Explaining OPERCOM® methodology
in commissioning
January 22, 2015
Here i am trying to explaining about the role of Opercom® in oil and gas
commission activity
1. What is OPERCOM® ?
Opercom® is a test methodology tailored to Oil & Gas production and
treatment, installations, which has been providing its worth for more than
twenty years now. Opercom® is for Commissioning specialists. The
methodology is used by the dedicated teams responsible for preparation
during the engineering phase and for execution at the end of the project.
Opercom® training modules are available for future users. Total has signed
agreements with training organizations for providing them.
Q: How long is the course?
A: One week.
Opercom® is used in the Pre-commissioning and Commissioning phases,
before handover to operations. It is a tool that ceases to be used at the end of
the project. The Opercom® methodology can also be used to test
exhaustively any modifications, executed on an existing installation. An
installation tested down to the smallest detail will be operational faster and
more safely with the Opercom® methodology!
2. What is Pre-Commissioning Phase ? (Issuing RFC after completion)
The Pre-commissioning phase includes three main types of activities:
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Conformity checks.
Static/de-energized tests.
Piping tests.
On completion of these tests, an “RFC” (Ready For Commissioning certificate)
is issued for each Sub-system. A Sub-system is Ready For Commissioning
when ALL Pre-Commissioning operations on that Sub-system are completed
and there is NO outstanding punch item category A
We can then simply summarize in following:
CONSTRUCTION + PRE-COMMISSIONING = Ready For Commissioning
3. What is Commissioning? (Issuing AOC after completion)
Commissioning is a major activity in a project: it is the final quality check
before transfer to the start-up team. It is also the key to ensure a smooth and
quick ramp up to the production plateau as planned.
Commissioning engineering should start early in the project with some input
already during Basic Engineering and during the Call For Tender preparation.
The Commissioning competencies of the selected EPCC contractor, and of its
specialized sub-contractor are crucial and must be combined with a
mobilization plan well suited to both the contractor and the company.
Feedback at the end of the project is essential to help us improve our
knowledge and our technical standards.
The Commissioning phase essentially comprises three types of tasks:
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Dynamic verification.
Testing with substitute fluids,
The preparation of the piping and vessels for start-up.
We can say:
Commissioning -> Dynamic & Energized
On completion of these tests, an “AOC” (Achievement Of Commissioning)
certificate is issued for each Sub-system. A Sub-system is ready for
Achievement Of Commissioning when ALL Commissioning operations on that
sub-system is completed and there is NO outstanding punch item category B.
There is then a transfer between the Commissioning entity and the Operations
entity.
And AOC is Visa for each Sub-system to be transferred from Commissioning
to Operation phase
4. What is punch list?
Items that have not successfully passed the tests are listed in a punch list.
They are managed in accordance with certain priorities (A, B, C) such that
items ranked priority ”A” are to be cleared before the RFC can be signed.
Here is summarizing information about punch list categories
5. Features of OPERCOM®
A multi-discipline methodology:
The Opercom® methodology spans all the activities and every branch of
discipline: Mechanics, Piping, Process, Electricity, Instrumentation
A reliable and duplicable methodology:
Designed in the late 80s to test Oil & Gas installations, Opercom® is now
recognized for the breadth of its industrial spectrum: Agro-industry, building
and civil engineering…Used for over twenty years now, the method has
benefited from the feedback very many projects which has further enhanced
its reliability. Any installation in any sector of activity can be tested using the
Opercom® methodology.
A fully comprehensive methodology:
With Opercom®, it is impossible for any item to be left out of testing! Each
discipline – Mechanics, Electricity, Instrumentation, etc. – draws up check lists
to be processed by Commissioning. There are several thousand items for
each project. And a test card for each test. With the complete set of
documents, traceability objectives are always met.
OPERCOM® methodology relies on a series of four E&P General
Specifications:
GS EP EXP 101: (Pre-commissioning and Commissioning specification)
This General Specification defines: The different phases of a project in
relation to Commissioning (the test phase),
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The certification steps,
The organization,
The certification methodology.
In compliance with the Opercom® methodology, to leave nothing to chance,
installations are broken down into Systems and Sub-systems, with a transfer
of responsibility at each step. Specification GS EP EXP 101 sets out the
organization to be put in place to prepare and execute the Commissioning.
This way, the role and responsibility of each person are clearly defined.
Likewise, Specification GS EP EXP 101 frames the Handover of the
installations to the Operator or the end Client.
GS EP EXP 103: (Pre-commissioning and Commissioning Engineering)
After the key step of breakdown into Systems and Sub-systems, Specification
GS EP EXP 103 organizes the Engineering of Pre-commissioning and
Commissioning, detailing how the tasks on the equipment to be tested are
allocated.This comprises three main parts:
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The general preparation of Pre-commissioning and Commissioning
Management: The preparation of all tools and procedures which are
necessary for the general management of both Pre-commissioning and
Commissioning.
The preparation of Pre-commissioning Engineering: for each System,
Sub-system and item, tasks to be carried out on the equipment to be
tested are allocated.
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The preparation of Commissioning Engineering: allocation of tasks to the
small sub-assemblies to be tested, and drafting of the Operational Test
Procedures (OTP).
GS EP EXP 105: (Pre-commissioning execution)
This set of some 400 test sheets indicates in detail all the verification’s and all
the tests to be carried out as part of Pre-commissioning.
GS EP EXP 107
Commissioning execution)
This set of some 100 test sheets indicates in detail all the verification’s and all
the tests to be carried out as part of Commissioning.
Other definition: ICAPS© Integrated Commissioning And Progress System is
the associated software to support Opercom® methodology.
The use of ICAPS©, and Opercom® methodology likewise, is compulsory in
all TOTAL development projects.
ICAPS© guarantees the strict application of Opercom® methodology, ensures
better control over the Pre-commissioning and the Commissioning activities in
the course of a project and facilitates feedback (test sheets to be recovered,
statistical information on the project for input into the Commissioning databank, etc…)