Commissioning of Offshore Oil and Gas Projects: The Manager's Handbook a Strategic and Tactical Guide to the Successful Planning and Execution of the Commissioning of Large Complex Offshore Faciliti

230 Pages·2005·36.24 MB·English

by  Trond Bendiksen, Geoff Young

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;:ommissioning of Offshore
Oil and Gas Projects
The Manager's Handbook
A strategic and tactical guide to the successful planning and
execution of the commissioning of large complex offshore
facilities
by
Tron<!Jl'ndiksen
and
Geoff Young
authOfrlOUSE-
1663 LIBERTY DRIVE, SUITE 200
BWOMINCTON, INDIANA 47403
[phone]
www.AUTHORilOUSE.COM
© 2005 Trond &ndiksm and G~offYoung
All Rights &s~rv~d.
No part oft his book may b~ r~produud, stored in a retriroal system, or transmitt~d by any means without th~ writtm permission oft he
author.
First published by AuthorHouse 02123105
ISBN 1-4184-6414-7 (e)
ISBN 1-4184-4380-8 (sc)
Prinud in the Uniud Staus ofA merica
Bloomington, Indiana
This book is printed on acid-fru pap~r.
About the Author
Trond Bendiksen has 25 years of experience in the Oil and Gas industry in the North
Sea and eastern Canada. He has worked with all the major oil companies on GBS's,
Jackets, Floating Production Units (PFU's, FPSO's) and has completion experience from
a vast amount of mega-projects. He has solid operational experience from a variety of
management positions including Offshore Operations Manager on several platforms.
His involvement in Business Process Re-engineering projects and high level world wide
Benchmarking studies has given him a unique insight into the organizational aspects of the
job that is so important for the success of a project.
He has also published a book on Continuous Improvement Techniques and several papers
on Organizational Effectiveness.
TB is a Norwegian citizen currently residing in eastern Canada as a senior Completion
Advisor to east coast Canada's offshore Projects and Operations.
v
Geoff Young has 30 years of experience in the Oil and Gas industry in the North Sea and
world wide.
He has worked with all major oil companies on GBS's, Jackets, Floating Production units
(FPU's), FPSO's and onshore facilities, and has completion experience from a vast amount
of mega-projects, both as a senior commissioning engineer and senior planner.
GY has gained significant experience in commissioning planning and estimating through
his long career in the UK, Holland, Belgium, Saudi Arabia, Norway, the US and Canada.
GY is one of the few Senior Planners that can actually do all the initial planning, drawing
mark-up, estimating etc on his own as the first cut of the schedulelbudget before the
commissioning engineers are recruited- and extremely rare and valuable skill not easily
found in the industry.
GY is a UK citizen currently residing in eastern Canada as a senior Planning Advisor to
east coast Canada's offshore Projects and Operations.
VI
Acknowledl:ements
In compiling this work we have sought advise and guidance from a number of individuals
and sources but principally the greatest assistance has been provided by our own working
colleagues on a variety of projects.
We would especially like to acknowledge the guidance provided by Ed Martin and Gordon
Carrick of Petro-Canada who took the time to thoroughly read the whole manuscript and
offered valuable comments on the content, structure and layout.
We would like to thank Lynn Young for doing all the proofreading, an undertaking not
easy on a manuscript written by two language- ignorant engineers.
VII
CONTENTS
1.0
PLANNING .............................................. .......................................................... 1
The Key Performance Indicators & Report Structure ....................................................... 7
Defining the Work Scope and Building the Schedule ..................................................... 23
Planning and Planning Considerations .......................................................................... .45
Estimating; Strategy, Tools and Considerations ............................................................. 57
Estimating and Growth: Figures and Factors .................................................................. 73
2.0
PREPARATIONS ............................................ .................................................. 85
Organization .................................................................................................................... 87
Auditing/Gap review ..................................................................................................... 105
PREPARATIONS .......................................................................................................... 117
Risk Analysis ................................................................................................................ 117
Factory Acceptance Testing, Load Banks, N2 Testing of Compressors onshore,
Sub Sea issues and FPSO specifics ............................................................................... 131
3.0
EXECUTION. ............................................ ..................................................... 149
Monitoring and Improving the Plan .............................................................................. 175
Loop Testing, Preservation, Piping cleanliness, N2 Testing of Compressors, Oil
Flushing, Sub Sea simulation testing, SIT testing of subsea equipment and timing of
installation of main Control Valves and Pressure Relief Valves ................................... 179
4.0
DOCUMENTATION / HAND-OVER ............................................................. 207
IX
Preface
This book is specifically directed at Commissioning Managers, Project Managers and
Senior Project Planners but also provides valuable and useful information that will assist
Engineering Managers, Construction Managers, Commissioning Leads and Commissioning
Engineers in performing their jobs.
The concept of the book has been to break the commissioning activity down into four main
phases, namely, planning, preparation, execution and documentation/hand-over.
The goal has been to identify the main areas where managers need to keep their focus- the
key success factors - in order to prevent schedule and budget overruns. We have chosen
to narrow the focus down to the single most important elements of each of the four main
phases; those that contribute the most, and hence can make or break a project.
Contrary to what one might think, it is not the delay of major project milestones such as
sail-away from module yards, module lift at integration site or delays in offshore laying
activities that constitutes the major delay factors on a project. It is all the other important
big or small issues that pop up along the way that you have not properly prepared for that
make the biggest difference.
This book also provides some very accurate experience data on what you can expect in
terms of overrunning your initial estimates if you don't seriously pick up on, and resolve
the issues dealt with herein. Figures quoted in this book reflect multi-module large projects.
Smaller projects have the same issues, but figures may have to be scaled down to suit.
The book focuses only on the key issues that you need to resolve and does not provide
specific references or recommendations as to tools and equipment.
We have tried to put the issues in a Continuous Improvement perspective throughout
the book in order to encourage you to structure your work in such a way that you
always analyze the issues first, then improve and follow up on actions; the Continuous
Improvement Circle.
To our knowledge, a book such as this has never been published before. We sincerely think
that this book will assist you tremendously in performing your job, and we hope you enjoy
reading it as much as we have enjoyed writing it
Good Luck!
The AUlhors
Xl
1.0
2.0
~i'e~arations ..
Phase 1
Phase 2 Phase 3
Phase 4
~.
~
The concwt of the bookhas been.t o brea\< the commissioning activity down into four main phases,
namely; planning. preptiraiion, execution and d()cumentatJonihand~ve,..
We have chosen to separate the planning and preparations activities in two distinctly different phases
as the various elements of these are important 'enough to warrant separate detai.l discussions.