Preparation Activities To Set Up Commissioning Gathering .

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Commissioning & Start Up WorkshopDay 1PreparationActivities to set up CommissioningGathering informationSelecting the Commissioning TeamJustifying the ScheduleCreating Documentation Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopCommissioning ManagerLearning ObjectiveBy completing this module, you should understandthe attributes of a Commissioning Manager, whenhe / she should be engaged, be able to describetheir duties and responsibilities and define the typeof chart used for this purpose. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationCommissioning ManagerKey Attributes:Highly skilled in Interface ManagementHave intimate knowledge of the Plant / FacilityKnow how each System will operate and be controlledRole model to the Commissioning TeamEstablish good relations with Safety and Operations Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationCommissioning Manager – responsibilitiesFor the scope in the Completions Pyramid:Pre-Commissioning, Dynamic Commissioning, Startupalso, Normal Shutdown and Emergency ShutdownJustifying, hiring, training and leading the CommissioningTeam until Final Handover to Operations Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationCommissioning Team – responsibilitiesEngage Stakeholders, define and make clear requirements forpeople, materials, equipment, access;Participate in, and where needed, lead;Systemization, Design reviews, HAZOP Studies, Management ofChange (MOC), Pre Start Up Safety Reviews (PSSR), FactoryAcceptance Testing (FAT);Gap Analysis of systems, procedures and pertinent documentation;Production of procedures from the Gap Analysis;Evaluation and selection of the Systems Completions Database;Justifying the Handover program with Operations; Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationType of Commissioning Manager by Engagement Depending on the scope, the Commissioning Managercan be provided by Client or the Contractor; The Commissioning Manager representing eitherorganization may operate as staff or consultant; For the Commissioning Manager engaged on a staffbasis there will be different issues and concerns than ifengaged as a consultant; Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationType of Commissioning Manager by Engagement Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationType of Commissioning Manager by EngagementThere are advantages and disadvantages to whichorganization supplies the Commissioning Manager, and staffor consultant basis. The recommendation is: Staff Commissioning Manager Consultant Deputy Manager / Lead Engineer Split Commissioning Team between Client andContractor Teams as Completions Pyramid (slide 47) Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationThe Elephant in the RoomThe most effective single action any project can take is: Engage a Construction Manager with CSU experience Someone who was good at it! Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Problem withMechanical CompletionAs currently defined Falcon Global Ltd. 2000 - 2019

Falcon Global Ltd. 2000 - 2019

Falcon Global Ltd. 2000 - 2019

Falcon Global Ltd. 2000 - 2019

Falcon Global Ltd. 2000 - 2019

The Problem withMechanical CompletionThe Problem withMechanical CompletionAs currently defined Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationThe Problem with Mechanical Completion Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationThe Problem with Mechanical Completion Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationThe Problem with Mechanical Completion Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationThe Problem with Mechanical Completion Falcon Global Ltd. 2000 - 2019

The Problem withMechanical CompletionThe Problem withMechanical CompletionAs currently defined Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Problem withMechanical Completion Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Problem withMechanical Completion Falcon Global Ltd. 2000 - 2019

The Problem withMechanical CompletionThe Problem withMechanical Completion Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Problem withMechanical Completion Falcon Global Ltd. 2000 - 2019

The Problem withMechanical Completion Falcon Global Ltd. 2000 - 2019

Commissioning & Start Upwith API RP 1 FSCThe Solution –RedefineMechanical CompletionTo Something UsefulRaise the Bar Falcon Global Ltd. 2000 - 2019

Handover AssuranceSystems Completion Execution ProcessDocumentsStepsSystems Completion OverviewFactoryAcceptanceTestingVerification pletefunction testingFinalCommissioningactivities Pre-startup-safety reviewCommenceoperations andfinal performancetestInspection andtesting recordsand FactoryAcceptanceRecords“A” Checksheets/MechanicalCompletioncertificates andcompletion of “A”Punch List Items“B” Checksheets/completed functiontest/ready forcommissioningcertificate“C” Checksheets /ready- for-start-upcertificate signedSCPs completedand completion of“B” Punch ListItemsSystemsacceptancecertificate systemfoldersAPI RP 1FSC Recommended Practice for Facilities Systems Completion Planning and Execution, 1st Edition –Courtesy of API Falcon Global Ltd. 2000 - 2019

Current RealityContractor-Operator Commissioning TeamsPre-Commissioning toStart-Up by OperatorMechanical Completionby Contractor Falcon Global Ltd. 2000 - 2019

Raise the Bar 1Contractor-Operator Commissioning TeamsNote, only suitable for more capable Operators working with more technically advanced EPCs Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationContractor Scope to Pre-Commissioning All E ITRs & V ITRs through FAT Any outstanding PLIs from FATs A ITRs through Mechanical Completion and Cat A PLIs Discipline, Sub System and System MC Certificates B ITRs through Pre-Commissioning and Cat B PLIs Ready for Commissioning Certificate (RFCC) C ITRs, aka OTPs, aka Commissioning Procedures andCat C PLIs Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationContractor Assistance through Commissioning C ITRs, aka OTPs, aka Commissioning Procedures Leak Testing Chemical Cleaning Mechanical Cleaning Shutdown Tests Falcon Global Ltd. 2000 - 2019

Raise the Bar 2Contractor-Operator Commissioning TeamsStart-Up by OperatorTeamCommissioning byContractor TeamNote, only suitable for more capable Operators working with more technically advanced EPCs Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationContractor Assistance through Commissioning Decide scope and demarcation early on Include in Contractor scope, if assistance is required Know battery limits and activities Develop RACI Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationType of Commissioning Manager by Engagement Falcon Global Ltd. 2000 - 2019

Help is at HandAPI RP 1 FSCFirst Edition, July 2013Facilities Systems Completion, Planning & Execution Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationAPI RP 1FSC, 1st Edition – Courtesy of API Falcon Global Ltd. 2000 - 2019

API RP 1 FSCDeals well with Time, Money, People, Action Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopScope Definition and Contract RequirementsCertifying Authority & Regulatory RequirementsLearning ObjectiveAfter this module, you should be able to show anunderstanding of the Project's certification structureand its relationship with the regulatory framework. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationCertification Process to Final Acceptance Verify that the EPC Contract Exhibits accurately trackprogressive completion to Final Acceptance Record progressive certification on the CompletionsPyramid for the project Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationCertifying Authority and Regulatory Requirements Verify that all Witness Points, Hold Points and anyparticular requirement are identified Verify the means of tracking regulatory and certificationissues Assign people to interface with the Certifying /Regulatory Authority if none exist in the project team Establish Witness and Hold Points pertinent toCommissioning and Start Up. Cultivate a first-class relationship with external agentsfrom the Certifying / Regulatory Authority Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopTurnover API RP 1FSC, Annex A and Handover to FinalAcceptance / Develop Completions PyramidLearning ObjectiveAt the conclusion of this module you will showunderstanding of the contents of API RP 1FSC,create a visual representation of the SystemsCompletion process, produce the structure of aTurnover Completion Package and be able todemonstrate the need for agreement withOperations to determine Handover requirements. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationHandover / Turnover Procedures The work flows, procedures and documentation tosupport the process is known as the TurnoverCompletion Package, (TCP) All major Operating companies will have their ownversion of TCPs and the way in which Transfer of Care,Custody and Control (TCCC) is achieved Handover(s) to Operations are managed through theTCCC process Annex A of API RP 1 FSC contains a sample Turnover andCompletion Package Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationHandover / Turnover ProceduresAPI RP 1FSC, 1st Edition, Annex A – Courtesy of API Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationHandover / Turnover ProceduresAPI RP 1FSC, 1st Edition, Annex A – Courtesy of API Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationCreate the Completions Pyramid Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopDesign Reviews, HAZOP, Risk AnalysisMake Lessons Learned become Best PracticesLearning ObjectiveAfter this module, you will be able to demonstrateknowledge of when Design Reviews are carried out,by whom, when and why, articulate the need forCommissioning to actively participate in HAZOPStudies, explain how to conduct a "Lessons Learned"program and describe how to create Best Practices. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationDesign Reviews, HAZOP and Risk Analysis -1At key stages during FEED and Detailed Design, a number ofdesign reviews will be carried out. These will include:o Layout and 3-D model reviewso P&ID / Process Flow Diagram (PFD) reviewso Piping Isometrics reviewso Risk Assessments and Hazard & Operability (HAZOP) Studies Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationDesign Reviews, HAZOP and Risk Analysis - 2 Design reviews are an essential part of the process ofgood engineering design and project management The value to the project is that issues identified duringthe design phase will be many times less costly to rectifythan when discovered during Construction Cost ratios may be in the order of 1:1000 1 of design may cost more than 1,000 in the field With serious implications to the project schedule Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationDesign Reviews, HAZOP and Risk Analysis - 3 As defined by Wikipedia, “A hazard and operability study (HAZOP) is astructured and systematic examination of a planned or existing process oroperation in order to identify and evaluate problems that may represent risks topersonnel or equipment, or prevent efficient operation. The HAZOP technique was initially developed to analyze chemical process systems,but has later been extended to other types of systems and also to complexoperations such as nuclear power plant operation and to use software to recordthe deviation and consequence. A HAZOP is a qualitative technique based on guide-words and is carried out by amulti-disciplinary team (HAZOP team) during a set of meetings.” Refer to British Standard BS IEC 61882:2001 - Hazard and OperabilityStudies (HAZOP studies) Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationDesign Reviews, HAZOP and Risk Analysis - 4Outline of Methodology The method applies to processes (existing or planned) for which designinformation is available. This commonly includes a PFD, which is examined insmall sections, such as individual items of equipment or connecting pipework.For each of these a design Intention is specified. For example, in a chemical plant, a pipe may have the intention to transport 2.3kg/s of 96% sulfuric acid at 20 C at a pressure of 2 bar from a pump to a heatexchanger. The intention of the heat exchanger may be to heat 2.3 kg/s of 96%sulfuric acid from 20 C to 80 C. The HAZOP team then determines whatare the possible significant Deviations from each intention, feasible Causes andlikely Consequences. Then decide whether existing, designed safeguards are sufficient, or whetheradditional actions are needed to reduce risk to an acceptable level. Specialist software is used for documenting and recording outcomes fromHAZOP meetings. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationDesign Reviews, HAZOP and Risk Analysis - 5For guidance on how to perform Hazop Studies, refer to the embedded file. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationDesign Reviews, HAZOP and Risk Analysis - 6 All major Operating companies have their own version of performing Hazard &Operability (HAZOP) Studies. Examples from Chevron and Shell are shown on the next 2 slides Chevron – Hazard Identification (HAZID) Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationDesign Reviews, HAZOP and Risk Analysis - 7Shell – Flawless Start Up Initiative (FSI) Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationRisk Analysis / Assessment - 1 Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationRisk Analysis / Assessment - 2Lessons LearnedBest PracticesTwo Sides of the Same Coin API RP 1 FSC is a good example Lessons Learned, over many years from many projects, assessed bySMEs from major Operators to form a Best Practice. API RP 1 FSC does not talk about the way projects have beencompleted or are being completed, but about the way projectsshould be completed. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 1 Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 2Step 1 - Create a Safe Environment Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 3By three methods we may learn wisdom:First, by reflection, which is noblest;Second, by imitation, which is easiest; andThird by experience, which is bitterest.ConfuciusStep 2 - Allow Time for Reflection Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 4Step 3 – Begin to Gather Ideas Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 5Step 4 - Ask Some Questions Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 6Why, exactly is this important?As an engineer, technician, operator or manager, youmust get out on the job and walk around, eyes open,sensors on full alert and actively consider on-the-jobbehaviors.Be prepared to question what is happening and why.From BP Macondo, be prepared to Stop Work if youbelieve the situation warrants this action. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 7 Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 8Steve Rae, Piper Alpha survivor: I refer to these as my six Cs: CommitmentChange managementControl of workCompetenceComplacencyCommunicationNote, no mention of ALARP, Golden rules hazard management etc.The 6 Cs are far more fundamental than other elements used tosupport HSE activities across industry.The following slide reveals whatyou may see when these Cs are overlooked within your organisationor at your worksites. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationMake Lessons Learned become Best Practices - 9Why, exactly is this important?Refer to the embedded file from Professor AndrewHopkins of Australian National University reportingon a senior management visit to Deepwater Horizonjust hours before the BP Macondo well startedflowing disastrously out of control. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Commissioning PlanJustifying a Budget, Allowing for GrowthLearning Objectives 1By completing this module you will showunderstanding of the contents of API RP 1FSC, withrespect to the need for planning, reproduce thestructure of a typical Commissioning Plan, restatethe activities to evaluate & select a SCDB Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Commissioning PlanJustifying a Budget, Allowing for GrowthLearning Objectives 2You will be able to explain when a Commissioningbudget should be created and state budgetaryparameters in terms of project size and identifyfactors affecting performance.You will also be able to demonstrate knowledge ofestimating norms, know where these are obtained,how they are applied and what the limitations are. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopDay 2The Commissioning Plan Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Commissioning Plan - 1The Commissioning Plan is a method statement, read in conjunctionwith the project schedule, of the activities and work processes to beundertaken by the Commissioning Team.On projects where a specialist contractor or firm of consultants will beengaged to populate the Commissioning Team and perform the workuntil Close Out, a Commissioning Plan will be particularly useful.In such circumstances, the Owner may produce an initial release of theCommissioning Plan for the selected contractor or firm of consultantsto further develop.The Commissioning Plan will become a “living document’ which theCommissioning Team will use as their Bible and against which theirperformance will be measured by the Owner. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Commissioning Plan - 2A Commissioning Plan will typically be structured as:1. Purpose of the Commissioning Plan2. Commissioning Overview3. Scope of Work4. Aims and Objectives5. Commissioning Team Roles6. Commissioning Methodologya. Prepareb. Implementc. Close Out7. Initial Commissioning Systems8. The Systems Completion Database (SCDB)9. Commissioning and Start Up Challenges. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Commissioning Plan - 3Detailed contents will include:1. System P&IDs marked up in Systemization process2. Inhibits and Isolations Register3. All Checksheets and procedures for Cleaning, Drying, Leak Testing4. All Certificates and Notices:5.6.7.8.9.Construction CommissioningCommissioning OperationsActions from HAZOPsAll Queries and Management of Change documentsCommissioning ProceduresStart-Up Procedures (if different)Authority to introduce hydrocarbons / process media Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopThe Commissioning Plan - 4API RP 1FSC, 1st Edition, Table 1 – Courtesy of API Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopDay 2Justifying a Budget, Allowingfor Growth Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 1 Little information in the public domainEstimating scope, schedule and budget is not easyLimited collaboration between Operators and ContractorsEach maintaining their own knowledge bases and their own normsInformation has been in a silo Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 2Elements that should form the budgetHow to allow for growthNorms from recent projects to estimate the overall budgetProjects vary with industry, types of processes, location and otherfactors, such as workforce competency Some broad guidelines are available For overall commissioning services at an onshore chemical plant: 3.5% of total capital investment is in Commissioning & Startup Approx. 70% in Trade costs Approx. 30% in Consumables Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 3Estimating Norms (left) and ActualAverage Manhours (below) from NorthSea projects from 2005 to 2015. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 4Taking averages across all Disciplines of the norms and actual manhours wehave:AITRs 5.6BITRs 10.0In the next section, these figures will be applied to two actual projects todetermine an allowance for productivity and punch listing.Estimating Commissioning ManhoursWe looked at two projects recently completed, in which we were involved. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 5What we knew: Project 1 - FPSO, Asia Shipyard SE Asia Shipyard, Developed Country, Benign Environment,Good Site Controls Final billings for work activities related to A, B & C ITRs,including Punch List Items Ratio of AITRs and BITRs to Tags Number of Systems and Sub Systems Number of CITRs Project 2 - Oil & Gas Plant Remote Location, Justifying Country, Harsh Environment, SiteControls Challenged Final billings for work activities related to A, B & C ITRs,including Punch List Items Ratio of AITRs and BITRs to Tags Number of Systems and Sub Systems Number of CITRs Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 6What we didn’t know: Project 1 - FPSO, Asia Shipyard Estimated Manhours per AITR and per BITR Actual productivity Actual Punch Listing activity, separate from billings for AITRsand BITRs Project 2 - Oil & Gas Plant Estimated Manhours per AITR and per BITR Actual productivity Actual Punch Listing activity, separate from billings for AITRsand BITRs Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 7We made some assumptions: Commonality exists in many of the Checksheets (ITRs) on projects,Onshore or Offshore, in a Shipyard or at a Gas Plant in a Justifyingcountry. Productivity at the Shipyard was good, assumed to be 1.00. The two projects were of similar size, with a similar number ofSystems and were comparable. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 8Then stated our method:1. In Project 1, by knowing the total billings of direct labour toperform Systems Completion and Commissioning Scope, in otherwords, the AITRs, BITRs & CITRs, but not the estimated manhours,actual productivity or Punch Listing, we applied the Manhournorms for AITRs, BITRs & CITRs from previous projects to Project1 and compared these with Project 2, total billings of direct labourto perform Systems Completion and Commissioning Scope, inother words, the AITRs, BITRs & CITRs allowing for the actualproductivity and Punch Listing. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 9Then stated our method:2. We normalised each project to have a Tag Count of 50,000, with100 Systems and 250 Sub Systems, then by knowing the ratios ofAITRs and BITRs to Tags, we calculated the direct manhours tocomplete AITRs, BITRs & CITRs in Project 1 and subtracted thesefrom Project 2, to leave the manhours that can be attributed to actualproductivity and punch listing. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 10Points to consider: Types of processes Geographic location Management ability and site control Workforce productivity and competencyActual billings including punch listing reflect quality and productivityProject 1 - Tag Count of 50,000, (normalised) billings of 1,500,000AITRs per Tag 3Manhours per AITR 5.6BITRs per Tag 1Manhours per BITR 10.0CITRs per Sub System 1Manhours per CITR 100Calculation: 50,000*((3*5.6) (1*10.0)) 250*100 1,365,000Total Manhours, including punch listing, assuming productivity of 1.00 Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 11 Assume Project 1 has good productivity of 1.00A total of 1,365,000 manhours were billed to A, B & C ITRsPunch listing accounts for 1,500,000-1,365,000 135,000 manhoursOn Project 1, each Tag had 135,000/50,000 2.7 manhours of punchlist activity, assuming productivity of 1.00.Project 2 had (normalised) actual billings of 2,100,000 directmanhours to complete the scope of A, B & CITRs including PunchList Items.Therefore, deducting 1,365,000 from 2,100,000 leaves 835,000manhours in Project 2 that could be attributed to productivity andpunch listing.Project 2, each Tag was billed for 17.4 manhours over and abovethe “estimated amounts” from this exercise.Site control, quality issues, plus remote location, in a Justifying countrywith poor access to supplies and materials.Refer to the embedded files for estimating a commissioning budgetderived from norms and actual project information. Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 12Broad Metrics:Estimating Norms and Actual ManhoursFactors to be aware of: Productivity Factor Punch Listing Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopJustifying a Budget, Allowing for Growth - 13Key Points on Budgeting: Total budget is importantIt is all about How not so much about How MuchPay Now or Pay LaterFailure costs much more than Success Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Systems for Initial Start-UpLearning ObjectiveOn completing this module you will be able toidentify the key Stakeholders and participants in theSystemization exercise, explain how Battery Limitsare defined, provide a definition of a viable SubSystem, articulate the contents of a TurnoverCompletion Package and identify the recipient. Falcon Global Ltd. 2000 - 2019

Phase 1 - PreparationSystemization and Priority Start-Up SequenceSystemization,Priority Start-Up Sequence,and Progressive SystemsCompletion Methodology Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1The Overall Systemization ProcessDefine System Priorities for Start-UpCreate Fishbone DiagramTurnover Process for TCCCPerform Systemization onP&IDs and SLDsPerform Gap Analysis of ITRsSet Certification Requirements Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1Systemization Guidelines Fishbone Diagram ITRs & Certificates Turnover ProcessSystemization Guidelines From Falcon Group Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1Systemization Guidelines Responsibility of Commissioning Manager Stakeholder Buy-in Operating Entity Iterative ProcessP&IDs used with Priority Systems Sequence & Fishbone DiagramFrom Falcon Group Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1Priority Systems for Initial Start-UpFishbone Diagram, aka Cause & Effect: Kaoru Ishikawa Priority 1 (P1) Power and Safety Systems Priority 2 (P2) Control Systems Priority 3 (P3) Utilities, Air and Water Systems Priority 4 (P4) Storage, Mechanical Handling, Loading Systems Priority 5 (P5) Production & Process Systems Priority 6 (P6) Metering, Import & Export Pipeline Systems Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1Fishbone Diagram System Priorities for Initial Start-Up Add Planning Information and WBS Codes Add Resources Monitor Daily with Skyline ReportsPriority Systems Sequence & Fishbone Diagram From Falcon Group Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1Fishbone Diagram Example Reproduced with grateful thanks to Chevron Corporation Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1Gap Analysis ITRs & Certificates All other types document needed Sort into 3 piles Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1Turnover Process TCCC Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Priority Start-Up Sequence, GapAnalysis, Turnover Process - 1 Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Tag Numbering, and ProgressiveSystems Completion Methodology - 1Tag Numbering Engineering are responsible for the engineering deliverables Engineering should have a system for Tag Numbering Ensure the Tag Numbering system is sufficient Drawing reviews of P&IDs, SLDs, Loop Diagrams to ensure everyCommissionable Tag is uniquely referenced and included Falcon Global Ltd. 2000 - 2019

Commissioning & Start Up WorkshopSystemization, Tag Numbering, and ProgressiveSystems Completion Methodology - 2Tag Numbering Be aware of what is not planned to be tagged as Commissionable For example, manually operated valves may not be assigned a uniqueTag Number When this happens, the item is not individually recorded in SCDBand

Commissioning & Start Up Workshop Day 1 Preparation Activities to set up Commissioning Gathering information Selecting the Commissioning Team . For example, in a chemical plant, a pipe may have the intention to transport 2.3 kg/s of 96% sulfuric

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