Module 10 - Managing Construction and Completions PowerPoint Presentation_Rev1

August 8, 2017 | Author: sayafrands6252 | Category: Construction Management, Safety, Risk Management, Occupational Safety And Health, Modularity
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Welcome to WorleyParsons Project Management Process (WPMP) Training Module 10 – Managing Construction and Completions

1

Introduction About this training session 

Welcome



Safety Moment



Emergency Procedures



Introductions



Learning Objectives



Learning Outcomes



Agenda—Module 10 Construction Management and Completions

2

Introduction Learning Objectives On completion of this module, you will have: 

A basic understanding of what the Construction and Completions functions provide to complete an EPCM project



An understanding of the methodologies and tools that will enable you to work with Construction and Completions to successfully deliver a project

3

Introduction Learning Outcomes On completion of this module, you will be able to: 

Understand the reasons for requiring Construction and Completions involvement early in project planning & TIC Estimate



Plan and incorporate constructability reviews and construction lessons learnt into project design and contracting



Address design strategy opportunities for design standardization, modularization and pre-assembly



Understand typical Construction and Completions organization charts and associated roles and responsibilities

4

Introduction Learning Outcomes (continued) On completion of this module, you will be able to: 

Have a basic understanding of the key processes used by Construction and Completions



Understand the needs of Construction, including AFC drawings and materials being available on time, and how this determines Engineering and Procurement priorities



Have a basic understanding of the typical progress reporting provided by Construction and Completions



Understand the importance of HSE in Construction and Completions



Have a basic understanding of Industrial Relations (IR) requirements

5

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability and Commissionability



Site Organizations and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

6

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

7

Overview 

What is Construction



What is Completions



What is Commissioning

8

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability



Site Organization and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

9

Roles and Responsibilities What is the role of Project Manager? 

Establish management processes and controls that result in a successful project



10

Responsible for total project delivery

Roles and Responsibilities What are the Construction Manager’s Responsibilities? 

Safety Management and promotion of HSE culture



Construction Management Planning



Cost Management



Time Management



Quality Management



Contract Administration



Construction Management



Industrial Relations

11

Roles and Responsibilities What are the Completion Manager’s Responsibilities? 

Safety Management and promotion of HSE culture



Completions Management Planning, Development & Execution



Cost & Time Management



Quality Management



Site Operator Interfaces



Site Administration after Construction



Operator training



Interim Facilities Turnover to the Customer/Operator, pending formal project Turnover by the Project manager

12

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability



Site Organization and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

13

Project Planning Key schedule deliverables by the Project Team 

The project schedule should be driven from the back end



Early Construction and Completions involvement is absolutely necessary



Project WBS must meet with the minimum Contracting and Construction requirements



Identify issue of key deliverables

14

Project Planning Pre-mobilization of Construction 

Construction Manager completes pre-mobilization details with Construction Team



Project and Construction Managers ensures that the Construction team do not mobilize too early



Project and Construction Managers ensure that the mobilization plan is based on an assured flow of ongoing work

15

Project Planning Construction & Completions Pre-mobilization Meetings 

When do you hold a pre-mobilization meetings



What are the Project Manager’s responsibilities

16

Project Planning Construction Methodology – Brownfield vs Greenfield 

What is the difference between Brownfield vs Greenfield construction projects



What expected delays on Brownfield projects may influence the estimate

17

Project Planning Prerequisites/Critical Construction Inputs 

Environmental impact of job



Successful scheduling



Site safety



Availability of materials



Logistics (road transport, shipping schedules, resources, etc)



Inconvenience to public caused by construction delays



Preparing tender documents

18

Project Planning Preliminary Construction Planning Construction Manager is responsible for: 

Completing construction preliminary planning

• Keeping Project Manager informed about issues and progress • Making recommendations to Project Manager where issues and needs may impact on planning by other disciplines 

19

Documenting the outcome of preliminary planning in a Construction Management Plan (CMP)

Project Planning Detailed Construction Planning Draft CMP

DEFINE

Review CMP

Customer approval

Revise at Approved for Construction (AFC) stage

20

EXECUTE

Issue to project team

Project Planning Construction Management Plan (CMP) As Project Manager you are responsible for: 

Ensuring CMP is prepared according to overall project requirements



Reviewing and approving the CMP



Issuing the CMP to the customer

21

Project Planning Site Establishment and Logistics 

Reviewing Construction Management Plan (CMP)



Determining responsibilities at the site—Customer and other stakeholders



Reviewing Mobilization Plan and considering the support services requirements for mobilization



Reviewing the Contracts Plan and confirming the contracts strategy



Determining the project layout for all temporary facilities



Obtaining necessary licenses and permits



Consideration of required temporary facilities

22

Project Planning Site Establishment and Logistics, continued 

Establishing utilities for and at the site



Establishing facilities at the site—for example, transport and storage, accommodation, sanitary arrangements, fire and other hazard protection



Developing site administration procedures



Developing a HSE plan for the site



Setting up site offices and services



Developing a plan to resolve site-related issues



Developing site security procedure

23

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability



Site Organization and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

24

Constructability Construction Team Input into Execution Planning and Design 

Ensures that BOD covers all construction cases i.e. Fabrication location, transportation and installation techniques



When is Construction Team input required in a project



What questions does constructability address

• Can it be constructed and how best to do it efficiently • Can it be maintained • Can it be operated

25

Constructability Constructability Reviews 

Safety, including safety in design



Interfaces with operations and other contracts



Ability to pre-assemble as much as possible off site or on the ground prior to erection



Installation access



Transportability



Ease of construction



Standardization



Ease of Commissioning

26

Constructability Constructability Reviews continued 

Cost effectiveness



Fabrication, Installation and Completions methodologies to reduce schedule



A check that design cases cover ‘Construction Phases’ as appropriate and not just operating conditions

27

Constructability Constructability Reviews – Outputs 

Inputs to ALL Plans including BOD and project schedule



Specific constructability checklists across all functions, scope and disciplines



Action lists for changes to design and procurement



Early planning for proper activity sequencing including Completions



Identifying any unusual factors affecting construction



Identifying any unusual costs not identified by normal estimating methods

28

Constructability Constructability Reviews – Outputs Continued 

Identifying staffing requirements, facilities, warehousing, documentation, information flow, quality, safety, cost and schedule



Identifying heavy lift/rigging plans requirements and development of cost options for major and complex lifts

29

Constructability Modularization and Pre-assembly 

Methodology – Pre-assembly



Methodology –modularization



Early definition



Module grade levels



Module configuration



Module sizing



Module contents

30

Constructability Activity One – Group Discussion 

What are five examples of benefits that constructability gives to a project?



What would each benefit mean for a project’s schedule and costs?

31

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability



Site Organization and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

32

Site Organization and Resource Management

Site Organization – Roles The organization structure is dependant on the size, contracting strategies and complexity of the project and may differ than what is typically shown in the charts 

Mechanical / Piping / Structural Superintendent



Electrical and Instrumentation Superintendent



Civil and Earthworks Superintendent



Document Controller



Field Engineering



QA/QC Inspector



Senior Planner/Scheduler



Senior Cost Engineer



Senior Contracts Engineer.

Scaffolding Superintendent



HSEC Advisor(s)



Tie-in Coordinator (Brownfields Projects)

33



Sample Project Organization Chart WorleyParsons Project Sponsor

Customer Project Manager

WorleyParsons Project Manager

Project Quality Manager

HSE Manager

Procurement Manager

Purchasing Supervisor

Materials Management Supervisor

Project Engineer Manager

34

Engineering Manager

Construction Manager

Contracts Supervisor

Lead Civil/Structural Engineer

Project Controls Manager

Lead Cost Engineer Const Org Chart

MCS Supervisor

Vendor Inspection Coordinator

Lead Process Engineer

Administrative Assistant

Lead Planner

Lead Piping Engineer

Prime Contract Administrator

Project Accountant

Comm Org Chart

Lead Estimator

Lead Document Controller

Piping Design Coordinator

Commissioning Manager

Lead Mechanical Engineer

Lead Electrical Engineer

Lead Control Systems Engineer

Sample Construction Site Organization Chart

Project Manager

Project Quality Manager

Construction Manager Site Services *

Materials Management * Materials Controller Warehouse Field Purchasing

35

Construction Management Superintendents Supervisors ? Civil ? Structural ? Mechanical ? Piping ? Electrical ? Instrumentation ? Welding ? Scaffolding ? Rigging

HSE Manager * Safety Advisors Training Security Environment Community

Construction Engineering * Resident Engineer Field Engineers Document Control

Construction Inspection * Inspectors ? Civil ? Structural ? Mechanical ? Electrical ? Instrumentation ? Welding ? Piping

Office Services Human resources Industrial Relations Accounting

Contract Administration * Contracts Administrator Contracts Engineers

Project Controls * Cost Eng Planning Eng Estimating Eng Reports Eng

* Functionally reporting to relevant Home Office Manager

Sample Completions Site Organization Chart

WorleyParsons Project Manager

Handover/ Turnover Coordinator

Operations Representative

Commissioning Superintendent

Senior Commissioning Discipline Technicians

Commissioning Discipline Technicians

36

-Electrical -Instrument -Process -Mechanical

Commissioning Engineer -Electrical -Instrument -Process -Mechanical

Completions Manager

Permit To Work Coordinator

Punchlist Coordinator

Commissioning Planner

Site Organization and Resource Management

Resource Management 



Construction Staffing Plan



Preliminary plan to be developed at FEED to form basis of CM Labor estimate



Project, Construction and HR Managers to formulate proposed construction organization resource plan

Obtaining suitably experienced staff, subcontractors

• 

Demobilization



37

Project, Construction, Procurement and HR Managers to source

Conducted either by the Construction or Completions Managers

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability



Site Organization and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

38

Communication and Team Work Project Culture, Trust and Teamwork 

As a Project manager encourage a Positive project culture



Mutual trust and team respect



Team work

• • • • •

39

Coordination Cooperation

Communication Compromise, and Trust

Communication and Team Work Home Office and Site Office Communication and Teamwork 

Ensure Construction and Completions Managers are included in key project meetings



Project meetings to be held on site at regular intervals during Construction phase



Have engineering spend time on the construction site to conduct follow on engineering



Have a well-defined and adequately resourced Field Engineering group to manage on-site engineering queries linking back to the Home Office



Construction and Completions to be included in project team building sessions.

40

Communication and Team Work Coordination Your role as Project Manager is to provide support and guidance to the Construction and Completions Management Teams 

Regular on-the-job meetings



Ensure work is organised according to schedule



Ensure that the Site logistics plan supports all phases of the project



Monitoring and expediting the processing of shop drawings, samples and other submittals for approval in a timely manner



Immediate reporting of damage or loss

41

Communication and Team Work Cooperation Your role as Project Manager is to encourage cooperation 

Settling money issues promptly



Submission of progress and final payment applications using the contract’s established procedure



Communications between the Construction Contractor and the Engineer is being facilitated through WorleyParsons



Nurturing relationships being conducted between WorleyParsons Construction Management Team and Construction Contractors’ authorized representatives

42

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability



Site Organization and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

43

Issue Resolution Problem 

What is the effect of saving up issues for resolution later

Action 

44

What should Project Managers do about resolving issues

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability



Site Organization and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

45

Quality Management Quality Assurance Plan 

Project procedures



Quality processes used at project level



Continuous improvement



Audit program

46

Quality Management Construction Contractor’s Responsibilities for Quality Control 

Reporting deficiencies that may affect delays in completion of work



Issuing of Non-conformance Reports and Corrective Action Requests to the Construction Manager



To accurately reflect the project Quality Plan expectations and desired outcomes

47

Quality Management Inspection and Test Plans 

Ensures the status of inspection and test is known at all times



Provides documentary evidence of the satisfactory completion of required tests

48

Quality Management Checklists and Rectification of Defects 

Checklists provide a verification record of a test OR

the completion status prior to a non-reversible step 

49

An inspector produces a Defect List when they find defects or requirements for rework

Quality Management Inspection Completion and Punch Listing 

A Construction Contractor may request inspection clearance from the Site Inspector



Where the inspector finds defects a punch list must be attached to the Inspection Release Certificate



Punch list

• Can only be cleared by the site supervisory team and forms part of the contract quality records

• Indicates the category of the punch list items and dates by which they will be completed

50

Quality Management Quality Records 

Construction Contractors must provide a Manufacturer’s Data Report (MDR)



MDR contains

• Documentary evidence of inspection and test activities • ‘As-built’ status of work • Compliance status with relevant standards, codes and specifications

51

Agenda 

Introduction



Overview



Roles and Responsibilities



Project Planning



Constructability



Site Organization and Resource Management



Communication and Team Work



Issue Resolution



Quality Management



Protocols for Construction Site Visits

52

Protocols for Construction Site Visits The Security Plan… 

Is project-specific and covers legalities and that Customer requirements are addressed and who controls security and access



Oversees project security measures



Is reviewed by WorleyParsons Executive Project Management and the Customer



Ensures that correct Inductions and Orientations are conducted i.e.

• • • • 53

Permanent Construction Personnel Visitors Inducted but infrequent visits

Surveillance Visits

Protocols for Construction Site Visits

Dress Code 

Minimum PPE requirement

• • • • • • 

Hard hat Safety glasses Long trousers Long sleeve shirts High visibility vest or clothing

Additional PPE requirement

• • • • 54

Safety boots

Mono-goggles Gloves Hearing protection Fire retardant clothes

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

55

Health, Safety and Environment (HSE) Safety 

Safety is the Number One Concern of Construction work as it is conducted in high risk areas



Zero Harm applies to all projects



Promotion of safety culture

56

Health, Safety and Environment (HSE) Strategies for Promoting Safety 

Risk analysis

• • • 

Construction Risk Assessment

Job hazard Analysis (JHA)

Contractor selection

• • • •

57

Project Risk assessment

Based on proven safety commitment and performance Documented proof of a Company Health and Safety Program Development of a Project specific OHS&E Management Plan Conscious effort to avoid hazardous situations by planning and risk assessments

Health, Safety and Environment (HSE) Strategies for Promoting Safety, continued 

Other strategies

• • • • • • 

Safety in design Plans and preparation for emergency conditions

Periodic controlled audits on performance Quick and firm response if sub-standard performance found Recognition of safety performance and commitment Follow-up of OSH&E performance at contract close-out

Proactive involvement of key Construction Contractors

• Involve Contractors in regular on site HSE meetings 58

Health, Safety and Environment (HSE) Strategies for Promoting Safety, continued 

Training and Inductions of Contractor personnel



Site Safety policies and Procedures

• Develop a written safety policy of commitment to national and state safety laws and regulations

• Produce a comprehensive suite of safety procedures for use on site

• Ensure that adequate safety equipment is available

59

Health, Safety and Environment (HSE) Safety Communication 

60

Ensure a positive culture of relationships and communication by:

• • •

Early analysis of project scope to identify key risk areas

• • • • • • •

HSE incident reporting

Early involvement of key Construction Contractors Clear communication of safety approach, programs, roles and responsibilities Regular Job Start meetings Toolbox meetings Job Hazard Analysis (JHA), Safe Working Instructions Take 5 Continuous Improvement activities Site notice board

Health, Safety and Environment (HSE) Environment 

Project Environmental Plan

• All personnel are responsible for environmental observance and accountability 

Impact of unforeseen environmental problems

• Ensure contingencies are in the budget for unforseen problems

• Resolve issues expediently • Insurance concerns and project lenders liabilities • Adverse impact on community

61

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

62

Industrial Relations Industrial Relations Strategy 



What is the purpose of the Industrial Relations (IR) Strategy



To manage Industrial relations during Define and Execute phases to minimize time lost due to Industrial disputes



The Industrial Relations must be jointly managed by the Project and Construction Managers throughout the Project lifecycle

What are the requirements of the IR Plan

• • • 

To reflect our global requirements of managing IR That it be a sub-section of the PEP

Who is in the IR Team



63

Where there is a need to have one within a project area

The Customer, WorleyParsons IR specialist, Project Manager, Construction Manager and collective Construction Contractors

Industrial Relations Management of Construction Contractor Industrial Relations 

Jointly responsible for policies, procedures and principles contained in the IR approach with the Construction Manager



Workplace consultative committees

64

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

65

Risk Management – Construction Aligning with Corporate Zero Harm 

Risk Management Workshops

• Ensure that both Construction and Completions participate to capture activity risks 

Planning and review process

• The process to capture all activities so that they can be performed in a safe and timely manner

• All activities should be aligned with the OneWay to Zero Harm philosophy

66

Risk Management – Construction Construction Risk – Key Elements 

Maximize Customer satisfaction



Minimise risk

• Contractual/commercial exposures such as process and performance guarantees, warranties, liabilities

• • • • • • 67

Labor productivity risks for lump sum projects Supervisory quality

Staff availability, morale, competency, retention HSE & security Intellectual Property (IP) protection

Business ethics

Risk Management – Construction Risk/Hazard Control The hierarchy of control is the systematic strategy used to: 

Elimination



Substitution



Engineering



Administration



Personal protection equipment

68

Health, Safety and Environment (HSE) Mitigation Plans 

Continuous education and training in safety and safety awareness



Strict safety requirements and experienced safety supervision



Regular safety inspections and audits to verify compliance



Requirements of the Construction Safety Case



Requirements of Operational Safety Case



Permit to Work System (requires Permit Holders)

69

Health, Safety and Environment (HSE) Mitigation Plans, continued 

Excavation Procedure



Works executed under an approved Work Instruction



Construction HAZID Workshops and Risk Analysis Workshops



Customer presence for tie-ins and shutdowns.



Close interaction between construction and commissioning phases

70

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

71

Construction and Field Procurement Considerations for Construction Contracts 

Market conditions



Division of work



Project Schedule (and other KPIs)



Quality of scope definition



Customer staffing model for the project

72

Construction and Field Procurement Examples of Construction Contracts 

Lump sum



Reimbursable



Cost plus fixed fee



Unit rate



Mixed strategy



Day work



Incentive based

73

Construction and Field Procurement Interface between Construction and Procurement 

Key decisions and operational directions

• Construction Manager participates in key decision and operational directions including assisting in the compilation of SoW, Tender reviews and Construction Contractor selection 

Site requisitions

• These are primarily used where a service is not covered by a project office issued contract or purchase order 

Program for site purchasing

• The Project Procurement Management Procedure will confirm the limits set for site purchases

74

Construction and Field Procurement MARIAN 

Materials Management

• Inspection and expediting • Materials receipt, quality control and inspection, identification and resolution of deviations, item identity/tagging, and quarantine

• • • • • 75

Warehousing Issue control Material reconciliation Surplus identification

Storage, packing and preservation requirements

Construction and Field Procurement Managing Site Contracts 

The construction team administer the construction Contractors activities on site



Vendor representations

• Construction and Completions interface with Engineering office to establish vendor timing to site and arrange visit via Procurement ►

Contracts placed by the Customer • Encourage a Customer to relinquish control of the Contractor for the full duration of the Contract

76

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

77

Construction Control and Reporting Construction Progress Measurement and Control 

Construction progress against the budget and schedule



Contractor reporting of all contracts involving works at a construction site

78

Construction Control and Reporting Measurement Tools and Methodologies 

Construction KPIs

• • • • • • • ►

Meet project health and safety requirements Meet project schedule Meet project budget Meet project quality objectives Minimize environmental impact during construction Minimize inconvenience to local community and landowners Meets the Customers expectations

Construction Progress

• Progress is determined based on the measurement of physical quantity of work done 79

Construction Control and Reporting Measurement Tools and Methodologies, continued ►

Construction Forecasts

• Baseline schedule is used to monitor progress • Schedule critical paths is update weekly ►

Contractor Performance Measurement

• Earned hours by task are calculated by the actual progress achieved

• Performance against the budget is monitored comparing actual vs earned hours

80

Construction Control and Reporting Construction Reports 

Report Format

• 

81

Reports must follow format as agreed between the Project Manager and the Customer

Construction Site Reports

• • •

Safety Incidents, near misses and hazard identification



Numbers of personnel on site, broken down by Construction Contractor and construction work, supplier, material and equipment

• • •

Areas of concern

Progress, summary of activities, key deliveries at site Details about these reports are listed in the Progress Measurement Construction Guideline, PCP-0005

Contractual issues, variations, field instructions raised Other as agreed

Construction Control and Reporting Project Meeting 

Construction Project Meetings

• Construction Contractor progress meetings are convened weekly

• Shorter duration projects may require meetings twice a week • Project Manager should attempt to participate in progress meetings at least once per calendar month.

• Agenda • Minutes

82

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

83

Document Management Controlled Documents 

Specific constructability checklist



Construction Management Plan



HSE Management Plan



Environmental Management Plan



Drawings

84

Document Management Document Control Procedure for Construction Site 

Formal, documented procedure



Procedure covers receipt, issue, transmittal and recording of drawings, specification and other documents



Includes documents issued to or received from Contractors



Documents must be uniquely numbered and registered



Document Controller is responsible for document management and control

85

Document Management Document Review and Sign-off 

A document and drawing library must be maintained at the Construction site office

Document Control Registers 

86

Document Control Registers must be maintained for all drawings, documents and correspondence

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

87

Completions – Commissioning and turnover to the Customer

Completions 

Pre-commissioning is now referred to as Commissioning Stage 1

• Historically referred to as pre-commissioning 

Commissioning has four stages

• • • •

88

Commissioning Stage 1 — Mechanical Completion Commissioning Stage 2 — Function Testing Commissioning Stage 3 — System Commissioning Commissioning Stage 4 — Start-up and Ramp-up

Completions – Commissioning and turnover to the Customer

Completions 

89

Commissioning Stage 1 – Mechanical Completion

• • •

Features of this phase will include:

• • • • •

Includes device installation checks.

• •

Leak testing.

Single discipline activity. Static or un-energized checking of equipment and components to ensure specification compliance and correct installation. Calibration checks. Includes cable insulation and continuity checks. Includes motor rotation checks using rotation instruments Piping hydro-testing (usually completed in the fabrication yard) and flushing.

Bolt up and torqueing verification (usually in conjunction with QA Inspection).

Completions – Commissioning and turnover to the Customer

Completions, continued

90



Preparation of site teams for introduction of power and upcoming live plant testing.

• • • • • •

First fill lubrication of equipment Alignment checking Preservation and warehousing. Acceptance of Red line As Built Documents. Inspection, agreement of the Mechanical Completion Punch List. Entry of all punch list items into CMT.

Completions – Commissioning and turnover to the Customer

Completions, continued 

Commissioning Stage 2 – Function testing

• • • • •

91

Single discipline activity. Energized function testing.

Completions phase Permit to Work system is in place. Inspection and agreement of the Stage 2 Punch List. Entry of all punch list items into CMT.

Completions – Commissioning and turnover to the Customer

Completions, continued Customer Operations participation in these activities is now mandatory 

Commissioning Stage 3 – System commissioning

• • • •

Transformation from static checking to live testing Dynamic testing of complete systems and sub systems Completions and placing into service the utility systems. Confirmation that systems are ready to start up or accept product

• Inspection and agreement of the Stage 3 Punch List • A Pre-Start Safety Review (PSSR) • Entry of all punch list items into CMT. 92

Completions – Commissioning and turnover to the Customer

Completions, continued All work will be completed by system or area previously identified and included in the completions schedule 

Commissioning Stage 4 – Start-up and ramp-up

• • • • •

93

Introduction of product (or inert medium, followed by product) Start up and ramp up to operating operational status Inspection and agreement of the Stage 4 Punch List Entry of all punch list items into CMT Turnover of process systems

Completions – Commissioning and turnover to the Customer

Completions, continued 

Operation & Performance Testing



Interim Turnover to the Customer



Interim Facilities Turnover



Interim Facilities Turnover Features

94

Completions – Commissioning and turnover to the Customer

Completions, continued ►

Commissioning and Turnover Documentation

• • • • • • •

95

Facilities Turnover Meeting MOM Turnover Certificates Facilities Turnover Punch List

Commissioning Dossier Outstanding Works Plan Site Administration Records and Reports Deliverables as per Commissioning Execution Plan

Completions – Commissioning and turnover to the Customer

Completions Management Tool (CMT) 

Management of mechanical completion and function testing activities and interfaces between various stages



CMT selected during BOD and implement during FEED



Selection of CMT depends on size and complexity of project and Customer preference

96

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

97

Change Management Project Manager’s Responsibilities 

Approved procedures are in place and personnel are trained



Compliance to procedures



Construction Team are integrated into Management of Change process

98

Change Management Key Procedures 

Management of Project Change Procedure



Site Queries Procedure



Site Based Contract Administration Procedure

99

Agenda, continued 

Health, Safety and Environment (HSE)



Industrial Relations



Risk Management – Construction



Construction and Field Procurement



Construction Control and Reporting



Document Management



Completions – Commissioning and turnover to the Customer



Change Management



Summary and Feedback

100

Summary and Feedback 

Review Learning Objectives and Outcomes



Summary – review topics



Questions



Evaluation

101

Module 10 Managing Construction and Completions Thank you for your participation

102

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