mechanical completions- welding

8/10/2019 Mechanical Completions- WELDING

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Completion Documentation RequirementsFor Projects

Hook Up / Construction,Commissioning to Operations

Handover

PMT

By Andy Lang


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Completions Overview

Completed Inspection and Test Records (ITRs).

Marked-up As-Builts, Loop Diagrams etc.

OWL and Punch List control including consolidation of both.

Discipline Acceptance Certificates

Manufacturing Record Books (MRBs).

Mechanical Completions Systems Dossiers.

Document Control System (via DCC in / out of the Project).

Material Certification and Data Sheets

Dossier Index and Reports

Inspection Reports & IndexCertificates & Index

Final Handover / Asset Transfer Certificate

Mechanical Completions Certificates

Technical Queries, DCN s, NCRs etc.


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Completions Overview

In order to control Construction activities from a Completion point ofview, wherever possible, each item shall have a Tag number assigned to it.

To ensure correct installation and pre-commissioning of items ofEquipment & Materials, Inspection and Test Records (ITRs) shall be

assigned to them by disciplined Engineers.

Tag numbers are grouped per their Commissioning System/Sub-System,progress can be measured by the completion of ITRs as they re receivedand entered into the Mechanical Completions Database.

Reporting on ITRs received has clear advantages from a safety view pointas it ensures important inspections & tests are carried out.


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Completions Principles

The overall goal of Mechanical completion and commissioning is toverify that the system is designed and built to fulfil its purpose andspecified requirements.

Early establishment of commissioning packages is essential for an

orderly and effective project completion. All fabrication and installationplanning shall be system oriented.

Mechanical completion, commissioning, FAT, Preservation and suppliersassistance requirements shall be specified in purchase orders.

Overall Goal:


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Completions Phases

In this phase the following is carried out:Completion philosophy.Coding structure and system breakdown.Completion requirements to suppliers and contractors.

Definition Phase:

In this phase the following is carried out:Commissioning Package & MC Package definition.Assignment of Mechanical Completion Check Sheets (ITRs).Define commissioning network.Produce commissioning procedures.

Engineering Phase:

Equipment suppliers shall execute MC, FAT and commissioning and preservation asspecified in the purchase order. The completion shall be documented as part of thecompletion system which leads up to handover to COMPANY.

Suppliers Completion Phase :

Contractor(s) shall perform MC, Pre-Commissioning and preservation as specified inpurchase order/contract documents. The completion is documented as part of the

completion system which leads up to handover to Client for Commissioning and Start-up.

Construction / Assemble Phase:


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Completions Responsibili ties

Responsibilities are Defined in the Contract. All Pre-commissioning activities are theresponsibility of Contractor(s) with Client personnel.MC execution and registration/documentation, shall be performed by anyone who has ascope of work to be performed, such as equipment suppliers, fabrication contractors,installation contractor and hook-up contractors.

Responsibilities:

The Contractor(s) will be responsible for all activities associated with completing the HookUp and construction of the facilities within the Scope of Work.The Contractor(s) shall make provisions for working under the supervision and conditions ofPermit to Work Systems and other Project requirements.

Hook-Up and EC:

Turnover is defined as the sequence of events leading to transfer of custody of aSystem/subsystem from Contractor(s) to Client and Client to Operator. It is the demarcationbetween the construction / pre-commissioning phase and the commissioning/start-upoperations.Once pre-commissioning activities have been completed per sub-system, formal turnover toClient shall be made for final commissioning and start-up operations.

Facility Completion & Systems Turnover:


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Completions Responsibili ties

This Presentation represents the basis for preparing plans, procedures and documentationfor Mechanical Completion and Commissioning. The implementation of this Procedurerequires the use of a coding system for item and system numbering.

Common Requirements:

Only Pinnacle Mechanical Completion documentation completed per test pack, item orequipment Tag number shall be held in the MC Dossier. Commissioning documentationshall be documented on a commissioning package level.

Documentation:

A Mechanical Completions Database is the system for the administration of Mechanicalcompletion, pre-commissioning and Punch List Register.

Mechanical Completion System:

All MC activities shall be planned on fully integrated Fabrication, Mechanical Completionand Commissioning Schedules on a system prioritised basis in order to meet the optimalsequence of completion.

Planning:


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M echanical Completion

Mechanical completion shall take place through all phases of the project, starting atequipment supplier and continuing through fabrication up to the commissioning phase.Mechanical completion encompasses all disciplines. Detailed responsibilities are described inthe contract. Contractor(s) shall be responsible for establishing and compiling the MCdossiers and report status into the computer based Completions System.

Introduction:

The MC package shall include MC Certificate's, a MC Status Index and a Punch ListRegister printout as described below.Mechanical Completion shall be notified on a MC Certificate (MCC) which shall becompleted by the Contractor(s) and verified and endorsed by Client after all MC has beencarried out. A MC Certificate shall be raised for each MC package. A MC package shall,when signed, be ready for start of pre-commissioning activities. These shall be stored in its

respective discipline in the MC Dossier section.

Documentation for a MC Package :

The Inspection and Test Records (ITRs) shall be completed by the Contractor(s) to recordthe results of all checks, inspections and tests carried out for each individual item.

An Outstanding Work List (OWL) should be prepared by Contractor(s) for its own internalcontrol of outstanding work items and be available to the Client.


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M echanical CompletionA MC Punch List shall be prepared by Client and issued to Contractor(s) nearing the MCstage. In each MC package a printout from the Punch List Register shall be included todocument the incomplete work.

A MC Status Index listing the status of all ITRs for the completed MC package shall beincluded in the front of each MC dossier. Once all ITRs have been received for a MC SystemDossier(s) a Preliminary Handover Certificate (Mechanical Completion) shall also be storedin the front of the MC Dossier. Pre-Commissioning activities may start.

Once OWL and Punch items are reduced for a particular sub-system, a joint walk around(Client/Contractor) shall be carried out, and any new items recorded.Both lists should then be consolidated into a single Consolidated Punch List which,supersedes all previous lists to focus attention on remaining items.

Once pre-commissioning activities have been completed for a particular MC system byContractor and Client, a Provisional Handover Certificate (Pre-CommissioningComplete/Ready for Commissioning) shall be raised. This shall be considered the handoverfrom Contractor to Client Commissioning Team. This certificate shall also be stored in thefront of the MC Dossier. On completion of Commissioning an Interim Handover Certificate(Commissioning Complete/Ready for Start-Up) shall be added to the front of the Dossier tofinalise the Dossier.

Handover at Mechanical Completion :


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OWL s & Punch I tem Categor ies

Civil

Construction

Commissioning Electrical Engineering

Instrumentation High Voltage

Piping

Refractory Insulation

Mechanical Coatings

Quality

Safety

Vendor

Telecomms

Steel Structure


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Carry Over Work RegisterThe Carry Over Work Register (COWR), when necessary, lists all punch items that theProject accepts as cannot be completed during present phase. The COWR is used for therelease of the work from the EC and will as such be an input to the scheduling and planningof outstanding work to be performed during later phases.

The COWR Item Number and cross reference to the Punch List Register/Check Recordsshall be given. COWR work shall be marked up on drawings or sketches and be included inthe records.

COWR Material Status List (MSL) and marked up drawings/instructions shall containsufficient information for job setting in a later phase.


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OWL s & Punch I tem Categor ies

A database to print more specific reports according to individual ContractHolders, Engineers or Supervisors requirements can include:

By Discipline and Phase, Area or System

By Phase /Area

By Sub-System

By Discipline

Total remaining OWL and Punch Item Statistics

Total items remaining


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Certif icate Control

A summary report of all certificates for a given System / Sub-systemcould also provide information on the following topics required tocomplete a sub-system dossier:

System Limit P & ID Diagrams

Marked -up As- Built Drawings (red lined)

Instrumentation Loop Diagrams

Technical Queries , Site Queries , Design Change Notice etc.

Corrective Action Request , Non -Conformance Reports , OS&D etc.

The above records act as a guide for the system administrators that thisinformation needs to be investigated and included in final completionsdossiers.


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Cer tif icate Control

To enable a controlled and safe plant start-up, the Certification systemfollows the following sequence per individual Commissioning system /sub system.

Mechanical Completion/Ready for Pre-Commissioning

Pre-Commissioning Completion/Ready for Commissioning

Commissioning Completion/Ready for Start-Up

Final Handover (Performance Completion)

Discipline Acceptance Certificates


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Progress Reports

The most commonly used reports are:

Project Certification and Punch List Statistics

Certification Progress by Phase, Area, System and Sub-System

Progress by construction category per Area and Sub-System

All system reports need to be based on Quality Control InspectionReports received. These reports are required to prove the integrity ofa Plant based on Quality and Safety.


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Completion Structure

Hook Up &Pre-Comm

MechanicalCompletion

Execution

Preservation

SubSystem

SubSystem

SubSystem

SubSystem

MC

Dossiers

System System System System

Mech Elec Inst Piping

Handover Certs (Ready for Pre-Commissioning)

ITRsPunchlists

Equipment Tag Index

As-Builts (Red Line Marked up) & Index

Management of Change SQ, TQ, DCN, CR

Equipment Preservation

Certification

SubSystem

SubSystem

SubSystem

SubSystem

MC

Dossiers



Handover Certs (Ready for Commissioning)

ITRsPunchlists

Equipment Tag Index




Certification

SubSystem

SubSystem

SubSystem

SubSystem

MC

Dossiers



Handover Certs (Ready for Start-Up)

ITRsPunchlists

Equipment Tag Index




Certification

Commissioning Operations

By: Andy Lang Email: [email protected]

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