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
Ipedex Commissioning
Integrated Services
IPCIS
ExperienceProvision of commissioning
services worldwide since 1970
Extensive Reference List
MethodologyCommissioning methodology
based on OPERCOM
Ipedex licensed by TFE
ManpowerExperienced Project Managers, Site Leaders, Superintendents,
Engineers, Technicians and support personnel
SoftwareIPCIS 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
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
Phase Activities Milestone
Pre-commissioning Conformity checksStatic testsHydrotestsFlushing & cleaning
Ready for Commissioning(Mechanical Completion)
Commissioning EnergisationDynamic testsEquipment running-inUtilities start-upPre-start-up activitiesOperational tests
Ready for Start-up
Start-up Feed inPerformance testsBringing the plant on-line
Provisional AcceptancePlant in Operation
IPCIS Methodology – Phasing of Activities
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PERFORMANCETESTS
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IPCIS Methodology – The System Hierarchy
Location
System 1 System 2 System n
Subsys 1 Subsys 2 Subsys n
Discipline Discipline Discipline
Item 1 Item 2 Item n
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
IPCIS Methodology – The System Approach
SYSTEM APPROACH=
TIME SAVING
Start-up
Commissioning
Pre-commissioning
Pre-commissioning
Commissioning
Start-up
USING SYSTEM APPROACH
WITHOUT SYSTEM APPROACH
Mechanicalcompletion
Ready forstart-up
Provisionalacceptance
TimeSY
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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 passwordsLevels of access and authority are defined for each userThroughout the commissioning, users are recorded when
• Test sheets and certificates are signed
• Punchlists are set and clearedThis ensures integrity of the commissioning documentation and allows auditing of the activitiesMultiple users may operate the software simultaneously using a network of PC’s
IPCIS Software – Preparing for Commissioning – Database
Data can be entered using a variety of methods:• Import from spreadsheets• Manual data entry• Selection of data from AutoCAD P&ID’s
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
IPCIS Software – Preparing for Commissioning – Dossiers
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
Use the Publishing Module to:• View and edit the contents of the Pre-
Commissioning 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
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 pre-commissioning 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
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
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 Pre-
Commissioning and Commissioning Dossiers
• Include other documents into the dossiers as required through the commissioning activities
• Print out individual sheets, sections or the complete dossier
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