INTRODUCTION

Completions and Start-up is a complex, progressive and phased process which requires early detailed definition and planning in order to facilitate efficient and seamless project execution and control.  This in turn allows for timely client approvals and final acceptance, thus enabling early project technical and commercial close out, and thereby minimising the risk of contractual penalties.

The Unasys business function is to identify and manage such complexities in order to optimise project turnover, handover and close out.  Unasys provides integration of Completions using the expertise of specialist managers and engineers, together with an effective software.

This unique combination enables projects to deliver structured Certification Management, which enables documentation packages to be delivered concurrent with completion of the physical works. The waiting period for final documentation, a common feature of so many projects, is eliminated.

This proposal will show how Unasys can assist DMC to deliver structured completions in accordance with approved procedures and plans.  The intent is to safely deliver facilities that will be in a state of readiness for operation.  It also puts forward the case for using an electronic completions system (ePM) to support this operation.

STRATEGY

The aim of Unasys working together with DMC, is to manage completions to facilitate the smooth transition of the project scope of work, through Construction and Completions culminating in the handover of the facilities as one, to the client.

The objective is to generate and manage completions activities, for all sub contractors and suppliers in order to achieve seamless handover of the project as a whole.

This will include the requirements for certification and documentation.

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TO DO THIS, WE

1) Develop and manage the scope of work for project certification and documentation throughout the project life cycle - engineering to start-up; for all sub-contractors and suppliers

2) Provide site support

3) Provide our proprietary software

COMPLEXITY MADE SIMPLE

Better life cycle management of project information leads to time and cost savings, enhanced productivity and safer more efficient project execution and start-up. This demands that for all projects one should ‘begin with the end in mind’. Unasys are raising the standard for Completions and e-PM is the unique result of deploying this approach in an integrated solution with standardised models firmly founded on best practice.

THE PROCESS - Systems completions

Whatever the project type, all of the equipment, whether static or dynamic, is generally encapsulated within a specific ‘System’. How we manage that Equipment from Engineering to Operation we refer to as Life Cycle Management. How we control Life Cycle Management we refer to as Systems Completions Management. There are a series of very specific levels or gates to be passed which require actions and tests to be carried out and supported by certification and documentation. These gates are categorised by phase and the progress of each phase shall be constantly monitored and reported in detail, providing for thorough feedback and close control of all project activities. Life Cycle Management is defined as the sequential activities within a project that verify and prove that the construction, installation, integration and testing of systems, including all of their component parts, have been completed properly and thus the facility is ready for start-up and operation. The Systems Completions process is designed to help manage the transfer of care, custody, and control of facilities through appropriate certification and documentation. Systems Completions Management is defined as the sequential activities, the management team must undertake to ensure a seamless process.

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SYSTEMS COMPLETIONS MANAGEMENT

The potential for failure increases significantly if the project team does not start defining early for systems completion. This means that the project team must develop a Systems Completions Execution Plan that is updated as the project progresses. The best approach is for the project management team to decide how the facility will be started up and handed over and then develop performance testing and acceptance criteria for the facility. Establishment of this information will provide the data required by the project to determine how the facility should be constructed and tested for a safe and smooth start up. This information will form the core of the contract work scope. As we have said earlier, Systems Completions is subdivided into ten project phases. Each phase will have a corresponding Management Level as shown on the Overview of Project Phases chart below and the accompanying index. Each Management Level, ie Contract / Brief, will have a series of actions. The actions are as detailed below.

Contract / Brief

  • System Completions Management

  • e-PM

  • Definitions

Cost / Procurement

  • Man hours / Rates

  • Vendor Co-ordination

  • Completions Strategy

  • Execution Plan

Quality and Scope

  • Preservation

  • Certification

  • Change Control

  • Inspection and Test Plan

  • TQ and Punch list

Strategic Planning

  • Weightings

  • Start Up plan

  • Regulatory Requirements

  • Man hours / Resources

  • Responsibility Matrix

  • Vendor Schedule / Call out

  • Hook Up and Commissioning

Health & Safety

  • Hazop

  • RAMs Risk Assessment and method statements

  • Identify SCE

  • Permit to work

  • Temporaries

  • Manage PSVs

  • Manage ATEX

  • Resources

Relationships and Reporting

  • Relationships

  • Reports

  • TOPs

  • KPis

  • Turnover

  • Progress Management

  • Construction Co-ordination

  • Schedule

Resources

  • Consumables

  • Labour

  • Vendor Co-ordination (SITE)

  • OPS Integration

Performance

  • Acceptance Criteria

  • System Performance

  • Performance Testing

Acceptance

  • Cause and Effects

  • Punch lists

  • TQs

  • Acceptance Testing

Handover

  • Black Start Operational Readiness

  • Operational Compliance

  • Warranties

  • Interface CMS / SAP

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LIFE CYCLE MANAGEMENT - Systems & Equipment

Life Cycle Management identifies two main phases — Definition and Execution. Definition begins in FEED and comprises evaluation/planning through the beginning of fabrication/construction. The Execution Phase starts with Factory Acceptance Testing (FATs) and ends with stable operation and acceptance of the facility by Operations. Systems completion definition and execution activities overlap at detailed engineering and procurement and fabrication/construction. Life Cycle Management, like Systems Completions Management, will have the distinct levels that match each project phase. Each level is sub-divided into a series of actions; and each level will be validated, through offer and acceptance.

HOW WE DELIVER YOUR PROJECT ON TIME…

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Tag & Data Intelligence

  • Tag Information

  • Tag equipment identified

  • Systems / Subsystems

  • Areas / Construction Areas

  • Attributes

  • Spec complete

  • Data sheet complete

  • Relationships / Mapping

  • Maturity

  • QR Codes

  • AFD – Data good to share

Supplier Data

  • Enquiry issued

  • Bid documents received

  • Review supplier data

  • Supplier data approved

  • Quality plan

  • Engineering design data complete – AFC

  • PO issued

Inspect and Test

  • Inspection and Test Plan

  • Vendor data agreed and in e-PM

  • Assembly procedures

  • Operational spares

  • Commissioning spares

  • Factory acceptance test

  • Inspection release note

Preservation

  • Packing list / manifest

  • Storage assigned

  • Call out schedule

Fabricate & Assemble

  • Shop fabrication

  • Equipment installed

  • Equipment assembled

  • Inspections complete (internal)

  • Vendor punch list closed

  • Hydrotest

  • NDT

Mechanical Completion

  • DAC (Certification)

  • Calibration / PSVs

  • Mechanical Completion Certificate

  • (Certification)

  • ATEX compliant

  • Line walk / inspection (Turnover)

  • Punch list

  • MC-1 (Turnover)

Pre-commissioning

  • Temporaries

  • Pre-commissioning certificate

  • Consents and approvals

  • PC-1

Commissioning

  • HC-1 (Certification)

  • Prerequisites (Safety)

  • SCE / System Performance (Testing)

  • Risk (Safety)

  • Isolations (Safety)

  • Training

  • Site Acceptance Testing (Testing)

  • System Commissioning (Testing)

  • Tech Queries Closed

  • As Built

  • Test Preparation (Testing)

Performance Testing

  • Start up and readiness review

  • Black start

  • Acceptance criteria

  • Cause and effects

Readiness

  • Warranties

  • Spares

  • Deficiencies

  • Operational interface / compliant

  • Interface with SAP

About EPM

e-PM is an integrated solution that enables engineers and management to share a consistent basis of completions, pre-commissioning, hook-up, commissioning, start-up and equipment information, whilst providing up-to-the-minute progress status throughout the lifecycle of the project.

The e-PM certification management system operates with the project lifecycle in the following stages:

Definition

  • Collate source data from client, suppliers and other 3rd parties

  • Intelligently extract relevant information from a variety of source document formats

  • Electronically batch import selected data required to speed up project population

  • Establish flexible project certification options from the suite of client, vendor & Unasys certificates

  • Assign certification and documentation activities to parties creating local scope of work

  • Generate Completions & Start-up schedule

Execution

  • Make available certificates and documentation electronically or generate barcoded hard copy certificates

  • Accept completed hard copy certificates and documentation into the system via automated scanning process and links to the clients document control system

  • Provide a comprehensive punch list management tool compatible with electronic barcode tagging

  • Point in time reporting suite with custom reporting options for specific need

  • Ability to review and revise scope where engineering changes dictate

  • Progress management

    e-PM is a versatile and configurable application capable of supporting large scale data sets with large numbers of tagged items.

How information is secured and electronically backed up

Information is primarily secured within e-PM by limiting uncontrolled changes, confining access to the project data to only those users who need it, while at the same time making data available to all project staff in a read only manner.

Electronic change control and versioning are at the centre of the process for securing data reinforced by a full audit log.

The e-PM data load process accepts project data from a variety of sources and is able to quickly secure data into the system. Data is tagged with its source document details for reference and logged in the audit history.

Unasys and the e-PM software ensure both the quality and security of the project data by following recommended industry best practices for data storage and access control. Populating e-PM with project data is achieved via several unique and time saving technologies developed by Unasys.

PROJECTS

OFFSHORE - OFFSHORE WIND - WASTE TO ENERGY - PHARMACEUTICAL - GAS STORAGE - PETROCHEMICAL - DECOMMISSIONING - BROWN FIELD - NEW BUILD