Copyright 2011 ISA.
All Rights Reserved
I & PCS Pre-Commissioning
Roadmap
By: Muhammad Al-Khalifah
Standards
Saudi ARAMCO
Certification
Education & Training
Publishing
Conferences & Exhibits
Distributed with permission of author by ISA 2011 Presented at ISA Automation Week 2011; http://www.isa.org
Copyright 2011 ISA. All Rights Reserved
Objective
• Deliver a roadmap for the planning and execution of
instrumentation and process control system pre-
commissioning to:
– Minimize inefficiency in such complex process
– Avoid startup and commissioning delay
– Quality Control / Quality Assurance
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Copyright 2011 ISA. All Rights Reserved
Some Facts
• Instrumentation and process
control system scope is
significant and complex.
• The last peace of the puzzle
following civil, piping and other
disciplines.
• Project schedule float often
consumed in the early stages,
leading to reduced
instrumentation and PCS pre-
commissioning schedule.
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Copyright 2011 ISA. All Rights Reserved
Outline
• I&PCS pre-commissioning Roadmap
• Team Structure & Responsibilities
• Loop package & documentation
• Loop check & functional test
• Optimization strategy
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Copyright 2011 ISA. All Rights Reserved
Pre-Commissioning RoadMap
Mechanical Completion
Construction
Team Matrix
Testing Strategy
Loop packages
Loop check
Functional testing
Commissioning & Startup
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Team Responsibility
Operation
Project
Engineering
LSTK
Inspection
Maintenance
Contractor
Management
Planning,
Loop
Witnessing
Installation
Quality
Loopcheck &loop
Assurance
scheduling
check performance
configuration
&&Control
Loop
Looppackage
Front acceptance
coordination.
end check
Configuration
Installation & sign off
& verification
configuration
Pre-Loop
Progress
Installation
Functional
verification reporting
checkinspection
test &&sign
readiness
records
off.
Functional
Pre-commissioning
Pinch test &test
Red mark readiness
teamreview
documents
Calibration leader
Red
Exception
mark and
certificate
Performance itemsexception
clearanceitems
acceptance
logProject
and control.
closeout
Quality control and Assurance
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Copyright 2011 ISA. All Rights Reserved
Team Structure
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Copyright 2011 ISA. All Rights Reserved
Loop Package Generation
• Loop package preparation starts as soon as PCS FAT
completed
• It is typically started on or around end of SAT
• Folder contents are database and construction drawings
• Loop folder generation is the key activity that lead to loop
check commencement
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Loop Package & Documentation
• Typical Loop folder consist of:
– Folder Test/Cover Sheet
– Installation Inspection Records (IIR)
– Exception Items List
– Calibration Certificate.
– Instrument Specification Sheet
– ILD
– P&ID
– Cable Megger Test
– Loop Check Sheet
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Copyright 2011 ISA. All Rights Reserved
Installation Inspection Record
• List all the required inspection, testing and
documentations per instrument loop
• Assuring that instrument loop is mechanically completed
and ready for loop checking
• Most Important content in the loop package, and
consume most of the pre-commissioning time.
• Must be completed before releasing to loop checking
• Must be signed by all involved pre-commissioning
parities (Maintenance, inspection, contractor and PMT)
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Installation Inspection Record
TEST ACCEPTANCE CRITERIA PASS FAIL DATE
Calibration &Testing Certificates
A.1 Validate instrument range against calibration certificate and specification
sheet
Contractor shall maintain, control, adjust and calibrate all tools, gauges
A.2
and other measuring and testing devices used for controlling quality
PCS Factory Acceptance Test (FAT) and Site Acceptance Test (SAT)
A.3
Certificate
Inspection & Instalation Records
B.1 Support installation, instrument mounting, pressure testing, tagging and
identification as per installation drawings.
Impulse tube , pneumatic line & line support in accordance to hook up
B.2
drawings
Check instrument location and accessibility per construction drawing
B.3
Electrical installation, termination, megger testing core and cable tagging
Documentation Review
C. 1 Checking Loop folder content which consist of P&IDs, ILDs,
Specification, punch list item, loop check sheet,
Pre – Loop Check
D. 1 Conducted by contractor to assure instrument loop mechanical and
functional readiness before releasing loop for final check by OME team.
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Other Reference Documents
• P&ID
• ESD logic diagrams
• Cause & Effect
• Wiring diagrams
• Motor Control Circuit
• Layout drawings
• One line diagrams
• Process control narrative documents
• System manual
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LOOP CHECK
• Performed/Witnessed by
Maintenance & Operations and
supported by Engineering
• Loop check includes:
– Wiring integrity check in field and at
control system
– ILD verification vs installation
including control system information
– Analog inputs & outputs 3-point
check, 0%, 50%, 100%; or more if
needed
– Switch & button contact check
– Verify alarms, set points, limits, PCS
graphic
– Outline exception items & loop folder
sign off.
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Engineering Final Cehck
• Pre-commissioning Engineer shall verify the following
– Loop passed testing and is signed by Operations and
Maintenance
– Verify History, Sequence Of Events (SOE) and other applications
as required
– Redlining of associated drawings is completed
– All exception items are closed
– All red marks are transferred to master drawings
– Engineer signs Loop Folder
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Functional Test
• Performed by Contractor/Engineering and Operations supported by
Maintenance
• All loops associated with function test are completed
• Function Test Folder complete and ready
• Folder Contents
– Function Test List
– Control Narratives (if applicable)
– P&IDs, with associated loops marked as passed loop check
– ESD Block Diagrams (if applicable)
– Logic Diagrams (if applicable)
– Cause and Effect (if applicable)
– Function Test Procedure as applicable
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Functional Test FlowChart
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Optimization Strategy
• Communicate clear division of
responsibilities in pre-commissioning
• Review and obtain buy-in from the team
about the pre-commissioning approach
implemented
• Think “Loop System” not instrument
system
– Prepare loop list
– Assess progress based on loops
ready/completed
• Optimize exception item handling to fit
team needs
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Optimization Strategy
• Overlap function test activity with loop check
• Overlap non-loop check with loop tests
• Set target production from each group of the team
• Introduce more than one fix team and divide
responsibilities properly
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