FPSO Commissioning Engineering and Management (Activities) Who Prepare and Execute?

SUMMARY

What does the Offshore Oil & Gas Commissioning Team (Manager, Coordinator, Engineer, Superintendent/Supervisor, Technician, and Operation team) what do they do? Engineering and Management during Commissioning

Who prepares the entire set of commissioning documents and what are the documents required to carry out commissioning throughout the commissioning engineering and commissioning phase when a project is ongoing.

In particular, when PETROBRAS manages EPC Management directly and contractual derivatives are provided in full in Engineering, Procurement, Construction, Commissioning and Operation Handover, I have mentioned below the actions that will be carried out during the EPC FPSO project.

TOTAL FPSO or Oil and Gas Facilities Execution details given in Pre-commissioning and Commissioning Specifications, Pre-commissioning and Commissioning Engineering, Pre-commissioning Execution, Minimum maintenance requirements and TOTAL MC Handbook.

SHELL FPSO or Oil and Gas Facilities Execution details given in Precommissioning of pipelines, Field inspection prior to commissioning of mechanical equipment, Field commissioning of electrical installations and equipment, Field commissioning and testing of electrical installations and equipment, ect.

In order to manage the life cycle of the project scope and deliverables by collaborating with the builder, client, and authority (Shipyard, Fabrication yard, Module fabrication, Vendor facilities, and Classification society), he must first identify his team members and their skills.

I have responsibility for Initiating, Planning, Executing, Monitoring & Controlling, and Closing. As a commissioning project manager and project manager of oil and EPC project. I have applied and implemented the PMI-PMP process group and knowledge area to manage the project services. 

S/N       Activities

1             Overall Commissioning Plan

1.1         Commissioning organization chart

1.2         Commissioning Executive Plan

1.3         Work Breakdown Structure (WBS)

1.4         Commissioning master schedule

1.5         Commissioning precedence network

1.6         Commissioning Process histogram

1.7         Commissioning Progress curve;

1.8         Vendors’ technical assistance schedule

1.9         Commissioning Health, Safety and Environment plan

1.10       Commissioning Responsibility Interface Matrix

2             Documentation Management

2.1         Instrument Loop Test Folders

2.2         Telecom Loop Test Folders

2.3         Electrical Blank Test Folders

2.4         Systems and sub-systems list

2.5         P&IDS, Electrical, Instrumentation and Telecom Diagrams Marked up

2.6         Pre-commissioning, commissioning & start-up spare parts list;

2.7         Special tools list;

2.8         Oil & grease chart;

2.9         Consumables & chemicals evaluation;

2.10       Vendors technical assistance list;

2.11       FPSO Operation Manual

2.12       Documentation control procedure;

2.13       Procedure for data input of ICS's in Database

2.14       Procedure for data input of FTC's in Database

2.15       Commissioning Items Receipt Inspection Procedure

2.16       Procedure for Delivery of Data-Books, NR-13 and NR-10 dossiers;

2.17       Procedure for Mechanical Acceptance of Systems/Subsystems;

2.18       Procedure for TAP-1 and TAP-2 execution;

2.19       Procedure for obtaining the Substantial Completion Certificate;

2.20       Preservation Procedure

2.21       Valves Calibration Procedure

2.22       PSV re-calibration procedure

2.23       Instrument Calibration Procedure

2.24       Instrumentation Loop Test Procedure

2.25       Telecom Loop Test Procedure

2.26       Logical Interlocking Test Procedure

2.27       Electrical Blank Test Procedure

2.28       Electrical Hi-Pot Test Procedure

2.29       Electrical Functional Test Procedure

2.30       Megger Test Procedure

2.31       Electrical Components Calibration Procedure

2.32       Electrical Panel and Components Test Procedure

2.33       Thermography Procedure

2.34       Videoboroscopy Inspection Procedure

2.35       Procedure for Verification of Grounding System

2.36       Procedure for Preservation Criteria Payment

2.37       Procedure for Storage of items and Equipment at the job Site

2.38       Mechanical Equipment Tests Procedure

2.39       Ventilation and Air Conditioning System Test Procedure

2.40       Flame and Gas System Test Procedure

2.41       Electrical Motor Tests Procedure

2.42       CCM Electrical Test Procedure

2.43       Bars and Ducts Test Procedure

2.44       UPS System Test Procedure

2.45       Transformer Test Procedure

2.46       Battery Bank Test Procedure

2.47       Break Test Procedure

2.48       Cable Test Procedure

2.49       Electrical Panel Torque Procedure

2.50       Full Load Test Procedure

2.51       Punch list control procedure;

3             Software

3.1         FIC-Commissioning Management Software

3.2         SISPEN- Punch list software

3.3         GITEC- Planning software

3.4         SIGEM- Document Control software

4             Commissioning Activities

4.1         Site Activities

4.1.1     Modules fabrication surveillance (at Construction site)

4.1.2     Module release inspection (at Construction site)

4.1.3     Modules Receipt inspection (at the integration yard)

4.1.4     Factory Acceptance Tests

4.1.5     Material and Equipment Receipt Inspection

4.1.6     NR-13 Inspection

4.1.7     Instrument calibration

4.1.8     Electrical components calibration

4.1.9     Piping hydrostatic test

4.1.10   Piping cleaning: mechanical, washing, pigging, flushing, blowing and chemical;

4.1.11   Piping leakage test

4.1.12   Electrical loop test

4.1.13   Instrumentation/ control loop test

4.1.14   Megger tests

4.1.15   Mechanical completion inspection

4.1.16   Instrumentation functional test

4.1.17   Mechanical equipment functional test

4.1.18   Electrical panels & components functional test;

4.1.19   Start-up preparation (applicable to items, loops and sub-systems);

4.1.20   Sub-system logic-interlocking test (cause and effect matrix)

4.1.21   Sub-system Performance Acceptance Test (TAP);

4.1.22   Provisory transference of the sub-system to the Operation team (TTAS 1).

4.1.23   Control of the spare parts and special tools;

4.2         Document Activities

4.2.1     Management Reports (ex.: TTAS 1 progress, PSV re- calibration progress etc.).

4.2.2     Pressure safety valves (PSVs) folders control and issuance;

4.2.3     Prepare and issue the Mechanical Completion Reports;

4.2.4     Program, control, certify and supervise the development of the piping hydrostatic tests and pipe cleaning;

4.2.5     Commission Punch List control

4.2.6     Sub System and System's folders preparation;

4.2.7     Prepare and issue the Commissioning Completion Reports;

4.2.8     Updating of the Commissioning Management Software (FIC) with the field activities execution;

4.2.9     Program, control, certify and supervise the development of the commissioning activities and generated related report

4.2.10   Program, control, register and supervise the development of the preservation activities and generated related report

4.3         Coordination

 4.3.1    Vendors’ technical assistance coordination;

4.3.2     Class compliance coordination;

4.3.3     Shipyard each discipline coordination

4.3.4     Coordination of the systems’ (TTAS 1 and 2);

5             Assisted Operation

5.1         Operation of the marine systems;

5.2         Commissioning Punch list clearance;

5.3         Vendors support during the assisted operation contractual period;

5.4         Definitive transference of the system to the Client (TTAS 2).

6             Commissioning Facility at Job site

6.1         Temporary diesel generator (meet the total load requirement when necessary)

6.2         Electrical Load bank compatible with thermographic test

6.3         Commissioning tools, such like digital multimeter, AC/DC clip on ammeter, Various transmitter, Megger, Hi-Pot etc.

6.4         Fuel oil, grease, hydraulic oil or any lubricant component

6.5         Nitrogen or any type of gas for testing and leakage test

6.6         Chemical products and/or consumables for cleaning -

6.7         Consumables for commissioning and start-up

6.8         Spare parts, including PSV/VET replacement parts and paint for coating -

6.9         Repair in any component (Owner Equipment)

6.10       Lighting and electric power (AC/DC), compressed air, fresh water and firefighting equipment

6.11       Cargo handling facilities

6.12       Scaffolding and any kind of temporary structures -

6.13       Temporary devices (spectacles flanges, filters; bypass hoses, etc.)

6.14       Any kind of inspection related to construction (structure, painting, etc.)

6.15       Expenses to contract and/or mobilize Vendors

6.16       Warehouse and warehouse management -

6.17       Safety engineering support to establish safety, health and environment signaling and protection

7             Miscellaneous

7.1         Area to install tool shop container and test bench container m2

7.2         Office for the Commissioning Team, at job-site people xx

7.3         Telephone lines at job-site xx

7.4         Internet facilities at job-site

7.5         File cabinets and book shelves at job-site m2 xx

7.6         Commissioning staff PPE at job site