Mechanical completion

This PowerPoint defines the principles and structure of Mechanical Completion & Commissioning.

1. OILANDGASDOCS.COM
MECHANICAL COMPLETION &
COMMISSIONING
SCOPE
ThisPowerPointdefinestheprinciplesandstructureof
MechanicalCompletion&Commissioning.
SYSTEMS
AnOperationalSystemoraNonOperationalSystem.
OperationalSystemsareDynamicProcess,Utilityor
FacilitySystemssuchasSeawater,Diesel,HVAC,
Telecom,MainPower&Controlsystem.
Non-OperationalSystemsareSurfaceProtection,
Insulation,Civil,StructuralSteel,Markings&Signs,
Cable&Tubingtrays.
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2. MECHANICAL COMPLETION & COMMISSIONING
MECHANICAL COMPLETION STATUS INDEX (MCSI)
Thisisalistingofallitems/tagswithassociatedcheckrecordsstatusforeachMC(orcommissioning)Package.TheMCSIshouldbeproduced
basedontheProjectCompletionsystem.
SUBSYSTEM
Asystembrokendownintofunctionalsubsystems.
COMMISSIONINGPACKAGE
Apracticalscopeofworkunitwithinasystemorsubsystemforcommissioning,constitutingafunctionalunitwhichcanbetestedby
commissioningtoconfirmitssuitabilityforoperation.
MCPACKAGE
Apracticalunitofthescopeofworkforonedisciplinewithinacommissioningpackage.
COMMISSIONING(C)
Isthefunctionalverificationofequipmentandfacilitiesthataregroupedtogetherinsystems.
MECHANICALCOMPLETION(MC)
Thecheckingandtestingofequipmentandconstructiontoconfirmthattheinstallationisinaccordancewithdrawingsandspecificationsand
readyforcommissioninginasafemannerandincompliancewithprojectrequirements.
STATUS"PA"
Thismeansthatthischeckitemisnotcompleted,andthatremainingworkiscategory'A',i.e.,mustbecompletedpriortocommissioning.
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3. MECHANICAL COMPLETION & COMMISSIONING
STATUS"PB“
Thismeansthatthischeckitemisnotcompletedandthatremainingworkiscategory'B’.
PUNCHLISTREGISTER(PLR)
Apunchlistregisterisalistingofallpunchlistitems,preparedatatimewheninstallation,functionsoractivitiesshouldhavebeencompleted.
CARRYOVERWORKREGISTER(COWR)
Aregisterwhereincompleteitemsaredocumentedsufficientlyforworkpreparationandcompletion.TheCOWRisbasedonthePunchLists
Registeranddescribespunchlistedworktobetransferredtothenextprojectexecutor.
MCDOSSIER
MCdocumentationcompiledinMCpackage.
COMMISSIONINGDOSSIER
CommissioningdocumentationcompiledinCommissioningDossier.
EXECUTOR
Anorganisation,supplier,contractorthatperformsapredefinedscopeofwork.
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4. MECHANICAL COMPLETION & COMMISSIONING
COMPLETION PRINCIPLES
1. OVERALL GOAL
TheoverallgoalofMechanicalCompletion&Commissioningistoverifythatthesystemisdesignedandbuilttofulfilitspurposeandspecified
requirements.
Lifecyclecostprinciplesandsafetyshouldgovernalldecisionsandactions.
Earlyestablishmentofcommissioningpackagesisessentialforanorderlyandeffectiveprojectcompletion.Thecommissioningplanshallhave
maximumprioritytoenablereversedplanninginallprojectphases.Allfabricationandinstallationplanningshallbesystemoriented.
MechanicalCompletion,Commissioning,FAT,Preservationandsuppliersassistancerequirementsshallbespecifiedinthepurchaseorders.
RepeatingofMC/Cchecksperformedatsuppliersandassemblysitesshouldbeavoided,whereverpossible.
2. COMPLETION PHASES
2.1 DEFINITION PHASE
In this phase the following is carried out:
• Completion philosophy.
• Coding structure and system breakdown.
• Completion requirements to suppliers and contractors.
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5. 3. ENGINEERING PHASE
In this phase the following is carried out:
• Commissioning package & MC package definition.
• Define commissioning network.
• Produce commissioning procedures.
4. SUPPLIERS COMPLETION PHASE
EquipmentsuppliersshallexecuteMC,FAT,commissioningandpreservationasspecifiedinthepurchase
order.Thecompletionshallbedocumentedaspartofthecompletionsystemwhichleadsuptohandovertothe
company/client.
5.CONSTRUCTION/ASSEMBLYPHASE
TheExecutorshallperformMCandcommissioningandpreservationasspecifiedinthepurchase
order/contractdocuments.Thecompletionisdocumentedaspartofthecompletionsystemwhichleadsupto
handovertothecompany.
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MECHANICAL COMPLETION & COMMISSIONING

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6. RESPONSIBILITIES
Responsibilities are defined in the contract. MC execution and registration/documentation shall be performed by
anyone who has a scope of work to be performed such as equipment suppliers, fabrication contractors,
installation contractor and hook-up contractors.
Commissioning registration and documentation shall be performed by anyone who has this responsibility
implemented in their scope of work.
7. DOCUMENTATION
Mechanical completion documentation shall be completed/executed per item/MC package.
Commissioning documentation shall be documented on a commissioning package level. All check/test records
shall end up in a status.
8. PROJECT COMPLETION SYSTEM (PCS)
An electronic based system for administration of Mechanical Completion, Commissioning and Punch List
Register should be used.
9. PLANNING
All Mechanical Completion activities shall be planned on fully integrated fabrication, Mechanical Completion and
Commissioning schedules on system prioritised basis in order to meet the optimal sequence of completion.
MECHANICAL COMPLETION & COMMISSIONING

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10. MECHANICAL COMPLETION
This chapter forms the basis for the execution and documentation of mechanical activities. Mechanical completion takes
place through all phases of the project, starting at equipment supplier and continuing through fabrication up to
commissioning phase.
• Mechanical completion encompasses all disciplines.
• The detailed responsibilities are described in the contract.
• Executor of MC activities is responsible for establishing and compiling the MC dossiers and report status into the PCS.
10.1 DOCUMENTATION FOR A MC PACKAGE
TheMCpackageshallconsistofanMCCertificate,aMCStatusIndexandaPunchListRegisterprintoutasdescribed
below.
AMechanicalCompletionCertificate(MCC)isaformcompletedbytheExecutorafterallMC,sarecarriedout.The
MCCisthecoversheetforeachMCpackage.AMCpackageshallwhensignedbereadyforstartofcommissioning.
TheCheckRecords(CR)aretheformsonwhichtheExecutorsrecordtheresultsofallchecks,inspectionsandtests
carriedoutforeachindividualitem.
APunchListRegister(PLR)shallbepreparedbytheExecutoralongwiththeMCactivity.IneachMCpackagea
printoutfromthePLRshallbeincludedtodocumenttheincompletework.
AMCStatusIndex(MCSI)liststhestatusofallCRsforthecompletedMCpackageshallbeincludedintheMC
documentationdossier.
MECHANICAL COMPLETION & COMMISSIONING

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10.2 HANDOVER AT MECHANICAL COMPLETION
HandoveratMechanicalcompletiontocommissioningshallbeatcommissioningpackagelevel,documentedbythe
ReadyforCommissioningCertificate(RFCC).
10.3CARRYOVERWORKREGISTER(COWR)
TheCarryOverWorkRegisterlistsallpunchitemsthattheProjectacceptsascannotbecompletedduringpresent
phase.TheCOWRisusedforthereleaseoftheworkfromtheExecutorandwillassuchbeaninputtothescheduling
andplanningofoutstandingworktobeperformedduringlaterphases.
TheCOWRItemNumberandcrossreferencetothePunchListRegister/CheckRecordsshallbegiven.COWRwork
shallbemarkedupondrawingsorsketchesandbeincludedintherecords.COWRMaterialStatusList(MSL)and
markedupdrawings/instructionshallcontainsufficientinformationforjobsettinginalaterphase.
10.4TYPICALMECHANICALCOMPLETIONACTIVITIES
Mechanicalcompletionactivitiesincludescheckingoffabricationandinstallationwork.TheExecutorshallcomplete
packagesrelatedtolisteddisciplinesandasrequiredbytheMCSI.TheExecutorshallcompletethechecklistitemsas
pertheMCCR's.
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10.4.1 MECHANICAL ACTIVITIES
• Visual inspection for complete and correct installation.
• Flushing and cleanliness of equipment.
• Alignment.
• Bolt tensioning.
• Pressure test.
• Load test.
• Operation and mechanical handling.
• First fill consumables.
• Preservation.
• Completion of relevant verification certification. These are to be added on request by the reader.
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10.4.2 STRUCTURAL ACTIVITIES
• Visual inspection for complete and correct installation.
• QC documentation.
• NDE carried out.
• Welding.
• Load testing of lifting lugs and monorails.
10.4.3 SURFACE PROTECTION, INSULATION AND FIRE PROOFING ACTIVITIES
• Visual inspection for complete and correct application.
• Thickness checks carried out.
• Adhesion checks carried out.
• Preservation.
• Insulation.
• Painting.
• Fire proofing.
10.4.4 ARCHITECTURAL ACTIVITIES
• Visual inspection for complete and correct installation.
• Preservation & Doors.
MECHANICAL COMPLETION & COMMISSIONING

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10.4.5 SURFACE PROTECTION, INSULATION, FIRE PROOFING & ARCHITECTURAL ACTIVITIES
• Visual inspection for complete and correct installation.
• Thickness checks completed.
• Adhesion checks completed.
• Preservation.
• Insulation.
• Painting.
• Fire proofing.
• Completion of relevant verification certification. These are to be added on request by the reader.
MECHANICAL COMPLETION & COMMISSIONING

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10.4.6 ELECTRICAL ACTIVITIES
• Visual inspection for complete and correct installation.
• Insulation and continuity testing of cables.
• Ex enclosure checks.
• Insulation testing of generator, transformers and motors, panels, distribution board etc.
• Earthing checks.
• Static check of switches and control devices.
• Battery preparation.
• Lighting and socket outlet checks.
• Area classification checks.
• Function check of switch gear and controls.
• Heat tracing.
• Preservation.
• Completion of relevant verification certification. These are to be added on request by the reader.
MECHANICAL COMPLETION & COMMISSIONING

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10.4.7 INSTRUMENT/TELECOMMUNICATION/FIRE & GAS ACTIVITIES
• Line walk, punch and as-build.
• Calibration and testing of instruments prior to installation.
• Visual inspection for complete and correct installation.
• Insulation and continuity testing of cables.
• Cleaning, flushing, pressure and leak testing of pneumatic and hydraulic tubing.
• Adjustment and verification of control, alarm and shutdown settings.
• Cold Loop testing.
• Installation of control system software
• Earthing checks.
• Function testing of control systems.
• Function testing of field instruments.
• Area classification checks.
• Preservation.
• Completion of relevant verification certification. These are to be added at the request by the reader.
MECHANICAL COMPLETION & COMMISSIONING

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10.4.8 PIPING ACTIVITIES
• NDE carried out.
• Welding procedures.
• Removal of all items subject to damage during flushing, cleaning and pressure testing.
• Flushing of pipework.
• Chemical cleaning and testing of pipework.
• Drying of tested pipework.
• Preservation of tested pipework.
• Bolt torquing/Tensioning.
• Pipe supports completed.
• Thermal and protective insulation.
• Flow coding.
• Earthing.
• Correct piping penetrations (fire/explosive ratings).
• Line walk, punch & as-build.
• Reinstatement of all items after testing & Final inspection of pipework.
• Correct piping penetrations (fire/explosive ratings).
• Completion of relevant verification certification. These are to be added on request by the reader.
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10.4.9 HVAC ACTIVITIES
• Visual inspection for complete and correct installation.
• Cleaning of ductwork.
• Leak testing of ductwork.
• Alignment checks.
• Mechanical functions checks of equipment.
• Verification of settings.
• Correct penetrations (Fire/explosive ratings).
• Preservation.
• Flow.
• Punch and as-build.
10.4.10 SAFETY ACTIVITIES
• Visual inspection for complete and correct installation.
• Preservation.
• Area completion.
• Completion of relevant verification certification. These are to be added at the request by the reader.
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11. COMMISSIONING
Thischapterformsthebasisforpreparationandexecutionofcommissioning.Commissioningtakeplacewhen
Mechanicalcompletioniscompletedforasystemorpartofasystem.
Commissioningcanbedividedintothreemainactivities:
•Commissioningpreparation.
•Commissioningexecution.
•Commissioningdocumentationandhandovertooperation.
Establishacommissioningnetworkanddefinitionofcommissioningpackagesearlyinaprojectinordertoestablish
fabrication/installationprioritiesandmilestones.
Definitionofcommissioningofpartsystemsisessentialinordertoachieveanearlycommissioningcompletion.
11.1 TYPICAL COMMISSIONING PREPARATION ACTIVITIES
Thepreparatoryworkshallconsistofactivitiessuchas:
•Developmentofcommissioningorganisation&systembreakdown(partsystem).
•Commissioningpackagesdefinition.
•Commissioningschedules.
•Commissioningbudgetincludingsparepartsforcommissioning.
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11.2 COMMISSIONING PROCEDURE CONTENTS
Commissioningshallbeexecutedbyguidanceofadetailedproceduredescribing:
11.2.1OBJECTIVE
Detailstheoperatingparameterstobeachieved.
11.2.2DESCRIPTION
Shallcontainabriefdescriptionofthesystem/partsystemstobecommissioned,includingmarkedupP&IDasabasis
forallfunctionstobetested.
11.2.3LISTSOFTEMPORARYEQUIPMENTANDCONSUMABLES
Listsallconsumables,temporaryequipmenttoolsandrequirementsforsuppliersassistance.
11.2.4HEALTH/ENVIRONMENT/SAFETY
Alistofalltoxicandpollutingfluidsandmaterialsshallbemade,describingtheirhandlinganddisposal.Achecklistof
allrequiredsafetyprecautionsincludingrequirementsforworkpermitshallbemade.Priortoenergizationofelectrical
equipmentaliveningupnoticeshallbeissuedinordertoinformallinvolvedpartiesofforthcomingenergising.
11.2.5PRESERVATION
Requirementsforremovalofexistingpreservatives/protectionshallbemadeandsubsequentnewpreservationofthe
systemifthesystemshallbeoutofoperationforaperiodoftime.
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12 EXAMPLES OF COMMISSIONING ACTIVITES
12.1PIPING
• System Leak test.
• Sensitive leak test.
12.2 INSTRUMENT/TELECOMMUNICATION/FIRE & GAS
• Loop testing.
• Function testing of field instruments.
• Check of the installation, by line walking the installation verifying the correctness of key drawings.
• Function testing of control systems.
• Adjustment of control, alarm and shutdown settings.
• Verification of settings on equipment.
• Function test of equipment.
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12.3 FUNCTION TEST OF NEW FACILITIES
•Equipmenttestinaccordancewithvendorprocedures.
•HMItoSCADAtest.
•SignalI/Ofunctionality.
•Localandremoteindicatortesting.
•Localandremotestartstopfunction.
•Testingofemergencystopsbothlocalandremote.
•Opening/closuretimesonactuatedvalves.
•Startstopofrotationalequipment,checkrotationdirection,checkperformanceandproductquality.
•Dutyandstandbyfunctiontests.
•Filltanks/vesselsandcheckinstrumentslocalandremote.
•GasandUVdetectiontests.
•Illuminationtests.
•HVACtesting(Functionality,flow,controlandF&G).
•Firewatercoveragetesting.
MECHANICAL COMPLETION & COMMISSIONING
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13 TYPICAL MECHANICAL COMPLETION DOCUMENTS
13.1SCOPE
Thescopeshalldetailtheworktobedonestepbystepincludingthecommissioningpreparation.
Irregularitiesand/orfaultsshallbelogged.
Equipmentsuppliersstart-upproceduresshallbeincorporated.
Performanceparametersshallbeincludedforcomparisonofresultswithactualresultachievedduringcommissioning.
13.2PLANNING
Detailedcommissioningplansforsystem/partsystemshallbeworkedoutandshallincludemanhoursperdiscipline,includingsupplierassistance
man-hours.
13.3HANDOVER
Thehandovershallcontainacertificateandotherdocumentsagreedwithoperations.
13.4HANDOVERDOCUMENTATIONTOOPERATIONS
HandoverofsystemsfromExecutortoProject/Operationsshallbeaccordingtoaformalprocedurewhichasaminimumshouldconsistof:
•Completionacceptancecertificate(signedbybothparties).
•CommissioningP&IDshowingtheextentofthecompletedsystem.
•Authoritycertificates(ifany).
•Operationalproceduresandhandbooks.
MECHANICAL COMPLETION & COMMISSIONING
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MECHANICAL COMPLETION & COMMISSIONING