Mechanical Completions
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The document outlines requirements and procedures for mechanical completion and handover of projects from construction to commissioning. It discusses establishing inspection and test records, punch lists, certificates, and documentation like as-built drawings and manuals. Responsibilities include contractors performing mechanical completion and pre-commissioning activities with oversight from the client. Systems are handed over in phases from contractors to the client and eventually to the operator once pre-commissioning and commissioning are complete.
Mechanical Completions
- 1. Completion Documentation Requirements For Projects Hook Up / Construction, Commissioning to Operations Handover PMT By Andy Lang
- 2. Completions Overview Completed Inspection and Test Records (ITRs). Marked-up As-Builts, Loop Diagrams etc. OWL and Punch List control including consolidation of both. Discipline Acceptance Certificates Manufacturing Record Books (MRBs). Mechanical Completions Systems Dossiers. Document Control System (via DCC in / out of the Project). Material Certification and Data Sheets Dossier Index and Reports Inspection Reports & Index Certificates & Index Final Handover / Asset Transfer Certificate Mechanical Completions Certificates Technical Queries, DCN’s, NCRs etc.
- 3. Completions Overview Construction Completions Groups:
- 4. Completions Overview In order to control Construction activities from a Completion point of view, wherever possible, each item shall have a Tag number assigned to it. To ensure correct installation and pre-commissioning of items of Equipment & Materials, Inspection and Test Records (ITRs) shall be assigned to them by disciplined Engineers. Tag numbers are grouped per their Commissioning System/Sub-System, progress can be measured by the completion of ITRs as they’re received and entered into the Mechanical Completions Database. Reporting on ITRs received has clear advantages from a safety view point as it ensures important inspections & tests are carried out.
- 5. Completions Principles The overall goal of Mechanical completion and commissioning is to verify that the system is designed and built to fulfil its purpose and specified requirements. Early establishment of commissioning packages is essential for an orderly and effective project completion. All fabrication and installation planning shall be system oriented. Mechanical completion, commissioning, FAT, Preservation and suppliers assistance requirements shall be specified in purchase orders. Overall Goal:
- 6. Completions Phases In this phase the following is carried out: Completion philosophy. Coding structure and system breakdown. Completion requirements to suppliers and contractors. Definition Phase: In this phase the following is carried out: Commissioning Package & MC Package definition. Assignment of Mechanical Completion Check Sheets (ITRs). Define commissioning network. Produce commissioning procedures. Engineering Phase: Equipment suppliers shall execute MC, FAT and commissioning and preservation as specified in the purchase order. The completion shall be documented as part of the completion system which leads up to handover to COMPANY. Suppliers Completion Phase : Contractor(s) shall perform MC, Pre-Commissioning and preservation as specified in purchase order/contract documents. The completion is documented as part of the completion system which leads up to handover to Client for Commissioning and Start-up. Construction / Assemble Phase:
- 7. Completions Responsibilities Responsibilities are Defined in the Contract . All Pre-commissioning activities are the responsibility of Contractor(s) with Client personnel. MC execution and registration/documentation, shall be performed by anyone who has a scope of work to be performed, such as equipment suppliers, fabrication contractors, installation contractor and hook-up contractors. Responsibilities: The Contractor(s) will be responsible for all activities associated with completing the Hook Up and construction of the facilities within the Scope of Work. The Contractor(s) shall make provisions for working under the supervision and conditions of Permit to Work Systems and other Project requirements. Hook-Up and EC: Turnover is defined as the sequence of events leading to transfer of custody of a System/subsystem from Contractor(s) to Client and Client to Operator. It is the demarcation between the construction / pre-commissioning phase and the commissioning/start-up operations. Once pre-commissioning activities have been completed per sub-system, formal turnover to Client shall be made for final commissioning and start-up operations. Facility Completion & Systems Turnover:
- 8. Completions Responsibilities This Presentation represents the basis for preparing plans, procedures and documentation for Mechanical Completion and Commissioning. The implementation of this Procedure requires the use of a coding system for item and system numbering. Common Requirements: Only “Pinnacle” Mechanical Completion documentation completed per test pack, item or equipment Tag number shall be held in the MC Dossier. Commissioning documentation shall be documented on a commissioning package level. Documentation: A Mechanical Completions Database is the system for the administration of Mechanical completion, pre-commissioning and Punch List Register. Mechanical Completion System: All MC activities shall be planned on fully integrated Fabrication, Mechanical Completion and Commissioning Schedules on a system prioritised basis in order to meet the optimal sequence of completion. Planning:
- 9. Mechanical Completion Mechanical completion shall take place through all phases of the project, starting at equipment supplier and continuing through fabrication up to the commissioning phase. Mechanical completion encompasses all disciplines. Detailed responsibilities are described in the contract. Contractor(s) shall be responsible for establishing and compiling the MC dossiers and report status into the computer based Completions System. Introduction: The MC package shall include MC Certificate's, a MC Status Index and a Punch List Register printout as described below. Mechanical Completion shall be notified on a MC Certificate (MCC) which shall be completed by the Contractor(s) and verified and endorsed by Client after all MC has been carried out. A MC Certificate shall be raised for each MC package. A MC package shall, when signed, be ready for start of pre-commissioning activities. These shall be stored in its respective discipline in the MC Dossier section. Documentation for a MC Package : The Inspection and Test Records (ITRs) shall be completed by the Contractor(s) to record the results of all checks, inspections and tests carried out for each individual item. An Outstanding Work List (OWL) should be prepared by Contractor(s) for its own internal control of outstanding work items and be available to the Client.
- 10. Mechanical Completion A MC Punch List shall be prepared by Client and issued to Contractor(s) nearing the MC stage. In each MC package a printout from the Punch List Register shall be included to document the incomplete work. A MC Status Index listing the status of all ITRs for the completed MC package shall be included in the front of each MC dossier. Once all ITRs have been received for a MC System Dossier(s) a Preliminary Handover Certificate (Mechanical Completion) shall also be stored in the front of the MC Dossier. Pre-Commissioning activities may start. Once OWL and Punch items are reduced for a particular sub-system, a joint walk around (Client/Contractor) shall be carried out, and any new items recorded. Both lists should then be consolidated into a single ‘Consolidated Punch List’ which, supersedes all previous lists to focus attention on remaining items. Once pre-commissioning activities have been completed for a particular MC system by Contractor and Client, a Provisional Handover Certificate (Pre-Commissioning Complete/Ready for Commissioning) shall be raised. This shall be considered the handover from Contractor to Client Commissioning Team. This certificate shall also be stored in the front of the MC Dossier. On completion of Commissioning an Interim Handover Certificate (Commissioning Complete/Ready for Start-Up) shall be added to the front of the Dossier to finalise the Dossier. Handover at Mechanical Completion :
- 11. OWLs & Punch Item Categories Civil Construction Commissioning Electrical Engineering Instrumentation High Voltage Piping Refractory Insulation Mechanical Coatings Quality Safety Vendor Telecomms Steel Structure
- 12. Carry Over Work Register The Carry Over Work Register (COWR), when necessary, lists all punch items that the Project accepts as cannot be completed during present phase. The COWR is used for the release of the work from the EC and will as such be an input to the scheduling and planning of outstanding work to be performed during later phases. The COWR Item Number and cross reference to the Punch List Register/Check Records shall be given. COWR work shall be marked up on drawings or sketches and be included in the records. COWR Material Status List (MSL) and marked up drawings/instructions shall contain sufficient information for job setting in a later phase.
- 13. OWLs & Punch Item Categories A database to print more specific reports according to individual Contract Holders, Engineers or Supervisors requirements can include: By Discipline and Phase, Area or System By Phase /Area By Sub-System By Discipline Total remaining OWL and Punch Item Statistics Total items remaining
- 14. Certificate Control A summary report of all certificates for a given System / Sub-system could also provide information on the following topics required to complete a sub-system dossier: ‘ System Limit P & ID’ Diagrams ‘ Marked-up As-Built’ Drawings (red lined) ‘ Instrumentation Loop Diagrams’ ‘ Technical Queries’, ‘Site Queries’, Design Change Notice’ etc. ‘ Corrective Action Request’, ‘Non-Conformance Reports’, ‘OS&D’ etc. The above records act as a guide for the system administrators that this information needs to be investigated and included in final completions dossiers.
- 15. Certificate Control To enable a controlled and safe plant start-up, the Certification system follows the following sequence per individual Commissioning system / sub system. Mechanical Completion/Ready for Pre-Commissioning Pre-Commissioning Completion/Ready for Commissioning Commissioning Completion/Ready for Start-Up Final Handover (Performance Completion) Discipline Acceptance Certificates
- 16. Progress Reports The most commonly used reports are: Project Certification and Punch List Statistics Certification Progress by Phase, Area, System and Sub-System Progress by construction category per Area and Sub-System All system reports need to be based on Quality Control Inspection Reports received. These reports are required to prove the integrity of a Plant based on Quality and Safety.
- 17. Completion Structure Hook Up & Pre-Comm Mechanical Completion Execution Preservation Commissioning Operations By: Andy Lang Email: ralang1@hotmail.com Sub System Sub System Sub System Sub System MC Dossiers System System System System Mech Elec Inst Piping Handover Certs (Ready for Pre-Commissioning) ITRs Punchlists Equipment Tag Index As-Builts (Red Line Marked up) & Index Management of Change – SQ, TQ, DCN, CR Equipment Preservation Certification Sub System Sub System Sub System Sub System MC Dossiers System System System System Mech Elec Inst Piping Handover Certs (Ready for Commissioning) ITRs Punchlists Equipment Tag Index As-Builts (Red Line Marked up) & Index Management of Change – SQ, TQ, DCN, CR Equipment Preservation Certification Sub System Sub System Sub System Sub System MC Dossiers System System System System Mech Elec Inst Piping Handover Certs (Ready for Start-Up) ITRs Punchlists Equipment Tag Index As-Builts (Red Line Marked up) & Index Management of Change – SQ, TQ, DCN, CR Equipment Preservation Certification