A Presentation on Mechanical Completion and Commissioning Services by MCCS INTERNATIONAL www.mccsinternational.com MCCS-GN-PS-002 03
PRESENTATION BREAKDOWN MCCS INTERNATIONAL • A brief Introduction on MCCS International ( MCCS ) • MCCS Organisation Chart • Oil & Gas Projects Life Cycle • Preparation & Execution Phase • MCCS Services Offshore & Onshore • MCCS Work Track Record • AOB / Q & A
INTRODUCTION MCCS INTERNATIONAL ► Mechanical Completion and Commissioning Services Ltd. Formed in 1994 To fill a niche market in the area of Mechanical Completion and Commissioning ► M.C.C.S. Worldwide Ltd. Formed 2000 in the UK ► M.C.C.S. Worldwide Sdn Bhd Formed 2001 Kuala Lumpur Malaysia and renamed to M.C.C.S. International Sdn Bhd 2007 ► Branch Offices in UK, Spain and South Korea What makes M.C.C.S. unique? Maximise cost benefits M.C.C.S. comprises a team of people who M.C.C.S. involvement should be sought during have specialised in this difficult area for over the early planning and design phase of a 23 years. project. The principle spin off from this team approach Within schedule and under budget is “The Wheel is not Reinvented” M.C.C.S. team has an enviable record of achieving its tasks within schedule and under budget.
MCCS INTERNATIONAL CHAIRMAN MANAGING DIRECTOR COMPANY SECRETARY GENERAL MANAGER QMS KOREA OFFICE ADMIN PROJECT OPERATION DEPARTMENT DOCUMENT HSE MANAGER CONTROL CENTER (DCC) FINANCE HUMAN RESOURCE BUSINESS DEPARTMENT (HR) DEVELOPMENT PRE-COMMISSIONING & COMMISSIONING PROPOSAL MANAGER ENGINEERING COMMISSIONING PROJECT SITE PRE-COMMISSIONING SUPPORT MANAGER MANAGER MULTI DISCIPLINE WAREHOUSE (WMS) N2/He LEAK COMMISSIONING & PLANNING MACHINING TESTING MAINTENANCE COMPLETION FLANGE SYSTEM HYDROTEST MANAGEMENT ENGINEERING MCCSI-KL-GN-OC-001 R01
OBJECTIVES MCCS INTERNATIONAL TYPICAL PROJECT LIFE CYCLE Operation & Engineering Procurement Construction Commissioning Maintenance Safe Operation And Cost Reduction Via Operational Excellence Based On Advanced Methods
PREPARATION & EXECUTION PHASE MCCS INTERNATIONAL By Sub System Basic E RFC Detailed Eng. Eng. Procurement P MECH By Sub System COMP C RFSU Construction RFHO Pre-comm. - Preparation Pre-comm.-Execution C Comm. - Commissioning - Preparation Execution STARTUP OPERATIONS PROJECT SOFTWARE SUPPORT Equipment Population Precom - Precom. Execution Preparation Com - Com - Preparation Execution Punch List A Punch List B Punch list C
SERVICES ENGINEERING STAGE Operation & Engineering Procurement Construction Commissioning Maintenance The required preparation for: • Pre-commissioning execution phase • Commissioning execution phase • Start up stage Including: ➢ Identification of Systems and Sub Systems ➢ Loading of all technical information into software database ➢ Provision of check lists and test sheets ➢ Creation of level 1 to level 4 plans including networks (CPN) and critical paths ➢ Provision of pre commissioning procedures ➢ Provision of commissioning procedures ➢ Agreement on punch list control and management methods ➢ Compiling RFC/RFSU/RFHO dossiers based on systems and sub-systems
INTERNAL CLEANING SERVICES CONSTRUCTION STAGE Operation & Engineering Procurement Construction Commissioning Maintenance MCCS has the capability to ensure systems are clean prior to start up. This includes: ➢ Camera internal inspections ➢ Chemical Cleaning ➢ High velocity flushing ➢ Lube oil systems flushing and Analysis. ➢ Steam blowing ➢ Air Blowing ➢ Drying
FLANGE MANAGEMENT SERVICES CONSTRUCTION STAGE MCCS will provide joint and connection integrity which will ensure a Leak Free start up of the plant. This will be by : • Data management by specialist software • Manual bolt torquing • Hydraulic bolt torquing • Hydraulic bolt tensioning • Flange breakout / disassembly • Vendor packages FM • Installation, Commissioning and Maintenance of Breach Lock Exchangers
FLANGE MANAGEMENT SERVICES OVERVIEW CONSTRUCTION STAGE PRE-ENGINEERING: ➢ joint register ➢ preparation of work packs ➢ data sheets ➢ data records ➢ joint completion certificate (jcc) ➢ Exchanger work pack preparation. ( MCCS and Sealing and Bolting Technolgies LLC have joined forces in providing the engineering and on site expertise for the breach lock exchangers and other specialist heat exchangers) PREPARATION AND INSPECTION: ➢ line walking ➢ flange alignment, surface and cleanliness ➢ fasteners materials and cleanliness ➢ gasket materials and cleanliness
N2/HE LEAK TESTING SERVICES CONSTRUCTION STAGE Following the Flange Management and the Cleaning processes MCCS has the in house requirements to perform sensitive leak testing as a form of verification prior to start up. This also ensures the complete plant is inerted safely prior to start up.
SERVICES PRE-COMMISSIONING STAGE Operation & Engineering Procurement Construction Commissioning Maintenance PHASE ACTIVITIES MILESTONE CONFORMITY CHECKS (MC & RFC) STATIC TESTING PRE-COMMISSIONING MECHANICAL N2/He LEAK TESTING COMPLETION
SERVICES PRE-COMMISSIONING STAGE ❑ PRE-COMMISSIONING EXECUTION PHASE (MULTIDISCIPLINE) ✓ Visual inspection of Equipment ( Instruments, Motors, Cables...).Quality of installation Compliance with Project Specifications , Safety rules, codes,... ✓ « Cold Testing » : Calibration of Instruments, Machinery alignment , Setting of safety valves,...(De-energised Tests) ✓ Chemical Cleaning & Lube Oil Flushing
DOSSIER PRE-COMMISSIONING STAGE Combined RFC Certificate One Dossier Per Sub-System
SERVICES COMMISSIONING STAGE Operation & Engineering Procurement Construction Commissioning Maintenance PHASE ACTIVITIES MILESTONE ENERGISATION READY FOR START-UP DYNAMIC TESTS COMMISSIONING (RFSU) EQUIPMENT RUNNING-IN PRESTART-UP ACTIVITIES
SERVICES COMMISSIONING STAGE ❑ COMMISSIONING EXECUTION PHASE ✓ Electrical motors coupled runs , instrument loop testing , electrical breakers operation ....... ✓ Running-in and on-line tests of plant utilities, and main process equipment in closed loop (wherever applicable) ✓ Piping and Vessels N2/He Leak Testing (Mainly Hydro-carbon Systems) ✓ Start-Up Assistance ✓ Company / Client Assistance and support following successful Start Up.
DOSSIER COMMISSIONING STAGE RFSU Dossier Index RFSU Certificate One Dossier Per Sub-System
OPERATION & MAINTENANCE STAGE Operation & Engineering Procurement Construction Commissioning Maintenance Provision of a team to assist in routine, preventive & shutdown maintenance including : ➢ Electrical ➢ Telecoms ➢ Instruments ➢ Mechanical (Fixed and Rotating)
PRESERVATION AND MAINTENANCE SERVICES Preservation and Maintenance of the equipment and systems can be managed and performed by MCCS during the project duration from Equipment delivery through to the start up of each system. This can be in line with the Client Preservation Management System or using MCCS systems and procedures. This would include the preparation planning and provision of all hand tools and equipment, engineers & technicians (electrical, instrument, mechanical and piping)by MCCS Consumables can be provided by MCCS or Client depending on Client preference.
SOLUTION SUPPORT TEAM FOR COMPLETION ➢ Improving completion of remaining 1,500 + subsystems ➢ Dedicated team focused on Completion / Turnover process ➢ Free up area based teams to improve performance guiding their PC’s ➢ Construction completion on more predictable schedule and documentation ➢ Form support Team to expedite systems from bulk construction to full completion and turnover ➢ Mission statement for Support Team ➢ Drive subsystems/systems across the Completion finish line ➢ Complete any and all work not done or documented by PC’s ➢ Support precommissioning and then commissioning /operations after completion
THANK YOU www.mccsinternational.com
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