commissioning guidelines, fats and sats

© Falcon Global Ltd. 2000 - 2019

Learning Objectives 1

After this module, you will have an understanding of

the need for acceptance testing, whether at the

vendor facility in the case of a Factory Acceptance

Test (FAT), or a Site Acceptance Test (SAT) on arrival

at the final destination.

Phase 2 - ImplementationCommissioning Guidelines, FATs and SATs


Phase 2 - ImplementationCommissioning Guidelines

FATs and SATs


You will also gain an appreciation of the risk-based

approach to determine the selection of equipment

for FAT and SAT.

Additionally, the importance of knowing what

equipment has (or is due to) undergo FAT / SAT will

be emphasized and techniques for mitigating

impact to the project schedule.



You will also gain an appreciation of the risk-based

approach to determine the selection of equipment

for FAT and SAT.

Additionally, the importance of knowing what

equipment has (or is due to) undergo FAT / SAT will

be emphasized and techniques for mitigating

impact to the project schedule.

Phase 2 - ImplementationCommissioning Guidelines, FATs and SATs


Phase 2 - ImplementationCommissioning Guidelines

As an illustration of the work processes and way in which Zenator

(SCDB) can really streamline and transform the Commissioning &

Handover processes the following guidelines and flow diagrams are

included.

The embedded files contain Commissioning Guidelines and work flow

diagrams from a real project recently completed in Kazakhstan where

Zenator was very successfully deployed.

TIP

These guidelines are a great example of communicating the Systems

Completion with the role of the SCDB in the process to final

Handover in clear language to all Stakeholders.

Use these guidelines and modify to suit your project.


Commissioning & Start Up WorkshopCommissioning Guidelines

Factory Acceptance Testing

FAT

As Commissioning Manager, ensure you know about and your

relevant Commissioning Engineers participate in, all Factory

Acceptance Testing (FATs). It is just as vital to know what is to be

Factory Acceptance Tested as knowing what has not been Factory

Acceptance Tested.




FAT

Participating in and witnessing a FAT will give the Commissioning

Engineer invaluable first-hand knowledge of how a specialist item

is intended to operate and be integrated with connecting Systems

and controls. Being present at a FAT, he / she will help:

• Document the tests, checks and procedures

• Record all punch list items (PLIs)

• Review Supplier / Vendor documentation, particularly

Operations & Maintenance Manuals and audit during the FAT

for completeness and accuracy.




FAT

Use SCDB from the start of the FAT process to plan, track and

report the entire FAT program.

Deploying Walkdown Capture with Zenator (SCDB) to record and

clear Punch List Items (PLIs) will save significant management

manhours.

If a specialist item, such as major long-lead item, packaged

equipment, module, pre-assembled unit, vendor skid is not to be

Factory Acceptance Tested, find out why. It could be an omission.




FAT

If deliberate and not an omission:

• Find out who from the project team is participating in and

witnessing the Quality checks being carried out;

• Ensure you receive documentation for each package or

specialist item that has not had a FAT;

• Put a flag on these items for future reference as these

packages or specialist items could be a source of problems

when they arrive on site.



Site Acceptance Testing

SAT

Is usually performed on sensitive and / or high value equipment

that previously had a FAT, on delivery to the site location. The test

should be included in the original Purchase Order and is

particularly important in the case of:

• Situations where the condition of the equipment is likely to be

significantly different to that on completion of the FAT, eg,

transportation over long distances by air, land or sea

• Depending on the equipment and perceived risk, the scope

and reporting of SAT could be more than, similar to or less

than the requirements for FAT.


Commissioning & Start Up WorkshopPreservations

Learning Objective

At the conclusion of this module you will have

learned the fundamental principles of the need for

Preservation and the risks if this importance is not

put into practice.



Preservation activities are vitally important, recurring

checks carried out on costly, often sensitive

equipment, to:

1. maintain warranty in accordance with the

vendor’s instructions;

2. avoid risk of contamination or corrosion;

3. maintain workability;

4. maintain a controlled environment.



Preservations start from the time of delivery and

recur at regular intervals. Develop a Preservations

program and assign a Preservations Supervisor /

Engineer, ideally from within Operations or

Maintenance to perform the work.

A Preservations program is confined to following

package vendor recommendations.

Remain aware of your environment and any

changing conditions.



As part of your Risk Assessment, be aware of where

Commissionable Items are being stored following

delivery, exposed to the elements in an outside

compound, in a warehouse or climate-controlled

environment.

If Commissionable Items are stored on shelves in a

warehouse, Preservations will still be needed.

The Preservations Engineer must be vigilant and

keep a close eye on storage and handling.



• May not only be needed until the

Commissionable Items are installed and

Commissioned, but if something changes to

the project and mothballing is needed;

• Are not restricted to high value or sensitive

equipment. Refer to Case Study 1 on page 57.



Use the Preservations functionality in SCDB to

control, schedule, manage and report all work

pertaining to these recurring P Checksheets, (aka

PITRs, or P ITRs).

From Reports Plus you can get a complete

Preservations History across the project.


Commissioning & Start Up WorkshopCleaning and Drying Procedures

Learning Objective

After completing this module, you will have learned

about Cleaning and Drying techniques, evaluate

where these should be deployed and be able to

make a comparison of respective strengths and

weaknesses.


Commissioning & Start Up WorkshopDay 3

Cleaning and Drying

Procedures


Commissioning & Start Up WorkshopCleaning and Drying Procedures - 1

Next to Preservations, the internal cleanliness and dryness of Systems, specifically

piping and vessels, are the biggest ticket items to affect Commissioning & Start Up,

hence will impact the overall project schedule.

It is too often the case that Construction hand over to Commissioning, piping

Systems with debris and foreign material. These are recurring problems, from

company to company, country to country indicating a cultural problem in

Construction with respect to Quality.

Therefore the advice is beware – treat all piping Systems that are handed over

to Commissioning with a health warning.

Within the Commissioning Team, the designated Mechanical and Commissioning

Engineers will be responsible for tracking and documenting the internal cleanliness

and dryness of Systems with hydraulic tubing, piping and vessels.



Removal of Equipment and Internals to Facilitate Cleaning

To flush and clean pipework and vessel internals it will be necessary to

remove parts that would otherwise cause a blockage or obstruction.

Temporary spools may be inserted. The key, therefore for the

responsible engineer, is to know:

• What these items are

• When the items were removed and by whom

• Where any temporary items were installed

• Where the items were removed from

• Where the items are stored temporarily

• When the items were reinstated and by whom

Mark-ups of Piping Isometrics and P&IDs will be required.



Items commonly removed are:

• Filters, strainers, candles

• Valve internals, particularly non-return (check) valves

• Orifice plates

• Sensitive internals for temperature, pressure, flow from instrumented

valves

• Vessel baffles and internals

Temporary items commonly installed for Commissioning are:

• Blind flanges, skillets, strainers



Cleaning Methods

Commonly used are:

• Pneumatic blowing

• Steam blowing

• Flushing

• Chemical cleaning

• Mechanical cleaning, pigging



Pneumatic Blowing

Usually air or nitrogen are introduced from a high energy source to

remove loose items from piping Systems. Disconnect pipework from

vessels, remove all internals that cause blockage or obstruction. Place

temporary isolation valve at exhaust, build internal pressure and release,

removing debris.

Not to be used for cleaning:

• Vessels

• Tube Heat Exchangers

Important considerations:

• Air velocity of a minimum 200 ft/sec (approx 65 m/sec)



Pneumatic Blowing (continued)

Advantages Disadvantages

Cost

o Use of air is relatively inexpensive

o Easy to setup and operate

o May not require specialist

contractor

Effectiveness

o Useful only for dust, light debris

o Subjective effectiveness

Damage

o Risk to internal items and

pneumatic instrumentation tubing

Safety

o Restrict access, barriers erected

o Containment at exhaust

Link Facility

1 http://www.youtube.com/wa

tch?v=qJqhgIqzQDU

Dry Fork CFPP, WY pneumatic blow

http://www.youtube.com/watch?v=qJqhgIqzQDU

CSU - Movie Clips/Cleaning out pipes at Dry Fork Station.mp4



Steam Blowing

Used on steam piping services to remove scale and loose items.

Disconnect pipework from vessels, remove all internals that cause

blockage or obstruction. Ensure exhaust is sufficiently anchored. Not to

be used for cleaning vessels. Requires careful calculation to determine

the energy and pressure needed to remove mill scale and debris from

the System internal surfaces and volume.


• Calculated volume, pressure and duration of Steam Blow

• Beware of condensation traps – these will cause water hammer

• Ensure pipework is adequately supported and anchored

• Effect on other nearby operations and work activities



Steam Blowing -2

Important considerations (continued):

• Effect on other nearby operations and work activities

• Sufficient structural anchoring at exhaust(s) to contain the kinetic

energy

• Personnel protection – lagging of pipework and hearing protection

• Use of silencers



Steam Blowing - 3


Effectiveness

o Good at removing mill scale and

debris

Effectiveness


o Use targets, check for pock marks

Damage

o Risk to internal items

Safety

o Restrict access, barriers erected

o Restricts other work in area

o Lag piping for personnel

protection

o Hearing protection

o Achoring of exhaust

o Relief of steam at exhaust



Steam Blowing - 4

Link Facility


tch?v=wGXmeb956yY

Plum Point CFPP, AR steam blow


tch?v=YUbyTATgFTU

Plum Point CFPP, AR steam blow


tch?v=aYGWjJACzaI

ISCC SPP, Kuraymat, Egypt

4 https://www.youtube.com/w

atch?v=iDcEnSkrBlU

815MW CFPP, Paiton 3, Surabaya,

Indonesia


tch?v=InmhgwIyDN4

Using silencers

http://www.youtube.com/watch?v=wGXmeb956yY

CSU - Movie Clips/Plum Point's very first steam blow.mp4

http://www.youtube.com/watch?v=YUbyTATgFTU

CSU - Movie Clips/Plum Point steam blow 2.3g2.mp4

http://www.youtube.com/watch?v=aYGWjJACzaI

CSU - Movie Clips/Steam Blow at ISCC Solar Power Plant.mp4

https://www.youtube.com/watch?v=iDcEnSkrBlU

https://www.youtube.com/watch?v=iDcEnSkrBlU

http://www.youtube.com/watch?v=InmhgwIyDN4

CSU - Movie Clips/Twin Silencer Steam Blow.mp4



Flushing

Fresh water is introduced to remove loose items from piping Systems.


blockage or obstruction. Not to be used for cleaning vessels.

Not to be used on services where water could cause internal corrosion

to pipework.


• Ensure adequate supply of water

• Water velocities should be at least 12 ft/sec(approx. 3.75 m/sec)

• Ensure pipework is adequately supported for the weight of water

• Use of corrosion inhibitor

• Vent high points to prevent pulling a vacuum



Flushing - 2

Important considerations (continued):

• Ensure adequacy of plant drainage system to cope with volume of

water and expected contaminants

• Fit temporary strainers - agree removal procedure with Operations


Effectiveness

o For removal of loose debris

Cost

o Large volumes of water needed

o Temporary strainers to remove

later

Effectiveness


Risks

o Corrosion



Chemical Cleaning (Pickling)

Used on process piping services to remove scale and debris. Disconnect

pipework from vessels, remove all internals that cause blockage or

obstruction. Not to be used for cleaning vessels. Specialist contractor

required. Careful calculation of volume and concentration of chemical

needed to remove mill scale and debris from internal surfaces.


• Calculated volume and concentration of caustic chemical needed

• Chemical storage and disposal of spent fluid with contaminants

• Ensure pipework is adequately supported

• Ensure adequacy of plant drainage system to cope with volume of

spent chemical and expected contaminants

• Fit temporary strainers - agree removal procedure with Operations



Chemical Cleaning - 2


Effectiveness

o Very effective for removal of scale

o Measurable effectiveness

Cost

o Specialist contractor needed

o Temporary strainers to remove

later

Safety

o Restrict access, barriers required

o Storage and disposal of spent

chemical



Chemical Cleaning - 2

Link Facility


tch?v=rRSlMiHdQhs

Mechanical Pigging v Chemical Cleaning

For guidance on Chemical Cleaning Specifications, refer to the embedded file from Jacobs:

http://www.youtube.com/watch?v=rRSlMiHdQhs

CSU - Movie Clips/Mechanical Pigging v Chemical Cleaning for Pipelines.mp4



Pipeline Pigging

Pigging is the method of choice for cleaning pipelines. Specialist

contractor usually required.


• Decision on “piggable” lines made in Design Phase

• Launcher and Receiver are expensive additions if not part of original

design – considerable real estate required

• Length of pipeline and energy source (air or nitrogen usually) needed

to push pig through and not get stuck

• Type of pig and degree of measurement needed

• Adequacy of drainage system at Receiver end to cope with volume of

contaminated fluid pushed through pipeline



Pipeline Pigging - 2


Effectiveness

o Very effective for removal of scale


Cost


Safety


o Drainage implications at reception




For further information on this topic, refer to the embedded files on

pipeline Pigging and Cleaning services from a specialist contractor:



Pipeline Pigging

Link Facility


tch?v=ROrQc1T114w

Removing a Pig


tch?v=XT1cOip53R4

Intelligent Mechanical Pigging


tch?v=o2L6jvMaycY

Pipeline Drying - launching a foam pig

http://www.youtube.com/watch?v=ROrQc1T114w

https://www.youtube.com/watch?v=ROrQc1T114w

http://www.youtube.com/watch?v=XT1cOip53R4

https://youtu.be/XT1cOip53R4

http://www.youtube.com/watch?v=o2L6jvMaycY

CSU - Movie Clips/Drying of pipelines. Launching a foam pig.mp4



Mechanical Cleaning

Mechanical Cleaning is often the only effective method for cleaning large

vessels and columns. Be realistic about how long this may take, how

much it will cost and the many safety considerations to ensure a safe

working environment. A specialist contractor or painting contractor is

sometimes used, well-trained and expert in the use of various

mechanical cleaning methods:

• Retro Jet, currently the method of choice

• Needle Gun, Shot Blast, Wire Brush - using breathing apparatus when

working in confined spaces.


• Safety – confined space, vessel entry

• Removal of all debris



Mechanical Cleaning - 2


Effectiveness

o Effective for removal of rust, scale


Cost


o Manhour intensive, slow

Safety


o Confined space, vessel entry

Risk

o Residual contamination if all dust

and debris not fully removed



Mechanical Cleaning - 3

Link Facility

1 CSU - Movie Clips\High Pressure Water jet Cleaner for 5 to 12

in. Pipe Cleaning.mp4

Retro Jet Cleaning #1

2 CSU - Movie Clips\High Pressure Water Jetting.mp4 Retro Jet Cleaning #2

3 CSU - Movie Clips\HP Water Jetting Unit in Action.mp4 Retro Jet Cleaning #3

CSU - Movie Clips/High Pressure Water jet Cleaner for 5 to 12 in. Pipe Cleaning.mp4

CSU - Movie Clips/High Pressure Water Jetting.mp4

CSU - Movie Clips/HP Water Jetting Unit in Action.mp4



Drying Methods

For operational reasons to avoid contamination, slugging and corrosion,

most commissioned Systems are required to be clean and dry. Dryness

required for a particular System is achieved by degree.

• Nitrogen Blowing, suitable for initial drying, may leave piping damp

internally

• Vacuum Drying, suitable for pipelines, to remove all moisture



Drying Methods - 2



Drying Methods - 3

Refer to the embedded file for details of pigging and vacuum drying of

gas pipelines:

See this embedded file for details of how this company commissioned

and started up one of its pipelines:



Nitrogen Drying

Nitrogen has a low dew point and is therefore suitable as the drying

medium of choice in colder climates and subsea pipelines.

The gas is introduced from a high energy source to remove water

slugging and debris in piping and pipeline Systems.


blockage or obstruction.

Place temporary isolation valve at exhaust, build internal pressure and

release, removing debris.

Not to be used for cleaning:

• Vessels

• Tube Heat Exchangers



Nitrogen Drying - 2


• Nitrogen velocity of a minimum 200 ft/sec (approx 65 m/sec)

• Allow adequate purge duration, say 12 hours

• Sample test for dew point temperature (DPT) at System low points

As a guide:

• Continue purge if DPT higher than -30 deg C

• Stop purge and reinstate when DPT is lower than -30 deg C



Nitrogen Drying - 3


Effectiveness

o Very effective for removal of water,

debris


Cost

o Shipment, storage of N2 is expensive

o Requires operation by trained users

o Specialist contractor required

Safety





Vacuum Drying

Vacuum drying is particularly effective for piping Systems and subsea gas

pipelines that have been previously flushed to remove loose debris, but

where no moisture can be tolerated.

After flushing, specifically sized vacuum pumps are introduced by a

specialist contractor to remove any remaining water from piping and

pipeline Systems.

Remove sensitive instrumentation.



Vacuum Drying

Based on the application of Combined General Gas Law (Avogadro, Gay-

Lussac, Charles, Boyle-Marriotte's Law)

As the volume of air is reduced, the pressure drops, also the boiling

point of any liquid present in the system also drops.

At an absolute pressure of about 2 kPa, water boils at the ambient

external temperature of pipe.



Vacuum Drying

The vacuum drying process must be followed very carefully.

Vacuum pump speed must be maintained to prevent air being evacuated

too quickly, in which case any free water or moisture present will not

evaporate as intended, but cool and freeze.

The pipeline appears to be dry, but after putting into operation ice

gradually melts and the problems with water appears again.



Vacuum Drying

Therefore it is necessary to carefully follow the drying process, including

controlled dwell time when vacuum pumping stops allowing free water

to vaporize in the pipe. Dwell or Rest periods are calculated, determined

by the internal volume of the pipeline and ambient temperature and are

designed to prevent the residual free water from freezing. Dwell times

significantly prolong the drying time.

Refer to the graph on Slide 216 of a Typical Vacuum Drying Operation.

Vacuum drying makes the first gas admittance into the pipes much easier.

The gas is flowing into a vacuum, therefore the pipeline has been

deaerated as there is no risk of forming an explosive mixture.



Vacuum Drying



Vacuum Drying - 2

Outline procedure:

• After depressurising, any pressure increase indicates a leak

• Find and seal any leaks before continuing the vacuum test

• Monitor vacuum pump exhaust and oil filter for any emulsion,

indicating moisture is present

• When vacuum has been pulled, pump disconnected and pressure

reading stable for duration specified in the test procedure, release to

atmospheric pressure and fill System with a blanket of nitrogen

• Reinstate and proceed with commissioning



Vacuum Drying - 3


Effectiveness

o Very effective for complete removal of

water


Cost

o Requires operation by trained users

o Specialist contractor and equipment

required

Safety





Tip

Use or modify the A ITR and B ITR Checksheets supplied with SCDB to

record, track, and report progress in the sequence of activities to

achieve the internal cleanliness and dryness of tubing, piping and vessels.

New Checksheets or Commissioning Procedures should be rendered

compatible with SCDB. Referencing the project’s new Checksheets or

Commissioning Procedures within SCDB will enable the tracking,

controlling and reporting of progress, all intermediate and impacting

activities, such as Punch Listing and Management of Change.

For a reliable audit trail, use or modify the Isolations (Isolation removed)

feature in SCDB to record, track, and report the removal of internals, or

installation of spools, for temporary purposes.

Attach scanned copies of the marked-up Piping Isometrics and P&IDs in

SCDB.


Commissioning & Start Up WorkshopCommissioning Procedures - 01

System and Plant Commissioning


tch?v=0DuURyTtESw

Dry Fork CFPP, WY Scrubber


tch?v=Eg7yvX2M6VY

Ante Creek Gas Plant Commissioning

3

4

5

http://www.youtube.com/watch?v=0DuURyTtESw

http://www.youtube.com/watch?v=Eg7yvX2M6VY


Commissioning & Start Up WorkshopChecksheet & Certificates Types, Which Ones to Use /

TTM / Maintainable Tags / Punch List & PLI Types


After this module, the student will have learned the

types of Checksheet (ITR) used and the relevant

part of API RP 1 FSC, the dependent relationship

and hierarchy of certain Checksheets, how to define

Tag Types, what a Tag Type Matrix is, how to create

one for a project, and how to choose the correct

Checksheets for the project.





The student will understand that a Gap Analysis is

needed to determine which Tag Types do not have

Checksheets and how to go about filling the gaps by

creating them. The student will have learned the

types of Certificate and Notice used, the dependent

relationship and hierarchy of Certificate, the need to

understand the Contract requirements, incorporate

any Contract Exhibits in SCDB and how to choose

the correct Certificates for the project.





The student will understand that a Gap Analysis is

needed to determine which Certificates are needed

and how to go about filling the gaps by creating

them. On completing this module, the student will

know the distinction between Commissionable and

Non-Commissionable Tags and be aware of the two

categories Commissionable Tags come under;

Maintainable and Non-Maintainable.





The student will be aware that Maintainable Tags

can be further distinguished as Production or Safety

Critical, be aware of the Tag Types in these

categories, know how these are treated differently

and why. After this module the student will know

the purpose of Punch Listing, the priority treatment

of PLI Categories to achieve System Completion,

how PLIs are recorded, reported and cleared, with

techniques for managing these processes.


Commissioning & Start Up WorkshopChecksheet Types, Which Ones to Use


Commissioning & Start Up WorkshopChecksheet Types, Which Ones To Use


Commissioning & Start Up WorkshopDistribution of Tags in a Typical Project

Tags

Non-Commissionable Commissionable

Areas / Structural

A ITRs only

Architectural, Civil, Structural

Non Maintainable

Maintainable

A & B ITRs

Safety Critical

Production Critical

Other

95%

+/-1%

5%

+/-1%


Commissioning & Start Up WorkshopMaintainable and Non-Maintainable Tags

Tags in the Project

From a commissioning perspective, the project is comprised of

two types:

• Commissionable Tags

• Non-Commissionable Tags


Commissioning & Start Up WorkshopMaintainable and Non-Maintainable Tags

Commissionable Items

Referred to in this course and across the industry as Tagged

Items, or simply, Tags are two broad component types:

• Maintainable Items

• Non-Maintainable Items


Commissioning & Start Up WorkshopMaintainable Tags

Maintainable Items

There are two special types of tags, which by

definition are Maintainable Items:

• Safety Critical and

• Production Critical.

It follows that if an item is Safety Critical or

Production Critical, then it must be Maintainable..



Maintainable Items

The ratio of Maintainable Items to Non-

Maintainable Items on a Project is likely to be 5:95.

Only a very small proportion of Tags on the Project

will be Maintainable, roughly 5%, +/-1%

Safety Critical and Production Critical Items are a

subset of the Maintainable Items.



Safety Critical and Production Critical Tags


Commissioning & Start Up WorkshopNon-Commissionable Tags

Non-Commissionable Items

Usually Civil & Structural works, such as:

• Buildings, Structure, Fabric and Cladding

• Foundations, Roads, Drainage ditches

• Lighting standards

• Stairs, Ladders, Walkways, Access Platforms.


Commissioning & Start Up WorkshopPunch Listing & Types of PLI

An essential part in the process of being able to

bring complex projects to acceptable completion is

the role played by Punch Listing.

All snags and incomplete items are recorded as

Punch List Items (PLIs).

Over the life of the project, each System will get

walked many times by formal teams comprising

Owner and Contractor as the overall completion is

progressively achieved.



Checksheets for FAT and SAT

Equipment - E ITR

Vendor - V ITR

Used for specialist equipment

Produced by the equipment manufacturer, involving more

detailed, sometimes very specific checks to be carried out.

E ITR and V ITR may first appear during FAT and SAT.



Area Checksheets (Non-Commissionable)

Area ITRs - A Checksheet, with no B Checksheet to follow

Relate to Architectural, Civil and Structural discipline

Includes Foundations, Pads, Piles, Roads, Drainage Ditches,

Buildings, Fabric Cladding, Steel Structures, Ladders and

Walkways



One to One and One to Many Checksheets

A considerable amount of management time can be

consumed by signing high volumes of relatively low level

documents.



One to One and One to Many Checksheets

To overcome this, and by mutual agreement, Contractors and

Operators may recognize Tagged Items as suitable candidates for

collecting together on a Bulk ITR.

Bulk ITRs, types A and B, are a special type of one to many

Checksheet, somewhat similar to the Checksheets for Electrical

Circuits, Instrument Loops and Piping Test Packs



Bulk Checksheets

Used for multiple instances of the same Tag Type

Can be checked by the same Inspectors during the same visit

Low Voltage Cables - Electrical, Instrument or Telecomms

Junction Boxes - Electrical, Instrument or Telecomms

Instruments - of same Tag Type in same room or enclosure

Pressure Vessels - of same Tag Type in same area



Bulk Checksheets

In SCDB the same approach is followed so that Power Users can

quickly setup Bulk A ITRs or Bulk B ITRs for:

• Logical groupings of equipment

• Where both parties have agreed Bulk ITRs can be applied.

• The benefit is to the project by:

• saving management time

• but not compromising quality or integrity.



Test Packs, Loops and Circuits (TLC)

Electrical Circuit, Instrument Loops and Piping Test Pack have a

special type of one-to-many Checksheet that enable verification

checks to be performed on multiple Tagged Items of the

same Tag Type(s) (in the case of Piping Test Packs and Electrical

Circuits) or of the Instrument Tags that form a Loop.



Test Packs, Loops and Circuits (TLC)

Obtain agreement between Contractor and Customer on the size

and formation of logical groupings of equipment.

Creating Electrical Circuit ITRs, Instrument Loop ITRs

and Piping Test Pack ITRs in SCDB is a very similar process to

creating Bulk ITRs.



Preservation Checksheets

Preservation ITRs (P ITRs) are also status-sensitive with a unique

icon to differentiate these recurring activities from other

Checksheet activities, which are typically one-time events.



Rules for Successful use of TLCB ITRs



Rules for Successful use of TLCB ITRs

Apply the Trust / Competency – Deployment model

Ensure the Contractor and Customer work closely to agree the

size and composition of the logical groupings to be applied to

Bulks, Circuits, Loops and Test Packs.

Keep deployment of Bulks, Circuits, Loops and Test Packs

proportional to the level of trust



Trust / Competency – Deployment model

Establish rules that determine a “logical grouping”:

Tagged Items that have in common

• Tag Type

• Checksheets requiring responses: Yes / No; Initial; PLI

• Location, Room, Module, Building

• All verification checks can be completed by the same

Engineers / Technicians during the same visit



Trust / Competency – Deployment model

Establish rules that determine a “logical grouping”:

Two examples of historical abuses:

• Attempting to put all instruments of all types on Bulk

Checksheets

• Attempting to put every motor on the same Bulk Checksheet



In Zenator (SCDB), there are the following Checksheet types:

Single Checksheets, one to one relationship of one Checksheet to one

Tagged Item

Bulk Checksheets, one to many relationship of one Checksheet to many

Tagged Items

Electrical Circuits, one to many relationship of one Checksheet to many

Electrical Tags within the Circuit

Instrument Loop, one to many relationship of one Checksheet to many

Instrument Tags within the Loop

Piping Test Packs, one to many relationship of one Checksheet to many

Piping Tags within the Test Pack



For guidance on Checksheet types, definitions of the stages to

Final Acceptance and general guidance, refer to the embedded

file:


Commissioning & Start Up WorkshopGap Analysis – Which Checksheets to Use

Compare Checksheets to Tag Types

The list of Tag Types will come from the engineering deliverables,

including but are not limited to:

• Equipment List

• Piping Line List

• Cable Schedule

• Instrument Index

• Instrument Loop List



More Checksheets than Tag Types

An overage of Checksheets to Tag Types is a good place to be,

because then the project has more than are needed and can

remove those that are surplus to requirements.



More Tag Types than Checksheets

In the situation where the number of Tag Types is greater than

the number of Checksheets, two things will need to occur:

1. Logically rationalize the Tag Types, where possible, so that

several Tag Types can be adequately covered by a single

Checksheet. This situation often arises with Instrumentation

Tags. Many Instrumentation Tag Types, such as Transmitters,

Transducers, Transponders, Flow, Temperature, Pressure

measurement devices can legitimately be covered by a single

Checksheet for installation and another for calibration.



More Tag Types than Checksheets

If number of Tag Types is greater than number of Checksheets:

2. Create new Checksheets to fill the gaps:

a. With special items, get the vendor to prepare an initial

draft of scope, then customize a Checksheet template;

b. Discipline engineers in the Commissioning Team prepare

the scope, then customize an existing Checksheet template;

c. Choose an existing template closest in scope to the missing

Checksheet, then modify and “save as” new template.


Commissioning & Start Up WorkshopTag Type Matrix

In parallel with choosing the Checksheets required for the project

and the Gap Analysis is completing the Tag Type Matrix (TTM).

The TTM is an important summary level document defining the

choice of Checksheets to be used to complete each Tag Type.

For many experienced Contractors the TTM is formalized in their

work practices and routines. It is the way they do things. By

Discipline, Supervisors know that from project to project, certain

Checksheets are used to complete certain Tag Types.

On a new project, the Commissioning Manager will either need to

create the TTM from scratch, if one does not exist, or use a TTM

from a previous project.



When the TTM has been setup, importing it to Zenator is easy.



TTM in Reports Plus



TTM format from Reports Plus


Commissioning & Start Up WorkshopCertificate Types, Which Ones to Use


Commissioning & Start Up WorkshopCertificate Types, Which Ones to Use

Model the Contract requirements in SCDB

Decide which Certificate templates to use


Commissioning & Start Up WorkshopGap Analysis – Which Certificates to Use

Compare Certificates to Templates


Commissioning & Start Up WorkshopGap Analysis – Which Certificates to Use

Compare Certificates to Templates Supplied

More Certificates than Templates

Create new Certificates to meet Contract requirements

a. Use the Certificates contained in the Contract as Exhibits

and render these compatible with SCDB;

b. Ensure the sequence in the Contract matches that in the

Completions Pyramid and API RP 1FSC;

More Templates than Certificates

Select / customize the Templates required to meet requirements:



Punch List Item Categories

Category A - must be completed before Tag or System is

Mechanically Complete

Category B – can carry over through Static Commissioning but

must be completed before System is Dynamically Commissioned

Category C - must be completed before Start-Up &

Performance Testing is complete

Category D – can be completed at discretion of Operations.



When Punch Listing is Performed

Ad-hoc inspections

During completion of A ITR and B ITR Checksheet activities

During a formal System walkdown by Construction,

Commissioning and Operations.



Centralize the Punch List 1

Punch List Items can originate in 3rd party

databases, but control and good order

All Punch Listing must be contained in a single

database, for which the Commissioning Manager is

the custodian.



Centralize the Punch List 2

Use the functionality in Zenator (SCDB) with

Walkdown Capture to Record and Clear Punch List

Items (PLIs) at every stage in the project life cycle,

until Final Handover to Operations, the ultimate

End-User.

Track and monitor PLIs in Zenator, see reports in

Reports Plus.



Recording and Clearing Punch List Items 1


Commissioning & Start Up WorkshopManaging PLIs in SCDB


Commissioning & Start Up WorkshopLeak Detection

Refer also to Nitrogen-Helium Leak Detection on pages 77-83.

Following Flushing, and closely linked to the Cleaning and Drying

processes discussed earlier is Leak Detection. This occurs after

the Handover from Construction to Commissioning, following

completion of all remaining Category A PLIs in that System.

The purpose of Leak Detection is to discover all leaks within the

System, therefore it necessarily means all items removed during

the Construction tests will have been reinstated, temporary spool

pieces removed and the permanent valves or other equipment

finally installed.

Discuss leak rates



Test pressures, test media and test duration will be stated in the

B ITR Checksheet template, specifically modified to match the

parameters for the System being tested.

At specification changes in the System, where operating pressures

change, isolate the higher pressure parts and progress to

establish the integrity of that part of the System operating at the

lowest pressure.



Progress the System test on the higher pressure parts of the

System until the System has been completely tested.

A great deal of visual inspection will be needed by the

Commissioning Team to check for leaks.

With pneumatic testing, test joints with soapy water.

For N2-He leak testing, a specialist subcontractor will test joints

using a mass spectrometer with laboratory for results analysis.

Particular attention will be paid to tests at the specification

changes, to ensure integrity of the joint.



Considerations for leak detection are:

• Service Test, with an inert utility, usually air, water or

occasionally nitrogen

• Test pressures are set in the B ITR procedure, for example

at x% of Design Pressure for n hours

• Pipework is adequately supported for the weight of water

• Vents are at high points, drains are at low points

• Relief valves installed

Add leak rates




• Supply of water arranged

• Work Permit obtained based on the procedure contained

in the B ITR

• Test rig, pumps, hoses, test gauges and recorders all ready

• Area is cordoned off with barriers

• Safe disposal of test media arranged




• If successful, with no PLIs to carry forward:

• All Checksheets, procedures and Certificates are

signed off

• The System is physically tagged as “Live”

• If unsuccessful, with PLIs to carry forward:

• PLIs are recorded, any materials needed are sourced

• Work continues on the System until it can pass the

leak test


Commissioning & Start Up WorkshopHot Oil Flushing

Hydraulic Systems / Lube Oil Systems

Hydraulic systems are extremely sensitive to contamination, so

achieving the required standard of cleanliness is paramount.

Anecdotally, it is reckoned that perhaps 75% of the downtime

with hydraulic systems can be attributed to contamination.

Cleanliness is important because these are critical systems in the

operation and control of the facility.

For an oil of a given kinematic viscosity, at a temperature of

around 40o to 65o C and at a velocity higher than that at normal

operation to ensure turbulent flow, as calculated in the flushing

procedure, oil is flushed and filtered through the hydraulic

systems, until the required standards are attained.




In theory, this can be performed either by Construction or

Commissioning – see recommendations below - but it will be

necessary and will take time, running into several weeks on most

projects.

There are various standards in use in the hydraulic industry, of

which ISO 4406:1999, NAS1638 and SAE AS 4059 are probably

the most common.

These standards relate to the size and quantity of particles

passing filters of decreasing size. Liquid Particle Counters are

used to determine the quality of the liquid passing through them.

The size and number of particles can determine if the liquid is

clean enough to be used for the designed application.




Each project will specify the degree of cleanliness to be attained.

The Commissioning Manager needs to decide early on, by whom

and when hot oil flushing will be performed, and plan accordingly.

The objective is to attain the required cleanliness standards in the

least time and at the least expense;

Considerations are:

• Where in the project schedule to fit hot oil flushing

• Extent of Lube Oil and hydraulic systems on the project

• Quantity of oil needed to attain the required standard




Further considerations are:

• Equipment needed

• Hire a specialist contractor and attendance on site

• Bed space

• Budget

The advice is to schedule the work as a Static Commissioning

activity, within the scope of B ITRs, and hire a specialist

contractor who will provide the personnel, pumps, hoses,

laboratory with measuring equipment and the cleaning fluid.




All A ITRs for Hydraulic and Lube Oil Systems are complete, with

no outstanding Category A PLIs or MOCs.

All B ITRs for Leak Testing Hydraulic and Lube Oil Systems are

complete and Category A PLIs or MOCs




The fluid sample size used to determine cleanliness is proportional

to the total volume of fluid in the System.

When the required cleanliness standard is attained for the System,

Commissioning retains custody until Handover to Operations.




Refer to the embedded files:

POCKET_BOOK_EN_St

andard.pdf

GE_Cleanliness_Requi

rements.pdf




Notes on varying cleanliness standards:

Commonly quoted: NAS 1638 Class 6; ISO 4406: Class 17/15/12




Kinematic Viscosity v Temperature:


Commissioning & Start Up WorkshopProcess Safety Management and PSSR

Learning Objective

After completing this module, the student will have an

understanding that the Pre-Start-Up Safety Review originates in

the OSHA regulations concerning process safety with the

sequence of activities leading to a successful PSSR that should

ensure a safe Start Up of the facility.



Process safety management of highly

hazardous chemicals

In accordance with CFR 1910.119 (OSHA regulation 3132) for

process safety management (PSM), the Owner or Operator shall

follow established procedures and observe specific requirements

leading to the Start-Up of a plant or facility.



Process Safety Management today

• Many developments since OSHA 3132 in 2000

• Reactive models with lagging indicators proven insufficient

• Positive ROI for good PSM, examples from IOGP and et al

• Use Proactive indicators and metrics

• Asset Integrity = Process Safety



Risk Management - Swiss Cheese Model

https://www.aiche.org/resources/publications/cep/2017/september/plug-holes-swiss-cheese-model

https://www.aiche.org/resources/publications/cep/2017/september/plug-holes-swiss-cheese-model



Risk Management – Barrier Analysis

https://www.aiche.org/resources/publications/cep/2016/december/use-bow-tie-diagram-help-reduce-process-safety-risks

https://www.aiche.org/resources/publications/cep/2016/december/use-bow-tie-diagram-help-reduce-process-safety-risks



Table 1 OSHA PSM Regulation

The employer shall perform a pre-startup safety review (PSSR) for new

facilities and for modified facilities when the modification is significant

enough to require a change in the process safety information.



Table 1 OSHA PSM Regulation (Cont’d)

The pre-startup safety review shall confirm that prior to the

introduction of highly hazardous chemicals to a process:

(i) Construction and equipment is in accordance with design

specifications;

(ii) Safety, operating, maintenance, and emergency procedures are in

place and are adequate;

(iii) For new facilities, a process hazard analysis has been performed

and recommendations have been resolved or implemented before

Start-Up; and modified facilities meet the requirements contained in

management of change, paragraph (l) [of this regulation].



Table 2 OSHA PSM Guidance

For new processes, the employer will find a Process Hazard Analysis

(PHA) helpful in improving the design and construction of the process

from a reliability and quality point of view.

The safe operation of the new process will be enhanced by making use

of the PHA recommendations before final installations are completed.

P&IDs are to be completed along with having the operating procedures

in place and the operating staff trained to run the process before

startup.

The initial startup procedures and normal operating procedures need

to be fully evaluated as part of the pre-startup review to assure a safe

transfer into the normal operating mode for meeting the process

parameters.



Table 2 OSHA PSM Guidance (Cont’d)

For existing processes that have been shutdown for turnaround, or

modification, etc., the employer must assure that any changes other

than “replacement in kind” made to the process during shutdown go

through the management of change procedures.

P&IDs will need to be updated as necessary, as well as operating

procedures and instructions. If the changes made to the process during

shutdown are significant and impact the training program, then

operating personnel as well as employees engaged in routine and non-

routine work in the process area may need some refresher or

additional training in light of the changes. Any incident investigation

recommendations, compliance audits or PHA recommendations need to

be reviewed as well to see what impacts they may have on the process

before beginning the startup.



Discussion of the Regulation

The first paragraph of the regulation states that a PSSR is needed

whenever Process Safety Information (PSI) is changed.

In effect, this requirement is such that virtually all changes will have to

be reviewed in a PSSR.

There are very few changes that do not require some information

changes to do with topics such as safe limits, engineering drawings and

equipment lists.



Discussion of the Regulation (Cont’d)

(i) Construction and Equipment

Paragraph (i) of the standard requires that construction and equipment

is in accordance with design specifications.

PSSR team members can carry out spot-checks of the installed piping

and equipment, and compare it with the piping lists and equipment

data sheets.




(ii) Procedures

Paragraph (ii) requires that the facility’s procedures reflect the manner

in which the facility is to be operated after the process changes have

been made.

The PSSR should check that safety, operating and emergency

procedures for the new operation have been written down, and that

they accurately describe what has to done.

This paragraph does not mention training, but it can be assumed that

operators and maintenance workers must be trained in the use of the

new procedures.




(iii) New / Modified Facilities

The regulation requires that new facilities conduct a PHA.

The PSSR team should check that the PHA was in fact carried out, and

that its recommendations were either resolved or implemented.

During the pressure of construction, there is sometimes a tendency to

postpone some of the PHA recommendations until ‘there is sufficient

time’.

The PSSR should check that the recommendations have been closed

out properly.



Fishbone Diagrams

According to Wikipedia, Ishikawa diagrams (also called fishbone diagrams,

herringbone diagrams, cause-and-effect diagrams, or Fishikawa) are causal

diagrams created by Kaoru Ishikawa (1968) that show the causes of a specific

event.[1][2] Common uses of the Ishikawa diagram are product design and

quality defect prevention to identify potential factors causing an overall effect.

Each cause or reason for imperfection is a source of variation. Causes are

usually grouped into major categories to identify these sources of variation. The

categories typically include:

People: Anyone involved with the process

Methods: How the process is performed and the specific requirements for

doing it, such as policies, procedures, rules, regulations and laws

Machines: Equipment, computers, tools required to accomplish the job



Fishbone Diagrams (cont’d)

Materials: Raw materials, parts, pens, paper, etc. used to produce the final

product

Measurements: Data generated from the process that are used to evaluate

its quality

Environment: The conditions, such as location, time, temperature, and culture

in which the process operates.

Refer to the embedded

Fishbone Diagram from a

recently completed major oil

& gas production facilities

project.

Refer to the embedded

PSSR Checklist from

AICE.



Management of Change and Audits

The way in which PSSR, MOCs and audits link to one another is

demonstrated in Figure 1.

Figure 1 - PSSR / MOC / Audit


Commissioning & Start Up WorkshopLessons Learned [Practices Worth Replicating]

Make Lessons Learned become Best Practices

Now, and at key stages in the life cycle of a project we have the

opportunity for capturing the lessons to be learned and enabling them

to become best practices.

Document and embed the ideas that follow in the learning

organization through training, modified work practices, processes and

procedures.


Commissioning & Start Up WorkshopTurnover Completion Packages

aka Commissioning Dossiers or Workpacks

Learning Objective

On completing this module, the student will again be reminded of

the importance of having excellent relations with Operations and

being able to make timely contributions to the PSM and PSSR,

achieved by delivering on the well thought-through agreements

made with Operations during Step 4 of the Simplified

Commissioning Logic, while the project was early in Detailed

Engineering.

These concern the timing of TCCC around agreed battery limits

and contents of TCPs.




API RP 1FSC, 1st Edition, Annex A – Courtesy of API




API RP 1FSC, 1st Edition, Annex A – Courtesy of API (Cont’d)


Commissioning & Start Up WorkshopHandover to Operations


Commissioning & Start Up WorkshopReady for Initial Start-Up (RFISU)

Guidelines on Timing and Scope

• RFISU of a defined portion of the Facility is when the

agreed target status has been demonstrated for all

material items, and can be safely energized.

• The defined portion is an ‘operable entity’ of the Facility.

• Successful testing prior to RFISU is a good indicator that

reliable and continuous Initial Start-up operations may be

productively commenced


Commissioning & Start Up WorkshopPre Start-Up Safety Review (PSSR)


• Focus on high energy processing or critical equipment

within the boundaries of a pre-defined plant area, or

within the boundaries of the whole facility

• Prior to initial start-up of unit / facility on process

hydrocarbons or hazardous chemicals, or critical Utilities

before Initial Start-Up

• Not greater than 90 days from start-up date

• Not less than 35 days from start-up

• Formal process carried out by external auditors




– Facilities are constructed as per design

– In compliance with Operations philosophy

– Asset integrity is verified and can be demonstrated

– Vendor support is identified and scheduled

– Operations staff are sufficiently trained and competent

– OMS is operable and ready for steady-state operations

– Commissioning ‘prerequisites’ are in place

– Project assurance is in place

– HSE Management System is in place



Checklist Guidelines

Reproduced with grateful thanks to AICE:

Performance Monitoring

Reproduced with grateful thanks to Chevron Corporation:


Commissioning & Start Up WorkshopStart-Up on Paper (SUOP)


• Risk assessment, preparation and familiarization

• All personnel required for SU must be involved in Start-

Up On Paper (SUOP) as it ensures

– Start-Up/Ramp-Up (SURU) procedure for Initial Start-Up is

fully understood

– Requirements in event of an emergency are known

– Roles and Responsibilities are identified

– Interfaces are known and the communication protocol for

Start-Up is fully understood.




• Commissioning issue the RFSU Certificate to Operations

for TCCC

• All ESD/PSD testing has been completed before Start-Up

– A full ESD test will be carried out post Initial Start-Up

• To accept TCCC, the Operator shall:

– review all Systems status until assured that integrity criteria

has been demonstrated and required test criteria verified

– verify any necessary approvals have been received

– ensure remaining PLIs / Exceptions are agreed in terms of

scope, cost and schedule




• Commissioning and Operations agree Systems are at

RFSU status, initial start-up procedure can commence

• Large projects with multiple Production Units, or phased

introduction of hydrocarbons, verification of the RFSU

status will be required and included in the Final

Acceptance Certificate (FAC) documentation.

commissioning guidelines, fats and sats

Documents