Commissionning of Oil and Gas Processing Plants

Oil & Gas Processing Plants
Design and Operation

COMMISSIONING Training Course
DGEP/SCR/ED/ECP - 7/18 October 2002

COMMISSIONNING OF OIL AND GAS
PROCESSING PLANTS

COMMISSIONNING OF OIL AND GAS PROCESSING PLANTS : CONTENTS
• 1- COMPLETION ACTIVITIES DEFINITION
• 2- DESCRIPTION OF THE METHODOLOGY
• 3- OVERALL SEQUENCE AND DOSSIERS OF COMPLETION ACTIVITIES
• 4 - TOOLS (ICAPS)
• 5 - CONTRACTUAL ASPECT AND ORGANIZATION
• 6- TFE PRECOMMISSIONING AND COMMISSIONING POLICY
• 7- CONCLUSION : EXPERIENCE OF TFE
• 8- QUESTION / ANSWER SESSION
DGEP/SCR/ED/ECP - 7/18 October 2002 3

COMPLETION ACTIVITIES DEFINITION
1 - COMPLETION ACTIVITIES DEFINITION

Project phase and completion activities
Operations
Routine operation
Provisional
Acceptance
START-UP
Ready for
COMMISSIONING StartUp
EXECUTION Mechanical
PRECOMMISSIONING Completion
EXECUTION
Commissioning preparation
CONSTRUCTION
PROJECT
&
Precommissioning preparation
PROCUREMENT
5
DETAILED
General preparation
ENGINEERING
BASIC
ENGINEERING

Pre-Project
Preliminary and
conceptual studies
COMPLETION ACTIVITIES = PRECOMMISSIONING + COMMISSIONING
- Verifications just before the Plant is brought on line to ensure that every
piece of equipment operates as per design.
- Ultimate goals : make the plant oil or gas in as safe and troublefree as
possible.
- Rough split :
¤ Precommissioning = Static Tests
¤ Commissioing = Dynamic Tests
START - UP

PHASE ACTIVITIES MILESTONE
CONFORMITY CHECKS
PRECOMMISSIONING MECHANICAL
STATIC TESTING COMPLETION
FLUSHING & CLEANING
ENERGIZATION
DYNAMIC TESTS READY FOR

COMMISSIONING START - UP
EQUIPMENT RUNNING-IN
PRESTART-UP ACTIVITIES
OIL & GAS IN

PROVISIONAL
START - UP BRINGING PLANT ON LINE ACCEPTANCE
PERFORMANCE TESTS

¤ PRECOMMISSIONING :
- Visual inspection of equipment ( PG , motors , cables...).
Quality of installation
Compliance with Project specs , safety rules, codes,...
- « Cold testing » : calibration of instruments, machinery alignement ,

setting of safety valves ,pressure testing of piping...(De-energised tests)
- Pipes and vessels air or water flushing and cleaning
¤ COMMISSIONING :
- Electrical motors uncoupled runs , instrument loops test , electrical
breakers operation .......
- Running-in and on-line tests of plant utilities, and main process
equipment in closed loop (wherever applicable)
-Piping drying out , leak testing , inerting or loading of various
chemicals
COMMISSIONING
ALL THE TEST ACTIVITIES

CARRIED - OUT ON A NEW PLANT
BETWEEN
THE END OF CONSTRUCTION
AND
THE PRODUCTION START -UP

DESCRIPTION OF THE METHODOLOGY
2 - DESCRIPTION OF THE METHODOLOGY
2 - 1 The « System approach »

2 - 2 Precommissioning methodology
2 - 3 Commissioning methodology

DESCRIPTION OF THE METHODOLOGY : system approach
2-1 The « System approach »

« SYSTEM APPROACH »
- CONSTRUCTION : By Trades and Areas

( Not all parts of the Plant reach the same degree of completion at
the same time )
- START-UP SEQUENCE : Driven by Operational Constraints
( completion of multi-trade operational units : Fire water , pump ,
power generation...etc )
Optimization of Completion Activities & Start-up by « SYSTEM»

« Subdivision of an Installation that performs a given operational
function with no or little interference from the other parts of the Plant »

Projet without system approach
Project
Projet with system approach
Sous-systeme 1 TIME BENEFIT

Sous-systeme 2
Sous-systeme 3
Pre-Comm Comm Start-Up

Sub-system break-down
Fuel Utility
Oil Gas Water
Exch
Oil to
A Utilities
Exch
B
Exch
C
Heat A Heat B
Drain

Sub-system and discipline
VESSELS & PIPING

INSTRUMENTS
ELECTRICAL
MECHANICAL PUMP MOTOR

DESCRIPTION OF THE METHODOLOGY : precommissioning
2-2 Precommissioning methodology

DESCRIPTION OF THE METHODOLOGY : precommissioning
PRECOMMISSIONING METHODOLOGY
TASK DISCIPLINE NUMBER SUPPORT DOCUMENT
- 1 per item of - 1 Check List per type of

equipment ( Field ) equipment & subsystem(Field)
Conformity Checks All
- 1 Check List per package
- 1 per package
- 1 List of checks in the
Status Index
- 1 test per specified - 1 Test Sheet per test

Static Tests All item ( Field )
- 1 test per safety - List of tests in the
item ( Package ) Status Index
Flushing & Cleaning Process - 1 per subsystem or - Specific procedure &

Network or TestPack report

DESCRIPTION OF THE METHODOLOGY : commissioning
2-3 Commissioning methodology

COMMISSIONING METHODOLOGY
TASK DISCIPLINE NUMBER SUPPORT DOCUMENT
Preliminary Checks All - 1 per subsystem - 1 task report form per

subsystem + punch list
items in Precomm.
- 1 per package dossier
Electrical - 1 test per Basic - 1 Functional Test Sheet

Functional Tests Instruments Function List of tests in
Telecommunication Technical Data Base
- 1 operational Test
Operational Tests Test:multi-discipline - 1 per subsystem or Procedure by
Network Subsystem, specific
to the installation
- 1 per subsystem,or - Leak test, Inerting...

Pre-Start up Activities Process level of pressure, or reports, specific to the
main circuit Installation

Basic Function
- Item or group of items of equipment that performs

an elementary function of the plant
- It is the smallest equipment which can be subject

to a Commissioning operation
- e.g : Switchboards , transformers, heaters, process

control loops , loudspeaker loops , pumps , vessels ,
etc , ....

DESCRIPTION OF THE METHODOLOGY : Sequence & dossiers
3 - Overall sequence and dossiers of Completion Activities

HANDOVER PROCEDURE
by sub-system by sub-system by sub-system

or functional system
READY FOR OPERATIONAL READY FOR PLANT PROVISIONAL FINAL

cc
COMMISSIONING HAND OVER
TEST START UP ACCEPTANCE ACCEPTANCE
CERTIFICATE TT
CERTIFICATE CERTIFICATE STATE CERTIFICATE CERTIFICATE
MAIN ACTIVITY
CONSTRUCTION PLANT - IN
GAS - IN
OPERATION
COMMISSIONING
PERFORMANCE
START-UP ROUTINE OPERATIONS
TEST
MECHANICAL
COMPLETION (ALL UTILITIES PROCESS
SUBSYSTEMS)
READY FOR START
UP
DETAILED ACTIVITY (ALL SUBSYSTEMS)
Construction and precommissioning
Functional testing
Operational tests Post Gas-In Performance Warranty period

OPERATIONAL OTs Test
Pre Start-up activities
RESPONSABILITY
CONTRACTOR CONSTRUCTION
CONTRACTOR COMMISSIONING
COMPANY OPERATIONS
CONTRACTOR COMPANY
Permit to Work
Responsibility

Precommissioning dossier
Combined RFC Certificate
One Dossier
Per Sub-
System

Commissioning dossier
RFSU Dossier Index RFSU Certificate
One Dossier Per

Sub-System

Hand-over dossier
RFHO
Certificate
SUB SYSTEM
XX
SUB SYSTEM
YY
SUB SYSTEM
One Dossier
Per Hand Over
ZZ
Unit

Overall dossiers
308m 273m 206 HOU Dossiers

849 RFSU Dossiers
891 RFC Dossiers
1,946 Dossiers

DESCRIPTION OF THE METHODOLOGY : tools
4 - Tools ( ICAPS )


EXECUTION
PREPARATION PUNCH LIST
OPERCOM
FORMS PROGRESS
POPULATION
ENGINEERING REPORTING

DESCRIPTION OF THE METHODOLOGY : organization and contract
5 - Contractual aspects and organization

contractual aspects
- The Organization depends on the chosen strategy for the project and its
associated contractual schemes :
- E , P , C = separate contracts
- EPC = single contract
- EPCC + SU ( Turnkey )
- Responsability of completion activities ,
- Precommissioning by Contractors always
- Commissioning by Company if E , P , C or EPC
- Commissioning by Contractor if EPCC or turnkey
Commissioning methodology set up without presupposing which party is

in charge
It is the contract that stipulates « who does what » exactly

Transfer of responsability
- Generally :
- Contractors
- Company ( Project team )
- Company ( Operation team )
- Depending on contracts these transfers happen at various stages :
Contract Contractor / Company Project / Operations

EPC RFC RFHO
EPCC RFHO RFSU
- Transfer for Operation , Maintenance and Safety

(The accepting party is responsible for the consequences resulting from
misoperation )
- But Engineering / Construction contractors or vendors are not relieved
from their contractual obligations

General chart
TYPE A Project Manager (a) (a) or surface Manager in integrated project organisation
Construction (b) Operations
(b) including precommissioning activity Commissioning
TYPE B Project Manager
Construction (b) Commissioning
(b) including precommissioning activity
TYPE C Project Manager Operations
Construction (b) Commissioning
(b) including precommissioning activity

Commissioning
chart

DESCRIPTION OF THE METHODOLOGY : TFE P/C and Com policy
6 - TFE precommissioning and commissioning policy

TFE precommissioning and commissioning

policy is defined in a common PJC/EXP
Company Rules :
CR PJC 311

Rule #1
OPERCOM methodology as defined in GS EXP 101,103,105,107 is
mandatory
Rule#2
ICAPS is the mandatory software to be used
Rule#3
Precommissionning is Contractor’s responsibility
Rule#4
Field operation personnel has to witness commissionning activities
Rule #5
For each subsystem, an appropriate Interim Certificate must be issued for
RFC and RFSU
Rule #6
Hand Over Certificates must be issued at the formal transfers of
responsabilities.
Rule #7
The Commissioning Team must be at least at the same reporting level as
the Construction Team within the Project Organisation.

Recommandation #1
Commissionning activities should be the responsability of the Contractor :
i.e EPSCC or EPSCIC Contracts shoud be the preferred case. Selection of
the contractual strategy will be part of the first issue of the Project Execution
Plan (PEP) and will be validated by TDO/PJC and EXP at CTP n° 1.
Recommandation #2
A standard organisation as defined herebelow in article 4.3 should be set
up for commissionning activities.

DESCRIPTION OF THE METHODOLOGY : TFE experience
7 - CONCLUSION : Experience of TFE

DESCRIPTION OF THE METHODOLOGY : TFE experience
COST : 3 to 5% of the cost of the Project
DURATION : 4 to 8 Months of Preparation

4 to 8 Months of Execution
MANHOURS : 30,000 to 200,000 Manhours of execution
10% of the construction Manhours
HISTOGRAM : 40 to 200 persons of execution ( Peak ).

Commissionning of Oil and Gas Processing Plants

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Oil & Gas Processing Plants

Design and Operation

DGEP/SCR/ED/ECP - 7/18 October 2002

DGEP/SCR/ED/ECP - 7/18 October 2002

• 1- COMPLETION ACTIVITIES DEFINITION

• 2- DESCRIPTION OF THE METHODOLOGY

• 3- OVERALL SEQUENCE AND DOSSIERS OF COMPLETION ACTIVITIES

• 5 - CONTRACTUAL ASPECT AND ORGANIZATION

• 6- TFE PRECOMMISSIONING AND COMMISSIONING POLICY

• 7- CONCLUSION : EXPERIENCE OF TFE

• 8- QUESTION / ANSWER SESSION

DGEP/SCR/ED/ECP - 7/18 October 2002 3

1 - COMPLETION ACTIVITIES DEFINITION

DGEP/SCR/ED/ECP - 7/18 October 2002 4

DGEP/SCR/ED/ECP - 7/18 October 2002

COMPLETION ACTIVITIES = PRECOMMISSIONING + COMMISSIONING

DGEP/SCR/ED/ECP - 7/18 October 2002 6

PHASE ACTIVITIES MILESTONE

DYNAMIC TESTS READY FOR

OIL & GAS IN

DGEP/SCR/ED/ECP - 7/18 October 2002 7

- « Cold testing » : calibration of instruments, machinery alignement ,

ALL THE TEST ACTIVITIES

DGEP/SCR/ED/ECP - 7/18 October 2002 9

2 - DESCRIPTION OF THE METHODOLOGY

2 - 1 The « System approach »

DGEP/SCR/ED/ECP - 7/18 October 2002 10

2-1 The « System approach »

DGEP/SCR/ED/ECP - 7/18 October 2002 11

- CONSTRUCTION : By Trades and Areas

Optimization of Completion Activities & Start-up by « SYSTEM»

DGEP/SCR/ED/ECP - 7/18 October 2002 12

Projet without system approach

Projet with system approach

Sous-systeme 1 TIME BENEFIT

Pre-Comm Comm Start-Up

DGEP/SCR/ED/ECP - 7/18 October 2002 13

DGEP/SCR/ED/ECP - 7/18 October 2002 14

Sub-system and discipline

VESSELS & PIPING

MECHANICAL PUMP MOTOR

DGEP/SCR/ED/ECP - 7/18 October 2002 15

2-2 Precommissioning methodology

DGEP/SCR/ED/ECP - 7/18 October 2002 16

TASK DISCIPLINE NUMBER SUPPORT DOCUMENT

- 1 per item of - 1 Check List per type of

- 1 test per specified - 1 Test Sheet per test

Flushing & Cleaning Process - 1 per subsystem or - Specific procedure &

DGEP/SCR/ED/ECP - 7/18 October 2002 17

2-3 Commissioning methodology

DGEP/SCR/ED/ECP - 7/18 October 2002 18

TASK DISCIPLINE NUMBER SUPPORT DOCUMENT

Preliminary Checks All - 1 per subsystem - 1 task report form per

Electrical - 1 test per Basic - 1 Functional Test Sheet

- 1 per subsystem,or - Leak test, Inerting...

DGEP/SCR/ED/ECP - 7/18 October 2002 19

- Item or group of items of equipment that performs

- It is the smallest equipment which can be subject

- e.g : Switchboards , transformers, heaters, process

DGEP/SCR/ED/ECP - 7/18 October 2002 20

3 - Overall sequence and dossiers of Completion Activities

DGEP/SCR/ED/ECP - 7/18 October 2002 21

by sub-system by sub-system by sub-system