Ipedex Commissioning Integrated Services - IPCIS

An overview of the capabilities, methodology and software of IPCIS, for the provision of integrated commissioning services

Ipedex and Commissioning Services

Experience
Provision of commissioning services worldwide since 1970 Extensive Reference List

Manpower
Experienced Project Managers, Site Leaders, Superintendents, Engineers, Technicians and support personnel

Ipedex Commissioning Integrated Services IPCIS

Methodology
Commissioning methodology based on OPERCOM Ipedex licensed by TFE

Software
IPCIS Commissioning Software for Planning, Management, Execution and Documentation of Commissioning Activities

IPCIS Capabilities
Provision of a complete Commissioning Service

Commissioning planning
Preparation and supply of Commissioning Dossiers Supply of experienced manpower Implementation and management of commissioning tests Logistical Assistance Vendor Assistance Materials Assistance

Ipedex Capabilities
Supply of experienced manpower Operations and Maintenance for the Oil & Gas Industry Documentation Services Training Services

Individual Development Programmes

Commissioning References Worldwide Experience

Ipedex involved in Commissioning since 1970 Commissioning activities performed all over the world : Algeria, Angola, Argentina, Cameroon, China, Congo, Egypt, France, Gabon, Germany, Indonesia, Iraq, Iran, Ivory coast, Malaysia, Morocco, Nigeria, Oman, Portugal, Russia, Saudi Arabia, Senegal, Syria, Thailand, U.A.E., U.K., Uzbekistan,

Commissioning References Plant Experience Onshore oil recovery facilities Onshore gas recovery facilities Offshore oil recovery facilities Offshore gas recovery facilities Onshore gas treatment plant Drilling platform FPSO Dehydration gas units Gas terminal Oil terminal Oil depots Gas compression units Condensate stabilisation units Refineries (including heavy oil treatment, topping units, HDT, HDS, catalytic reforming, alkylation units, carbon Black units, isomerisation, merox, steam cracking, sulphur units, viscoreducer, ..) Ethylene / Polyethylene units Polyols units Solvent plants Aromatics plants (Benzene, paraxylene, orthoxylene) Lube oil units Dirty oil regeneration units

IPCIS Methodology Plant Commissioning Activities

Phase Pre-commissioning Activities Conformity checks Static tests Hydrotests Flushing & cleaning Energisation Dynamic tests Equipment running-in Utilities start-up Pre-start-up activities Operational tests Feed in Performance tests Bringing the plant on-line Milestone Ready for Commissioning (Mechanical Completion)

Commissioning

Ready for Start-up

Start-up

Provisional Acceptance Plant in Operation

Commissioning Complete

Commissioning is the verification of construction activities and preparation of the plant for Startup
Success of Startup (and hence the Provisional Acceptance) is dependant on a successful Commissioning An unsuccessful commissioning leads to problems in performance tests and delays Provisional Acceptance Commissioning involves many activities of short timescale. Even minor delays to these activities can have a great impact on overall schedule Commissioning involves different parties commissioning, vendors, operations, construction, engineering misunderstandings and ineffective organisation can lead to big delays in the overall schedule Commissioning needs careful planning and control to ensure that all activities are carried out effectively and in a timely manner

IPCIS Methodology Phasing of Activities

CONSTRUCTION

Plant
COMMISSIONING COMMISSIONING STARTUP START-UP COMMISSIONING OPERATION START-UP OPERATION COMMISSIONING

PRE-COMMISSIONING

DOSSIERS

PREPARATION

COMMISSIONING

Commissioning

MANAGEMENT

PROCESS STARTUP UTILITIES STARTUP PERFORMANCE TESTS

Operations

MECHANICAL COMPLETION OF FIRST SYSTEM

MECHANICAL COMPLETION OF SITE

TIME
PLANT IN OPERATION FINAL ACCEPTANCE

1st REQUEST FOR COMMISSIONING

UTILITIES READY FOR START-UP

PROCESS READY FOR START-UP

IPCIS Methodology The System Hierarchy

Location
As in the OPERCOM methodology a project is subdivided into a hierarchy of Systems and Subsystems by a set of delimitation rules These systems and subsystems reflect autonomous plant areas and divisions thereof As a result of the rules, each subsystem can be considered functionally independent for commissioning purposes Each subsystem comprises a number of disciplines (eg Instrumentation, Electrical, Piping, Mechanical) which relate to equipment included In terms of the commissioning, each discipline comprises the individual items under it which require to be tested under the commissioning activities

System 1

System 2

System n

Subsys 1

Subsys 2

Subsys n

Discipline

Discipline

Discipline

Item 1

Item 2

Item n

IPCIS Methodology The System Approach

Mechanical completion

Ready for start-up

Provisional acceptance

SYSTEMS

Time

USING SYSTEM APPROACH

Pre-commissioning Commissioning Start-up

SYSTEM APPROACH = TIME SAVING

Pre-commissioning Commissioning Start-up

WITHOUT SYSTEM APPROACH

IPCIS Commissioning Software

A multi-user software package developed by Ipedex for the planning, implementation, management and documentation of Pre-Commissioning and Commissioning activities Based on the OPERCOM methodology, featuring the Systems Approach to Commissioning Includes a database to include all relevant information for items to be commissioned plus management tools to implement the commissioning Used in the Preparation Phase to set up the database with engineering information Include all items to be commissioned into the database Assign test sheets and specifications (included within the software) Set up the format of Pre-Commissioning and Commissioning Dossiers Printout of Pre-Commissioning and Commissioning Dossiers Used in during the Commissioning Phase to implement and manage the commissioning activities Print out test sheets and specifications Entry of test results to the database Management of Certificates for Commissioning activities Viewing of status of activities and management of the commissioning Development and management of punchlists and materials / information requests Viewing and printout of Progress and Punchlist reports Automatic compilation of Pre-Commissioning and Commissioning Dossiers to include test results Viewing and printout of Pre-Commissioning and Commissioning Dossiers

IPCIS Software Managing Users

Users are defined as required for each project and assigned passwords Levels of access and authority are defined for each user Throughout the commissioning, users are recorded when Test sheets and certificates are signed Punchlists are set and cleared This ensures integrity of the commissioning documentation and allows auditing of the activities Multiple users may operate the software simultaneously using a network of PCs

IPCIS Software Preparing for Commissioning Database

Use the Design Module to: Set up the System hierarchy - Systems - Subsystems - Disciplines Input the items to be commissioned into the database Set up for multi-element loops (Global Functions) and Operational Test Procedures Assign Test Sheets and Specifications

Data can be entered using a variety of methods: Import from spreadsheets Manual data entry Selection of data from AutoCAD P&IDs

IPCIS Software Preparing for Commissioning Dossiers

Use the Publishing Module to: View and edit the contents of the PreCommissioning and Commissioning Dossiers Print out individual sheets, sections or the complete dossier The basic contents structure of a dossier is included within the software and may easily be edited, as required Database information is gathered automatically by the software, to include complete documents in the correct place Additional documents may be linked into the contents structure and viewed and printed as a part of the dossier A typical dossier is presented in a format reflecting the System hierarchy and includes: Certificates Status sheets Test sheets Punchlist reports Other documents, as required

IPCIS Software Carrying Out the Commissioning Test Sheets

Use the Input Module to: View the Test sheets and enter data relevant to the tests Print out individual sheets for use by commissioning personnel Test sheets and specifications are designed to make the maximum use of check boxes to allow rapid entry of results into the database Test sheets include electronic signature boxes. A suitably authorised user may electronically sign the sheet. Signatures and dates are recorded by the software

IPCIS Software Carrying Out the Commissioning Punchlists

If any test on a test sheet is failed, a punchlist is automatically identified for the item concerned One of four levels of punchlist must be selected, remedial action is assigned to a party, comments are included and materials / information requirements are identified. To clear the punchlist, reasons for the clear must be identified. The software records the user when the punchlist was generated and when it was cleared, for reporting and audit purposes. Cleared punchlists are still held by the software for audit purposes For levels of punchlist which block progress, the software automatically prevents signature of test sheets and certificates relevant until the punchlist has been cleared

IPCIS Software Carrying Out the Commissioning Status Information

From the Input Module, status information is available in a variety of formats For each discipline, subsystem, system, and for the complete location a status report is available showing the current status of activities for the next hierarchical level down These status displays provide extensive information for areas completed and areas blocked. Punchlist status displays are also available for each level showing complete information for punchlist items for lower levels Icons, and their colours, in the navigation window also give the user overview information at a glance

IPCIS Software Carrying Out the Commissioning Certification

The IPCIS software includes certificates for completion of precommissioning and commissioning activities for each subsystem, system and the complete location For a certificate to be signed it is necessary for all activities lower in the System hierarchy to have been successfully completed and all lower level certificates signed The user management facilities of the software ensure that it is only possible for a suitably authorised user to sign a certificate Certificates are accessed through the Input Module

IPCIS Software Carrying Out the Commissioning Progress Reporting

The IPCIS Software automatically tracks progress of the commissioning activities Report generation facilities are included, allowing progress to be viewed and status reports to be generated and printed out. Progress information is extracted from the database and analysed on Excel spreadsheets giving a very flexible presentation Progress information is easily available and may be input into project management software for effective control of commissioning activities

IPCIS Software Carrying Out the Commissioning Progress Reporting

Progress reports allow presentation of information in various formats

Punchlist Status reports give clear summary information of deficiencies found for appropriate remedial action to be taken

IPCIS Software Final Pre-Commissioning & Commissioning Dossiers

During commissioning activities the dossiers are automatically updated as test information is completed into that database. The Publishing Module is used to: Print out test sheets for use by the commissioning personnel View this development of the PreCommissioning and Commissioning Dossiers Include other documents into the dossiers as required through the commissioning activities Print out individual sheets, sections or the complete dossier

A typical dossier is presented in a format reflecting the System hierarchy and includes: Certificates Status sheets Test sheets Punchlist reports Other documents, as required

IPCIS Integrated Commissioning Services

30 years worldwide experience in commissioning activities IPCIS division dedicated to commissioning services

Methodology based on OPERCOM

IPCIS software for preparation, management, execution and documentation of commissioning activities IPCIS can provide services at a variety of levels Preparation / supply of commissioning dossiers Commissioning planning, manpower analysis / schedules, review and development of related documents (lists of consumables, spares, temporary means; procedures; specifications.) Commissioning management Commissioning supervision Complete commissioning execution

Additional support available from Ipedex including Training, Individual Development Programmes, Documentation Services, Operations and Maintenance, supply of experienced personnel