Mechanical Completion and Commissioning (abbreviated MCC), which includes testing and checking equipment as defined by a predefined check record lists, should be performed to confirm that prefabrication and installation is in accordance with drawings and specifications, and that equipment is ready for commissioning in a safe manner, and in compliance with government, environment and project requirements. The goals of MCC are:
Commissioning describes a complete workflow from planning and organizing the commissioning to execution and finally to handing over for operation. The sequence of work, in summary is as follows:
During commissioning, a structure for the verification documentation is created within IFS/Asset Design. This structure consists of a commissioning package, multiple MC packages, connection of the equipment objects to the MC packages, and definition of the content and format for the check records.
A commissioning package is a practical scope within a system or a sub-system for commissioning. A practical scope would be functional units that can be tested by commissioning to confirm its suitability for operation. For example, a commissioning package might consist of a new tank with related pipes, drainage, ventilation, pumps, motors, instruments, and other secondary equipment.
A commissioning package consists of one or many MC (mechanical completion) packages. Each MC package is a practical scope of work for one discipline within a commissioning package. A commissioning package is created as an object of the COMMISSIONING PACKAGE class. The commissioning package number is the Object ID.
A MC package is a practical scope of work for one discipline within a commissioning package (e.g. all instrumentation in a tank commissioning package). A MC package belongs to a commissioning package functional parent and is created as an object in the MC PACKAGE class with a object ID consisting of two parts: the parent commissioning package's number and the unique MC package number.
Equipment objects are connected to the MC Package by using the MC Package consists of connection type. IFS/Component Specification will later use these MC package equipment objects for generating a MC Package specification. IFS/Component Specification, an add-in to MS Excel, is used to create the templates for both the check records and the MC package specification.
A MC check record list is the actual check/test specification sheet for the various equipment objects within IFS/Asset Design. MC check records are prepared for one or many equipment objects for the recording of results from the checking and testing during mechanical completion. A check record corresponds to a piece of equipment and contains a protocol for testing and verification. An equipment object can have two defined MC check records to enable the object to exist in two check/test specification sheets within a complete MC package specification (one MC check record specification sheet could be for an electrical test and the other for a mechanical test).
MC check records are defined for equipment objects by using two technical attribute value fields, Check Record 1 and Check Record 2 fields. These technical attribute fields are found in the Commissioning technical attribute group. To be able to generate a MC package specification, a value in the Check Record 1 field has to be defined and one in the Check Record 2 field is optional. The value defined in the check record attribute fields 1 and 2 forms a link to the check record sheet in the MC package specification. The value added for the Check Record 1 and Check Record 2 fields must have the same value as the corresponding check record sheet name in the MC package template specification file.
System variables are defined to set up the Check Record 1 and Check Record 2 fields.
A MC package specification (an Excel workbook) is created for each MC Package to contain check records for that package's different pieces of equipment. A MC Package Specification is the MCC version of a component specification.
Performing the MCC involves testing and checking the equipment as defined by the MC check record specification. This testing confirms that the installation is in accordance with drawings and specifications and ready for commissioning in a safe manner in compliance with project requirements. The MCC is performed by engineering specialists within different instrument, telecommunication, electrical, mechanical, piping, HVAC, and architectural disciplines.
The MC check record specification documents the results for the various equipment after a performed MCC. After performing the MCC, each check record is signed by the specialist that performed the control/test and by the customer (the company with the design changes). The MC package specifications containing the check record verification information is registered as documents and connected to the corresponding MC package object.
Errors found are reported as punch items in a punch list and describes incomplete work, malfunctioning equipment, and/or improper construction. Complexity on reported punch items could differ a lot, where some are easily fixed and others are more complex. The latter could be corrected using a Work Order. Each punch item must be defined with at least a Design Object ID to ensure that a work order could be created for that item. ID of the Work order is saved on the punch item as a reference.