nasr Full Field Development Project – Package2 ADMA OPCO
PCS Database
- Status Index
- Technical Database
Precomm'g Procedures
(Hydrotest, Flushing, Leak test, preservation etc)
Operational Test Procedures
Comm'g Procedures
(N2/He leak, Energisation, Black Start etc.)
Precom'g Dossier
Comm'g Dossier
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DELIVERABLES & PLAN
Nasr Full Field Development Project – Package2 ADMA OPCO
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DELIVERABLES & PLAN
Nasr Full Field Development Project – Package2 ADMA OPCO
GENERAL PROCEDUES
2 ICAPS CONTROL & MANAGEMENT PROCEDURE AD220-705-G-00512 Ready to Issue IFA Rev.
4 OTP'S LIST AND OBJECTIVE (ACCEPTANCE CRITERIA) AD220-705-G-00541 IFCC issued (on 12nd Feb.)
MARKUP DRAWINGS
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SYSTEM & SUBSYSTEM
Nasr Full Field DEMARCATION
Development Project – Package2 AND ADMA OPCO
NUMBERING
2. MANY PLATFORMS
Applied the Sector Code (added Area Code and Location Column)
3. DEMARCATION RULE
As per General Rule, HHI Standard (refer to the next slide and
sample)
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COMMISSIONING PROCEDURE
Nasr Full Field Development Project – Package2 ADMA OPCO
Work
Project Methodolog
Client Type Volume PCS
Name y
(OTP No)
MHN FPU TOTAL FPU OPERCOM 76 ea (Topside) ICAPS
MHN TLP TOTAL TLP OPERCOM 39 ea ICAPS
BCP Carigali Hess F/P 35 ea HHIPCS
GOLIAT ENI FPSO 81 ea ProCoSys
DSO Chevron F/P 68 ea Zenator
OFON TOTAL F/P OPERCOM 42 ea ICAPS
BONGKOT PTTP F/P OPERCOM 38 ea ICAPS
BARZAN RasGas F/P 85 ea HHIPCS
SHWE DAEWOO F/P 145 ea HHIPCS
USAN TOTAL FPSO OPERCOM 116 ea ICAPS
USGIF ADMA F/P 85 ea HHIPCS
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PROJECT COMPLETION
Nasr Full Field SYSTEM
Development Project – Package2 ADMA OPCO
(ICAPS)
DATABASE PREPARATION
PRECOM COMM
Line DOSSIER DOSSIER
List DOCUMENTS DOCUMENTS
Equip.
List
OPERCOM
ICAPS
CERTIFICATES
Cable
List
STATUS INDEX :
Instr. PRECOMMISSIONING PUNCHLIST
scope of work DATABASE
List
Technical dBase :
Other COMMISSIONING
Lists scope of work PROGRESS
REPORTS
Subsystem
List
PRECOM/COMM
FEEDBACK
PLANNING
SUS REPORT
STATUS
COMMISSIONING EXECUTION
OPERATIONAL
3) Operating Tests
4) Pre-Start Up Activities PROCESS
(PSA)
AREA PRELIMINARY
FUNCTIONAL
CHECKS
BASIC FUNCTIONS TESTS
(PRC)
(FTS)
ITEMPACK
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PROJECT COMPLETION
Nasr Full Field SYSTEM
Development Project – Package2 ADMA OPCO
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PROJECT COMPLETION
Nasr Full Field SYSTEM
Development Project (ICAPS)
– Package2 ADMA OPCO
Mech.
Elec. Inst. Tele (Incl. HVAC,
Piping)
CCK 27 26 45 231
Precommissioning STS 26 10 5 14
PRC 1 1 1 1
FTS 26 11 20 N/A
Commissioning
OTS 1 1 1 26
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17.8/8
GTP ~
ICSS Package System Commissioning
18.3/16
Shore Power : 8.Aug.
17.9/5
EDG Test :
AP ~ Feb. 10
ICSS Package System Commissioning
18.6/12
Shore Power : 5.Sep.
17.10/13
MFT ~ MCC Package System Commissioning
18.4/3
Shore Power : 13.Oct.
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Hand a Priority Sub Shore Power Supply Commissioning will start as per
system List to --> SWBD test --> priority sub-system List and Hot
Construction Team in UPS/Battery Charger loop test will also start
order to early start --> ICSS system test
simultaneously.
Commissioning.
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②
① Accommodatio
n
D.O Tank
21m3 Platform
⑤ ③
② Gas
①
Treatment
D.O Tank
21m3 Platform
⑤ ③
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Chemical
Tank (tote) 8"x10" Gas
⑥ ③
Treatment
Platform
①
① Separation
Platform
②
⑤
8"x10"
④
Quay Side
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①
⑥ ⑥ Gas
TEMPORARY FRESH TEMPORARY FRESH
④ Treatment
WATER TANK 30 m3 WATER TANK 30 m3
Platform
⑤ ②
12”
③ No. Description Specification
① Supply Pump 450m3/h
② Screen mesh 40mesh
HHI Yard Fresh Water
③ Isolation Valve(2") 2"
④ Isolation Valve(2") 2"
⑤ Isolation Valve(2") 2"
① ⑥ Temp. water tank 30m3
⑥ ⑥
⑤
TEMPORARY FRESH TEMPORARY FRESH
WATER TANK 30 m3 WATER TANK 30 m3
④
② Separation
12” Platform
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1. F&G
2. PA/GA
3. CCTV
Pedestal Crane HVAC Units Mechanical
Load test System test Handling Equip. test
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132KV SWGR
Treatment
11KV SWGR
Platform
11KV ETR.
11KV SWGR
M/G
5MVA
11KV
11KV ETR. Accommodation
50HZ
Platform
POWER S TATION
13.8KV, 60HZ
Temporary Shore Power House
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6.6KV ETR.
132KV SWGR
M/G
5MVA
11KV
11KV TR.
50HZ
Manifold
415V SWGR Tower
POWER S TATION
13.8KV, 60HZ -Upper Deck
Temporary Shore Power House
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4. QA/QC
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CONTENTS
2. OPERCOM Instroduction
3. Completion Activities
4. PRECOMM/COMM Dossiers
5. PUNCHLIST
7. ICAPS DATABASE
- APPENDIX 1, 2 and 3
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QM Department
G. Mgr S. B. Kang
QA/QC Manager
G. Mgr O. J. Jeon
MC Room
Operator TBA
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2. OPERCOM™ Instroduction
OPERCOM™ : Trademark, property of Company, designating the methodolory
of the Pre-commissioning and Commissioning activities described through
a set of four specifications : "4 Specifications is organised as follow :"
EXP 101
● GS EP EXP 101 : Pre-comm. and Comm. Specification
● GS EP EXP 103 : Pre-comm. and Comm. Engineering EXP 103
● GS EP EXP 105 : Pre-commissioning Execution
● GS EP EXP 107 : Commissioning Execution EXP 105 EXP 107
2. OPERCOM Instroduction
2.1 SUBSYSYSTEM Definition
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3. Completion Activities
3.1 Completion Activities Definition
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3. Completion Activities
3.2 OERCOM Terminology
● BA SI C FUNCTI ON ( BF) :
Smallest equipment subject to a commissioning task.
A BF is a group of ITEMS that performs an elementary function of the plant.
only instrument, electrical and telecom BF's are subject to commissioning
FUNCTIONAL TESTS.
Ex : Switchboard, transfoemer, heater, process control loop, pump, vessel,….
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3. Completion Activities
3.3 Commissioning Phases :
● PCC ENGINEERING
Ⅰ - GENERAL OPERCOM PREPAREATION
SubSystem List, Start-up Sequence, MarkedUp Drawing
Ⅱ - PRECOMMISSIONING PREPARATION
Status Index, Precommissioning Dossiers & Procedure. PrecomTasks
Ⅲ- COMMISSIONING PREPARATION
Technical Database(TDB), Commissioning Dossiers & Procedure, Comm. Tasks
● PCC EXECUTION
Ⅳ- PRECOMMISSIONING EXECUTION
Conformity Checks, Static Tests, Piping Tests PrecomDossier, RFC
Ⅴ - COMMISSIONING EXECUTION
Preliminary Checks, Functional Test, Operating Tests, Comm. Dossier
Pre-StartUp Actvities, Handover to Operations
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3. Completion Activities
3.4 Precommissioning Execution
● Precommissioning shall be organized by SubSystems.
● De-energized tasks performed on equipment items / itemPacks :
-. Conformity Checks(CCK) :
Systematic checks on each equipment itemto verify itemcondition, quality,
compliance with drawings/specifications, vendor instructions, safety rules
standards and good practice.
-. Static Tests(STS) :
Cold testing performed on selected critical items to ensure quality, ie.
calibration, alignment, cable continuity, ……
-. Piping Tasks(PIP) :
Cleaning, gross air leak and pressure testing.
● A Ready-For-Commissioning Certificate(RFCC) :
is issued at the end of precommissioning for each SubSystem.
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3. Completion Activities
3.5 Commissioning Execution
● Commissioning shall be organized by SubSystems.
● Energized tasks performed on equipment Basic / Process Functions.
-. Preliminary Checks(PRC) :
-. Pre
Sitecom missioning
and docum =checks
entation Static
byTests
each discipline involved.
-. Functinal Tests(FTS) :
Hot test of each instrument, electrical and telecombasic function.
-. Operational Tests(OTP) :
Actual run-in and on-line tests of utility and major equipment.
-. Pre-StartUp Activities(PVV) :
-. Precommissioning
Preparation = Static
works for startUp suchTests
as inerting, leak testing, drying-out,
chemical filling and cleaning.
● A Ready-For-StartUp Certificate(RFSUC) :
is issued at the end of Commissioning for each SubSystem.
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4. PRECOMM/COMM Dossiers
4.3 Standard Commissioning dossiers :
Commissioning dossiers are arranged by SubSystems.
#. Each dossier should contain :
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5. PUNCH LIST
5.1 Punch List Processing :
● The remaining punch lists for FAT shall be input into the ICAPS by CTR
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Yes
Cat. "B" Punch
No
PUNCH LIST
Commissioning dossier signed
by CPY and CTR Comm. Mgr.
7. ICAPSDATABASE
ENGINEERING PREPARATION EXECUTION
Subsystem
List PRECOM/COM
M
PLANNING
FEEDBACK
SUS REPORT
STATUS
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7. ICAPSDATABASE
COMMISSIONING TASKS
COUNTRY PROJECT/
SUBPROJECT
OPERATIONAL
ZONE SUBSYSTEMS
TESTS(OTS)
PROCESS
PRESTART-UP
FUNCTIONS
ACTIVITIES(PSA)
AREA PRELIMINARY
CHECKS(PRC)
FUNCTIONAL
BASIC FUNCTIONS TESTS(FTS)
SUBAREA
ITEMS CONFORMITY
CHECKS(CCK)
Piping line
STATIC
Cable TESTS(STS)
Equipment
Instrument
ENGINEERING PRECOMMISSIONING TASKS
EQUIPMENT LISTS
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APPENDIX 1
READY FOR COMMISSIONING CERTIFICATE (RFCC) When all PRE-COMMISSIONING
inspections are completed within
sub-system or system with minor punches
NASR PKG 2 PROJECT
not affecting on the pre-commissioning,
Document No.
READY FOR COMMISSIONING CERTIFICATE – SUPPORT MATRIX
A B C
COMPANY CSL
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APPENDIX 2
When all COMMISSIONING inspections
are completed within sub-system or
system with minor punches not affecting
on the pre-commissioning,
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APPENDIX 3
NASR PKG 2 PROJECT NASR PKG 2 PROJECT
PRE-COMMISSIONING DOSSIER INDEX COMMISSIONING DOSSIER INDEX
Sub System No Description Sub System No Description : TICK
TICK AS
AS APPROPRIATE
APPROPRIATE
1. COMMISSIONING CERTIFICATE
1. PRE-COMMISSIONING CERTIFICATE 1.1 Ready For Start-up Certificate (RFSU)
1.1 READY FOR COMMISSIONING CERTIFICATE (RFCC)
2. CONSOLIDATED PUNCH LIST
1.2 STATUS INDEX SUMMARY
2.1 Punch List Report by Discipline
1.3 PUNCH LIST SUMMARY REPORT (Sorted by Discipline)
Note :
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5. Construction Engineering
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• JOINT NUMBERING
• TRAINING
- THEORY TRAINING
- PRACTICAL TRAINING
• CHECK POINT
• BOLTING
• SAFETY
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JOINT NUMBERING
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14B01-GACA-UEC-TP-0001
GACA00-0E-09277.05:JT003
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THEORY TRAINING
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PRACTICAL TRAINING
- Manual Torque
- Hydraulic Torque
- Tensioning
- Hub clamp or Compact flange
- Safety
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- Name
- Trainee No. (Cert. No.)
- Issue date
- Categories
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CHECK POINT
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Missing
Graphite
If graphite is removed from the gasket then the product should not be used.
The area of the gasket where the graphite has been removed could become a leak path or
may alter the product seating characteristics.
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CHECK POINT
(TORQUE)
2 – 3 THREADS ABOVE NUT
ALIGNMENT
SQUARE FLANGES
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BOLTING ACTIVITY
Hydraulic
Bolt Tensioning
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44 33 44 33
11 5
12 5
66 77
88 99
22 22
44 33
7
1 - 30% Cross 10
10 7
2 - 60% Cross
66 11
11
3 - 100% Cross 2
2
4 - 100% Round (until nut stops rotate)
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SAFETY
Pinch Points
Backing Spanner Pinch Point
fully engaged
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SAFETY
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Contents
* Preservation work scope in HHI
* Preservation Work Flow Chart in HHI
1. Protection work
2. Anti corrosion work
3. Lubricate equipment for preservation
5. N2 Charging work
6. Energizing anti condensation heater
7. Check insulation resistance of motor
8. Check battery voltage and recharge
9. Passivation work
10. Document management system in HHI
11. Sample of preservation weekly activity report (BCP)
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Initial Check/Confirm
Preservation Conditon of Equipment Maintenance preservation / De-preservation / Re-preservation
for transportation Check Initial Preservation
Work Scope
Equipment Design Vendor Equipment Storage location Receiving Preservation Preservation M/C & Preservation for
and PO issue Selection Fabrication Selection Inspection duing Storage after Installation Commissioning Sail away
VEIRIFCATION OF
SUBMISSION OF EQUIPMENT STORAGE RECEIVING PRESERVATION BASED ON PROCEDURE
PROJ ECT BIDDING
VENDOR DATA MANAGEMENT INSPECTION AND RECOMMENDATION FROM VENDOR
SPECIFICATIONS
FABRICATION AND PROTECTION OF REPORT ANY FAULT
SPECIFICATIONS VENDOR SELECTION MAINTENANCE PRESERVATION / DE- PRESERVATION / RE- PRESERVATION
TRANSPORTATION EQUIPMENT(BOX) TO CPY/HHI
ACTION UNPACKING / REPACKING
GETHERING VENDOR DELIVERY EQUIPMENT INITIAL
FOR RECEIVING POR FOR PRESERVATION CONSUMABLE
DOCUMENT MANAGEMENT PRESERVATION
INSPECITON
ATTENDING RECEIVING
A/S
INSPECTION
FAT
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1. Protection work
One of basis preservation. Cover equipment with Vinyl, Plywood, Pvc
Cover, Rubber etc to protect equipment from rain, rust, welding
scatter, paint and any contamination as well as physical damage.
1-1) Sample of protection work for equipment
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2-4) Grease Wire Rope for Winch, Main Crane Slewing Gear
a) Sample of grease work
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6. Energizing
. anti condensation heater
Power up space heater to avoid formation of condensation.
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9. Passivation work
Remove surface corrosion
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HEAVY INDUSTRIES CO., LTD.
Nasr Full Field Development Project – Package2 ADMA OPCO
HYUNDAI
HEAVY INDUSTRIES CO., LTD.
Nasr Full Field Development Project – Package2 ADMA OPCO
HYUNDAI
HEAVY INDUSTRIES CO., LTD.
Nasr Full Field Development Project – Package2 ADMA OPCO
HYUNDAI
HEAVY INDUSTRIES CO., LTD.