Module 10 - Managing Construction and Completions PowerPoint Presentation_Rev1
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Description
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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