c-56 NOC

NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.56

ELECTRICAL COMMISSIONING

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

GENERAL ENGINEERING SPECIFICATION ELECTRICAL COMMISSIONING

GES C.56 of 28 Rev 0 1999

INDEX SEC TITLE PAGE 1.0 SCOPE OF SPECIFICATION 3 1.1 Introduction 3 1.2 Other Specifications 3 1.3 Data Sheets 4 2.0 DEFINITIONS 4 2.1 Technical 4 2.2 Contractual 6 3.0 DESIGN & PERFORMANCE 6 3.1 Environmental Conditions 6 3.2 Codes and Standards 7 3.3 Phases and Milestones 7 3.4 Classification of Activities (Pre-commissioning, 8 Commissioning, and Start-up) 4.0 METHODOLOGY 11 4.1 Systems 11 4.2 Pre-commissioning 12 4.3 Commissioning 13 4.4 Technical preparation 16 5.0 ORGANISATION 18 5.1 Transfer of Responsibilities 18 5.2 Organisation and Composition of the Commissioning Team 19 5.3 Safety During Commissioning Activities 20 6.0 TESTING 20 6.1 Introduction 20 7.0 DOCUMENTATION 20 7.1 Requirements 20 8.0 FIGURES SUB-INDEX 21 Figures 22


GES C.56 of 28 Rev 0 1999

1.0 SCOPE OF SPECIFICATION 1.1 Introduction 1.1.1 This specification covers the minimum requirement for the completion of electrical pre-

commissioning, commissioning and start-up activities for refineries, onshore oil and gas installations and processing facilities including equipment purchased either directly or as part of a package.

1.1.2 This specification is generally based on ANSI/NEMA Standards. The Vendor/Contractor shall comply

fully with the provisions laid down in this specification. Any exception must be authorised in writing by the Owner, as failure to do so shall indicate full compliance; any remedial work then necessary, shall be at the Vendor/Contractor's expense.

In the event of any conflict between this specification and the data sheets, or with any of the applicable Codes and Standards, the Vendor/Contactor shall inform the Owner in writing and receive written clarification before proceeding with the electrical commissioniing work. 1.1.3 This specification and all the specifications listed below in Section 1.2, define how the completion

activities must be carried out, from a technical point of view without pre-supposing which party is in charge. Hence, these specifications will be equally applied by Vendor/Contractor and Owner within their respective limits of obligations.

1.1.4 Prior to commissioning activities taking place, the equipment has to be certified by the

Vendor/Contractor (who carried out the construction and pre-commissioning as specified in GES C.06, as being constructionally complete and pre-commissioned. It is then handed over to the commissioning team complete with the necessary signed and completed quality assurance paperwork, ready for commissioning.

The prior activities of construction and pre-commissioning are referred to where necessary in this

specification, but are excluded from the scope of this specification. 1.1.5 This general specification will form part of the Purchase Order/Contract, together with any Data

Sheets, drawings or other attachments. 1.2 Other Specifications The following specifications are an integral part of this specification and any exceptions shall be

approved in advance by the Owner: GES A.06 Site Data GES C.01 Protection of Materials and Equipment during Storage GES C.02 Protection of Materials and Equipment during Construction GES C.03 Safety Procedures on Construction Sites GES C.06 Electrical Installation Practices GES C.54 Commissioning of Microprocessor Based Instrument Systems GES C.55 Field Calibration and Testing of Instruments GES C.60 Plant Pre-Commissioning, Commissioning and Start-up Guidelines GES H.02 Safety Signs and their Application


GES C.56 of 28 Rev 0 1999

1.3 Data Sheets The technical data supplied by the owner for the equipment is given on the Data Sheets which will be

included at the end of the relevant equipment specification. The Vendor/Contractor shall complete the relevant part of the Data Sheets with the remaining information. 2.0 DEFINITIONS 2.1 TECHNICAL The Technical terms used in this specification are defined as follows: Commissioning: live tests and major equipment `on line' tests. Functional Test: live tests of an instrument, electrical or telecommunication basic function. Functional Test Sheet: supporting documents to record the results of a functional test. Hand over unit: group of subsystems constituting an operable part of the plant transferred to the Owner as a whole. Mechanical completion: status of the plant when it has been Constructed and Pre-Commissioned and all subsystems are ready

for commissioning. Operational Test: `on line' test of a subsystem in conditions as close as possible to the normal operating conditions. Pre-commissioning: conformity checks and cold tests verifying that a sub system has reached the 'ready for commissioning' stage. Pre-commissioning Check List: definition of the scope of work of conformity checks to be performed on elementary items of

equipment. Pre-commissioning Test Sheet: supporting document to record the results of static or de-energized tests carried out on certain items of

equipment.


GES C.56 of 28 Rev 0 1999

Pre-Start-Up Activities: process operations preparing the oil, gas or feed stock in. Project Team: the organisation set up by the Owner to manage all phases of the project, from Basic Engineering until

Final Acceptance. Ready for Commissioning: status of a subsystem when all pre-commissioning operations on that subsystem are complete. Ready for handover: status of a subsystem when all commissioning operations on that subsystem are complete. Ready for start-up: status of the plant when all subsystems required for oil, gas or feed stock are ready for handover. Status Index: list of equipment subject to pre-commissioning operations and summary of the pre-commissioning

scope of work. Subsystem: subdivision of system, that performs a given operational function. System: major subdivision of an installation, being either process or utility, including all the various equipment

required for that system to operate. KKS: Kraftwerk Kennzeichen System for Designation of Power Stations String Test: combined site (or Works) test on Packaged Equipment or a completed installation. EPC Contract: single Contract covering Engineering, Procurement, Supply, Fabrication, Installation and Hook-up. EPCC Contract: same as EPC but also extended to include Commissioning. 2.2 Contractual The commercial terms used in this specification are defined as follows:


GES C.56 of 28 Rev 0 1999

Owner The oil and gas company, an associate or subsidiary, who is the end user of the equipment and

facilities. Vendor The company supplying the equipment and material. Contractor The main contractor for a defined piece of work. Sub-Contractor A company awarded a contract by a Contractor to do part of the work awarded to the Contractor. Inspection Authority The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and

facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

Inspector A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN AND PERFORMANCE 3.1 Environmental Conditions 3.1.1 External Environment These conditions are fully detailed in GES A.06 and cover the principal conditions affecting the

electrical equipment including maximum and minimum ambient temperature, dust, humidity and altitude etc.

3.1.2 Internal Environment Electrical equipment may be housed in an enclosed, air-conditioned equipment room; full details are

given in GES B.12. Temporary excusions from these limits e.g. during short term power problems, shall be ignored for the

purposes of equipment rating. 3.2 Codes and Standards 3.2.1 General In general, the requirements specified herein are based on the ANSI/NEMA and other American Codes

and Standards, the most important of which are listed. Unless otherwise stated, equipment and materials shall comply with these Codes and Standards.


GES C.56 of 28 Rev 0 1999

Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and

Standards at the time of order shall be used. The Vendor/Contractor shall operate and supply certification for a Quality System complying with the

requirements of the ASQ Q9000 Series or BS EN ISO 9000, Part 1 (Design) Part 2 (Production) and Part 3 (Test and Inspection).

3.2.2 US Codes and Standards API 700 Check List for Plant Completion ASQ Q9000 Quality Management and Quality Assurance NFPA-70 National Electrical Code 3.2.3 IEC and other Recommendations When appropriate, equivalent International Standards which may be used as alternatives are listed

below and may be used with the prior approval of the Owner. Equipment and materials complying with IEC Recommendations shall be at least equal to the requirements of this specification. The Vendor/Contractor shall advise full details of any deviations to these requirements in his offer if IEC based standards are utilised.

ISO 9003 Quality System - Test and Inspection 3.3 Phases and Milestones 3.3.1 Completion Activities Their are four defined stages to be carried out as follows: Stage 1 - Construction - by the Construction Vendor/Contractor as detailed in GES C.06. Stage 2 - Pre-Commissioning - by the Construction Vendor/Contractor as stated in GES C.06 and this

specification. Stage 3 - Commissioning - by the Vendor/Contractor as stated in this specification Stage 4 - Plant Start Up - by the Vendor/Contractor as stated in this specification


GES C.56 of 28 Rev 0 1999

3.3.1.1 Pre-commissioning The pre-commissioning phase includes two main types of electrical field activities, which are carried

out by the Construction Vendor/Contractor as part of the Construction Purchase Order/Contract. a) Systematic conformity checks, carried out on each item of equipment or component, such as

transformers, motors, cables etc., to verify visually the condition of the equipment, the quality of the installation, the compliance with Project drawings and specifications, manufacturer's instructions, safety rules, codes, standards and good practice.

b) Selected equipment static/de-energized tests, to ensure the quality of a number of critical

components. The completion of pre-commissioning activities marks the end of the construction of a plant. The plant

status reached at the end of the pre-commissioning phase is called the "Mechanical Completion", or "Ready for Commissioning".

3.3.1.2 Commissioning The Commissioning phase essentially includes the following two categories of tasks, which are carried

out by the Vendor/Contractor as part of the Commissioning and Start-up Contract. a) The dynamic verifications of each elementary electrical and instrumental function that the

plant equipment is designed to achieve. Typical examples of such tests are electrical motors uncoupled runs, instrument loop tests, electrical breakers operation. The energisation of the electrical distribution network is part of this activity.

b) Full co-ordination and collaboration between all the trades and disciplines to perform the

mechanical preparation, then the actual running-in and on-line tests for a significant period of the plant utilities, and wherever applicable, of the main process equipment in closed loop.

Once commissioning operations are complete, the plant reaches the "Ready for Start-up"

status. 3.3.1.3 Plant Start-Up Since the start-up of utilities is considered a commissioning operation, the real start-up phase begins

with the introduction of the feedstock into the plant. The start-up activities are therefore: - oil, gas or feed stock in; - bringing the plant in operation; - performance tests, to prove the plant and equipment design capacities, product;

specifications, etc. Full details of the overall plant Pre-commissioning, Commissioning and Start-up covering other trades

and disciplines are given in GES C.60. 3.4 Classification of Activities (Pre-commissioning, Commissioning, Start-Up) The Project Completion Activities, broadly categorized in the preceding sections are now further

defined in the following "classification of activities". This classification, although it cannot be considered as an exhaustive scope of work, provides a useful

list of all main completion and start-up activities, by discipline and major types of equipment, and it establishes to which category they belong, namely pre-commissioning, commissioning, or start-up.


GES C.56 of 28 Rev 0 1999

Regardless of the contractual aspect and the division of responsibilities, this classification is a normal

technical definition of Pre-commissioning, Commissioning, and Start-up. The classification list may have to be completed on an `ad hoc' basis depending on the contract specific technical aspects of a given project.

3.4.1 Electrical PCom Com Start-Up a) Check condition of equipment, quality of installation, and

compliance with Project drawings, manufacturers' instructions, safety rules, specifications and good practice.

X

b) Perform preliminary Electrical and Instrumental tests with

equipment and cables de-energised including:

X

- insulation resistance measurements; - di-electric strength tests; - loops and circuits continuity tests; - earthing resistance measurements.

c) Fill transformers with oil and carry out breakdown test of oil

samples. X

d) Test and Start-up power plant. X e) Energise and test power system control. X f) Perform all functional tests, including: X - adjustment and testing of protective devices; - check-out and adjustment of electrical instruments; - operation of safety devices. g) Energise and test emergency and instrument power systems. X h) Carry out preliminary load test.

i) Energise sub stations.

X X

j) Fill in batteries with electrolyte. X

k) Carry out batteries discharge tests. X l) Test battery chargers, inverters, UPS. X m) Check direction of rotation of electrical motors. X n) Modify motor connections if wrong directions of rotation. X o) Perform motor 4 hour no load runs. Test motors ancillary

equipment. X

PCom Com Start-Up p) Check temperature rise of motors, bearings, transformers,

relays, when loaded. X

q) Check operation of manual and auto controls. X


GES C.56 of 28 Rev 0 1999

r) Check normal and emergency lighting intensities. X s) Conduct performance tests where applicable.

X

3.4.2 Electrical Works Associated with HVAC Equipment

a) Check condition of equipment, quality of installation, and compliance with Project drawings, manufacturers' instructions, safety rules, specifications and good practice.

X

b) Check alignment of motor/fans and drives. X c) Check that tension on drives is correct. X d) Check that fans and motors rotate manually and run freely. X e) Check that anti-vibration mountings are correctly installed. X f) Energize and run unit. Test sequences and interlocks. Check

vibration. X

3.4.3 Electrical Work Associated with Residential Area Equipment a) Check conditions of equipment, quality of installation, and

compliance with Project drawings, manufacturers instructions, safety rules, specifications and good practice.

X

b) Perform preliminary tests with equipment and cables de-

energised including: X

- insulation resistance measurements; - circuits continuity tests; - earthing resistance measurements.

c) Test and start-up Power System.

X

d) Energise specific (kitchen) electrical appliances and check

functions with reference to electrical procedures. X

e) Energise and Test Emergency Power Systems. X

f) Carry out preliminary load tests. X

g) Check operation of manual and auto controls. X h) Check normal and emergency lighting intensities. X 4.0 METHODOLOGY 4.1 Systems 4.1.1 The Systems Approach


GES C.56 of 28 Rev 0 1999

The checking and testing phases of a new plant are relatively long and complicated processes. Not all parts of the plant reach the same degree of completion at the same time and some areas or units of a plant may be mechanically complete while others are not. It would therefore be a waste of time to wait for the whole plant to be mechanically complete before starting commissioning activities.

Also, the start-up sequence of a new plant is driven by operational constraints: safety equipment is

given the highest priority, followed by the utilities, which are required earlier than the process equipment etc. For installations where there is no other power available the Power Generation will have to be commissioned first. Hence, contrary to the construction work progress which is planned by trades and areas, the optimisation of the start-up phase goes through the sequential completion of multi-trade operational units: fire pumps, power generation etc.

For obvious reasons of optimisation of means and resources, not all tasks related to pre-

commissioning, commissioning or start-up can be undertaken simultaneously. Therefore, the Project planning will be optimised if the completion activities are organised not as

whole plant activities, but by "system" i.e. a subdivision of an installation that performs a given operational function, with no or little interference from the other parts of the plant.

Hence, the basic principle of the plant completion organisation will be to define, prepare, carry out and

report all pre-commissioning and commissioning activities by systems (or rather subsystems as a dual-level subdivision is often found useful), since the partial overlapping of pre-commissioning, commissioning and start-up activities that this approach allows, will show a saving in time and an optimisation of resources.

One commonly used method is the `Kraftwerk Kennzeichen System' (KKS) which evolved in

Germany around 1970 for the designation of Power Systems. It is very detailed and covers all aspects of System and Equipment designation and identification. See Section 4.4 of this specification for Technical Preparation.

The changes of responsibilities, if several parties are in charge of the various completion phases, will

also take place on a `system', or `subsystem', basis. As a consequence, the "system approach" induces the following terminology, related to milestones: - A subsystem is `Ready for Commissioning' when all pre-commissioning operations on that

subsystem are complete. - A plant is `Mechanically Complete' when pre-commissioning is completed and all its

constituting subsystems are ready for commissioning. - A subsystem is `Ready for Handover' when all commissioning operations on that subsystem

are complete. - A plant is `Ready for Start-up' when all subsystems required for oil, gas or feed stock in are

`Ready for Start-up'. 4.2 Pre-Commissioning 4.2.1 Scope of Work The pre-commissioning physical scope of work is as previously stated in Section 3.3.1.1. The Vendor/Contractor may only deem it necessary to carry out reduced pre-commissioning on those

packages that have been thoroughly tested at the manufacturers works although this does not alleviate him of his responsibilities. Pre-commissioning of safety related items i.e. ESDs equipment protection


GES C.56 of 28 Rev 0 1999

etc. shall be fully pre-commissioned with no reduction in work scope whatsoever. 4.2.2 Check List First task of the pre-commissioning scope of work, the conformity checks, are carried out in

accordance with, and reported on, check lists. These check lists define the exact scope of work that must 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 and these check lists are prepared

on a contract specific basis. 4.2.3 Test Sheets The second key pre-commissioning activity, the static and de-energised tests are carried out in

accordance with this specification and the manufacturer's recommendation and reported on Test Sheets.

One Test Sheet form is needed for every type of pre-commissioning test listed in the classification of

activities. One Test Sheet is filled in for each test performed. 4.2.4 Status Index The pre-commissioning scope of work is listed in a reference Status Index. The Status Index is a list of

all equipment subject to one or several pre-commissioning operations. This list, arranged per subsystem, discipline and type of equipment, is created by the Owner from the various Engineering and Vendor/Contractor's equipment lists, cables list, etc.

The Status Index indicates for each item of equipment (pressure gauges, electrical cables, pumps etc),

the corresponding pre-commissioning tasks, i.e. checks, and tests when applicable, by showing the reference number of the task report document, i.e. Check Lists and Test Sheets numbers. The Status Index is therefore a summary of the pre-commissioning scope of work. The completion date of each task is recorded on the Status Index so that it is a working document used to follow up the work progress.

4.2.5 Punch List While the pre-commissioning checks and tests are being performed, as stated in this specification, all

discrepancies, damaged or missing equipment, malfunctions, missing documents, etc. are recorded in the subsystem punch lists, if the situation was not able to be corrected immediately. These lists are kept updated during the pre-commissioning operations, so as to have a precise status of each subsystem at the 'Ready for Commissioning' stage (by which time there should be few punch list items yet to clear, and of minor importance).

At this stage, these new items discovered by the Commissioning team during their cross checking of

the plant (see Section 4.3.1.2 - Preliminary checks) are incorporated in the pre-commissioning punch list, which becomes the combined Ready for Commissioning punch list of the subsystem.

4.2.6 Pre-commissioning Dossiers a) All documentation pertaining to the pre-commissioning operations is compiled in a specific

dossier, arranged by subsystem, which contains all the information required to demonstrate that a subsystem has reached the "Ready for Commissioning" status.


GES C.56 of 28 Rev 0 1999

b) Its content is the following: - ready for Commissioning Certificate; - punch List; - system Description and marked-up drawings; - status index; - check lists; - test sheets; - as-built drawings; - Vendor/Contractor's reports/information; - specific procedures and tests; - list of modifications. A summary of the Pre-commissioning Methodology is shown on Figure 8.3 in Section 8.0 4.3 Commissioning 4.3.1 Specifications The Commissioning and allied specifications are detailed in Section 1.2 of this specification. They provide details all of the required procedures and support documents to prepare and carry out

Commissioning activities. 4.3.1.1 Scope of Work The commissioning physical scope of work is stated in Section 3.3.1.2. From a methodological point of view, the commissioning scope of work has been divided into four

separate activities comprising: - preliminary checks; - functional tests; - operational tests; - pre-start-up activities. All operations are organised by subsystem, following a sequence, identical to that of pre-

commissioning, which optimises the start-up phase. Field equipment and packages are equally subject to the above commissioning operations, irrespective

of the amount of testing that may have taken place at the Vendor/Contractor's works. This is due to the fact that the factory tests: - are carried out with temporary wiring between the package and its control panel, and without

the actual interface with the plant systems such as ESD system, fire and gas system, remote control etc;

- are essentially aimed at demonstrating the contractual performance point, whereas

commissioning must prove all sequences, interlocks, safety trips; - are achieved long before that start-up on site, hence their validity is doubtful, and often not

assumed by the Vendor/Contractor for reasons of contractual guarantee.


GES C.56 of 28 Rev 0 1999

4.3.1.2 Preliminary Checks The preliminary checks are the cross verification by the Commissioning Team that a subsystem is

effectively "Ready for Commissioning". They take place when a subsystem nears or reaches the mechanical completion status, and consist of:

- a physical check on site of the installation; - a thorough review of the Pre-commissioning Dossier. The preliminary checks shall be carried out by each discipline and formalised by a specific report form. Their major outcome is usually a number of punch list items, that are included in the Pre-

commissioning (or Ready for Commissioning) punch list and related to construction/pre-commissioning operation.

4.3.1.3 Functional Tests These are the live tests performed on electrical equipment and materials, including elementary

functional testing. An item or group of items of equipment that performs an elementary function of the plant is named a

`Basic Function'. It is the smallest equipment which can be subjected to a commissioning operation and a list is needed to define all possible types of basic functions of a plant: switchboards, transformers, heaters, process control loops, electrical solenoid valves, loudspeaker loops, pumps, vessels, etc. but only instrument, electrical, and telecommunication basic functions are subject to functional tests.

The functional tests are carried out in accordance with this specification and manufacturer's

recommendations the results being recorded on Functional Test Sheets. One Test Sheet form shall be made available by the Commissioning Vendor/Contractor, for every type

of functional test listed in the Classification of Activities, one form being filled in for each test performed.

There are no spot or random functional tests; every item of electrical equipment and materials Basic

Function of the plant is subject to one functional test, be it part of field or package equipment. 4.3.1.4 Operational Test Once all Basic Functions of a subsystem have been functionally tested, the subsystem is subject to an

Operational Test, wherever applicable. It consists of bringing the system into operation under conditions as close as possible to normal, not

only to live test the automated devices, controls, normal and shutdown sequences, but also to reveal possible mechanical or electrical faults (watertightness, vibrations, overheating, overloading) which may occur during prolonged normal use. The mechanical preparation of the equipment before the first start-up is part of the operational test.

Typical subsystems subject to an operational test are: fire water pumps, air compressors, power

generation, ESD system, export pumps in recycle, process compressors in recycle (with air or nitrogen, if possible under gas, after gas-in, if not), freon or propane packages, hot oil loop etc.

Every operational test is conducted in accordance with an Operational Test Procedure (OTP), which

has been established during the Commissioning preparation phase and approved by the Owner. There is no standard OTP, since they vary with the plant.


GES C.56 of 28 Rev 0 1999

The operational test of a subsystem is the key commissioning activity, witnessed and countersigned by the Owner, when there is a change of responsibility at the Ready for Start-up.

4.3.1.5 Pre-Start-Up Activities These are all the specific activities required to prepare the oil, gas or feed stock as detailed in GES

C.60. 4.3.1.6 Technical Data Base At the preparation phase the Commissioning team shall prepare a Technical Data Base, the main tool

of the commissioning preparation and follow up, listing all basic functions, grouped by sub-system, discipline and type of basic function, which given an exhaustive description of the physical content of all systems. It will be the equivalent of the Status Index for Pre-Commissioning.

The Data Base will indicate, for each basic function, the type of commissioning operation required, by

reference to the task report form of this operation, and it will also give other relevant information (set points, drawings no. etc).

The completion date of each activity is also recorded, so that it is a working document used to follow

up the commissioning progress. It is good practice to use software to build this data base and make it available to Commissioning

Teams. 4.3.1.7 Punch List The subsystems punch lists once established at the `Ready for Commissioning' stage shall be

continually updated during commissioning operations, by adding all newly discovered items and deleting cleared ones.

At the time of the `Ready for Handover', those new items discovered by the Owner during their cross-

inspection of the plant shall be included in the punch list, which becomes the combined `Ready for Handover' punch list precise status of the subsystem, when handed over to the Owner.

4.3.1.8 Handover Dossier All documentation pertaining to the commissioning operations shall be compiled in a specific

Handover Dossier, arranged by subsystem, which contains all the information required to demonstrate a subsystem has reached the "Ready for Handover" status.

Its content is the following for the electrical scope: - handover certificate; - punch list; - basic functions list; - operational test procedure; - functional test sheets; - Vendor/Contractor's reports; - as-built drawings; - list of modifications. A summary of the Commissioning methodology is shown on Figure 8.4 in Section 8.0. 4.4 Technical Preparation 4.4.1 Policy


GES C.56 of 28 Rev 0 1999

The Pre-Commissioning and Commissioning activities shall be completed in the shortest possible time

and under no circumstances shall the period exceed three months after plants construction activities are completed.

The approach calls for the following sequence: - pre-commissioning; - mechanical completion; - commissioning/start-up; - handover to Owner; - performance testing. It is then impossible to afford in these areas a learning curve, or an initial period of loose organisation,

that could be disastrous for such short works and the project overall schedule. The best policy is to insist on thorough preparation long before the beginning of completion activities,

not only all pre-commissioning and commissioning tasks, but also side activities, such as co-ordination between various parties, gathering of documentation, spares, etc. so that the organisation can be efficient right from day one.

To ensure that pre-commissioning and commissioning preparation works become a standard feature of

projects the preparation procedures and tasks have been made standard. They are covered by the specifications listed in Section 1.2 of this specification.

4.4.2 General Preparation The general pre-commissioning and commissioning preparation activities shall be as follows: - define plant start-up sequence. - define list of systems and subsystems. - issue marked-up P&IDs and SLDs showing limits of subsystems. - compile equipment lists by subsystem. The above activities shall take place early during the detailed engineering phase, at a time when the

Commissioning Team senior staff may not yet be mobilised. These tasks are always part of the Vendor/Contractor's scope of work, with supervision by Owner. 4.4.3 Pre-commissioning Preparation 4.4.3.1 Documents - Establish, from the subsystems definition and equipment lists, the Status Indexes. - Adapt the pre-commissioning specification to the project particularities, by issuing Check List

and Tests Sheets for the project special equipment. - Itemise all Check Lists and Test Sheets. - Prepare pre-commissioning dossiers. 4.4.3.2 Planning - From the start-up sequence, produce a pre-commissioning/commissioning network and

sequence.


GES C.56 of 28 Rev 0 1999

- Evaluate tasks duration and issue planning and Ready for Commissioning (RFC) dates. 4.4.3.4 Contracts - Prepare pre-commissioning clauses of construction contracts. - Prepare vendor's assistance during pre-commissioning operations. All above pre-commissioning preparation activities are carried out by the Construction

Vendor/Contractor, including the preparation of Check Lists, Test Sheets, and pre-commissioning dossiers. They take place in parallel with the commissioning preparation, carried out by the Vendor/Contractor around 4 to 6 months before the beginning of the operations on site.

4.4.4 Commissioning Preparation It mainly includes the following activities carried out by the Vendor/Contractor: 4.4.4.1 Documents - Define Basic Functions by subsystem as Section 4.1.1. - Develop the Technical Data Base as Section 4.3.1.6. - Adapt the commissioning specification and issue Functional Test Sheets for the project

special equipment, as Section 4.3.1.3. - Itemise all functional Test Sheets as Section 4.3.1.3. - Define the list of operational tests, and issue the operational tests procedures as Section

4.3.1.4. - Prepare the Ready for Handover dossiers as Section 4.3.1.8. 4.4.4.2 Planning - Produce the tasks register and commissioning program. - Quantify the scope of work. - Produce integrated commissioning/start-up planning and handover sequence. - Produce manpower histograms. 4.4.4.3 Contracts - Prepare "assistance to commissioning" clauses in the construction contracts. - Prepare Vendor/Contractor's assistance to commissioning activities. - Include commissioning spare parts and special tools in Purchase Orders/Contracts. Most of the above commissioning preparation activities are carried out by the Commissioning Team

from 6 to 8 months prior to their mobilisation on site. However some `support' activities take place earlier in the Project, the contracts related activities

essentially. These are therefore carried out by the Engineering Vendor/Contractor as follows:


GES C.56 of 28 Rev 0 1999

- Gather all required engineering and Vendor/Contractor's documentation. - Perform detailed engineering of required temporary facilities. - Prepare stocks of spares, consumable, test equipment, chemicals, and logistics means. - Prepare execution personnel selection and mobilisation. 5.0 ORGANISATION 5.1 Transfer of Responsibilities 5.1.1 Ready for Commissioning (RFC) stage a) The transfer of responsibility at the RFC stage takes place as each plant is completed its Pre-

Commissioning, on a sub-system basis in accordance, as far as possible, with the start-up sequence. It is formalised by the signature by both parties of the "Ready for Commissioning Certificate".

This mutual agreement of the subsystem status is achieved through: - the inspection by the Commissioning Team of the subsystem facilities and their thorough

review of the pre-commissioning dossier; - the actual witnessing by the Commissioning Team of at least critical pre-commissioning

activities, such as Operation of Emergency Safety Devices, Motor rotations, protection relays setting;

- the establishment of a "Ready for Commissioning Punch List", mutually agreed between the

two parties. b) Ready for Handover (RFHO) stage The transfer of responsibility at the RFHO stage takes place as each plant completes its

Commissioning, which may be on a subsystem basis, but it is often convenient to transfer the facilities to the Owner by consistent groups of subsystem, named `Handover Units', as the start-up activities follow the commissioning progress less closely than the commissioning does with the pre-commissioning.

The transfer is formalized by the signature by both parties of the `Handover Certificate'. The mutual agreement on the subsystem status is achieved through: - the inspection by the Owner of the subsystem facilities, and their thorough review of the

commissioning dossier; - the actual witnessing and countersigning of the most significant commissioning Operational

Tests. In the case of Engineering, Procurement, Construction and Commissioning (EPCC) contracts, however all Test Sheets, on top of the Operational Tests, are also countersigned by the Owner;

- the establishment of a mutually agreed "Ready for Handover Punch List". The Certifying Authority may also witness completion activities according to their contractual


GES C.56 of 28 Rev 0 1999

obligations, as well as any other interested body as directed by the Owner. 5.1.2 EPCC Contracts The Vendor/Contractor responsible for the EPCC contract carries out the activities stated in the

definitions, Section 2.2, which includes Pre-Commissioning, Commissioning and start-up. Since the Pre-Commissioning and Commissioning are part of the same Vendor/Contractors scope of work, there is no transfer of responsibility, contractually speaking, at the RFC stage.

The Commissioning Group, however, will most often be an entity distinct from construction, which

means an internal transfer of responsibility. Although all the activities will be carried out by one company, all the requirements of this

specification will be strictly adhered to and all compiled exactly as if a contractual transfer was to take place.

5.2 Organisation and Composition of the Commissioning Team The Team's organisation will also be established case by case, but the following points will most often

be retained. The typical site organisation is based on: Commissioning Site Leader (CSL) - Managing The Commissioning Team `Discipline Superintendents' - directly managing their execution teams. `System Engineers' - in charge of the commissioning process activities, the

progress and documentation follow-up, the inter disciplines co-ordination, for those subsystems each of them has in charge. (These positions, very much specific to Commissioning Operations, are considered to be key roles).

`Support Positions' - (safety, planning, logistics, computers, etc). Such a typical organisation is shown in Figure 8.7 in Section 8.0. - For projects, for which a personnel rotation system is required, the two rotational

Commissioning Teams are complemented by a Commissioning Manager and a reduced staff based in Project Head Office, who ensure proper continuity between the teams and long term decisions. For smaller projects, this role, less required, is devoted to the CSL.

- The CSL, System Engineers and Discipline Superintendents, are most often Technical

Engineering Personnel (TEP) seconded from the Vendor/Contractor. Wherever possible a few commissioning supervisors, and as many operations personnel as possible originate from the Owner, to benefit from the training period the commissioning phase constitutes.

5.3 Safety During Commissioning Activities The Health Safety and Environment charter governs the position that must be taken for the

Commissioning activities within or under the control of the Owner. In particular "no economic priority shall overrule consideration of health and safety at work and

respect of environment". Therefore, it is normal policy :


GES C.56 of 28 Rev 0 1999

(a) when Commissioning activities are carried out in the Contract yard, to give responsibility of

the "Permit to Work" system to the yard authorities provided that their system is in accordance with a recognised international standard;

(b) when Commissioning activities are carried out on Owner's site, the Owner's "Permit to Work"

system shall apply. 6.0 TESTING 6.1 Introduction The testing required is covered in the individual equipment specifications and the related NOC

Specifications listed in Section 1.2 of this specification. Further details are not included here. 7.0 DOCUMENTATION 7.1 Requirements 7.1.1 'As-built' drawings as commissioning is complete. 7.1.2 Completed Test Sheets. 8.0 FIGURES SUB-INDEX Figure 8.1 - Sequence of Completion Activities Figure 8.2 - Summary of Completion Activities Figure 8.3 - Summary of Pre-commissioning Methodology Figure 8.4 - Summary of Commissioning Methodology Figure 8.5 - Commissioning Team Position (within Project Organisation) Figure 8.6 - Commissioning Team Position (within Plant Organisation) Figure 8.7 - Commissioning Team Site Organisation

c-56 NOC

Documents

Transcript of c-56 NOC