essentialelements&criticalsuccessfactorin flawless start up iniative

Essential Elements & Success factors in Flawless Start up Initiatives : 

Essential Elements & Success factors in Flawless Start up Initiatives Prepared By vinsus@rediffmail.com FSI Consultant

Objective : 

Objective Share & enhance understanding of FSI within FSI Team Simplify process of FSI implementation Provide key for success of Project Synchronize mindset within FSI team for forthcoming challenges due to delay in schedule.

Content : 

Content FSI Strategy Dimension of FSI FSI Process Essential Elements in Q areas Phase wise Essential Elements FSI Success factors Conclusions

Slide 4: 

FSI Strategy

Dimensions of FSI : 

Dimensions of FSI It is Risk Management tool which helps to reduce risk level as much as possible from early stage of the project till start up of facility by identifying flaws and implementing various mitigation actions to ensure smooth start –up. It helps to align mindset of project team to identify and eliminate flaws from the beginning of the project by setting Project KPIs targets. It helps to improve work practices to do right thing at right time by applying best practices in each phase of the project. It helps to save money & time during critical time of Commissioning & Start up by avoiding various failure / delay due to constant monitoring of flaws & mitigation action from early stage of the project. It provide opportunity to Engineering / Construction / QA/QC /CSU/Operation and other departments team members of Company /Contractor / Sub Contractor & Vendors to work to gather and share knowledge & experiences at every phase of the project.

Dimensions of FSI : 

Dimensions of FSI It emphasis to adopt approach of elimination of flaws rather than their accumulation with project progress for smooth handover from one phase to other phase till plant start up. At each phase of the project It helps to develop & establish system to control flaws by embedding mitigation actions in control documents & their monitoring during inspection. FSI implementation is collaborative effort of all team members at right time to stop induced flaws / eliminate suspected flaws in each phase. FSI is focusing on some generalised areas i.e. Q area where flaws are normally occurred e.g. Cleanliness , Tightness, Testing , Integrity, Prototype .Flaws related to these areas in any work are captured in Flaw list of that area then mitigation actions are suggested accordingly and finally embedded in control documents. FSI is not additional job whereas it is the part of a job which is expected to be done during the job only. During execution of any job ,mitigation actions should be taken care by the executor in order to mitigate the flaw or to stop induction of any new flaw.

Dimensions of FSI : 

Dimensions of FSI FSI is motivating to do right thing on right time instead of struggling for correcting the mistakes /flaw during peak time of project. It offer choice to invest relatively less money in strategic ways from the beginning of the project to reduce unwanted financial burden which cost more money & time on later stage of the project.

Slide 8: 

FSI Process Pillars of FSI Process Database of Flaws and learning. Defined and Specific Flaw list & lesson learnt record . Management Commitment and Road map for implementation Strong management Commitment to adopt FSI Clear Road map and milestones Q area Specifications Careful selection of Q areas Imbedding mitigation actions in system KPIs Select Project KPI Effective Monitoring of Current Indicators

FSI Process : 

FSI Process 10 Basic steps to manage FSI Process Gain senior management commitment. Set FSI management Commitment statement and KPIs. Appoint a FSI Coordinator & Set up a FSI organization Prepare plan for FSI implementation in the project i.e. QA plan Establish a process to manage risks. Set up a reporting system to record hazards, risks and actions taken. Train and educate staff. Audit your operation and investigate incidents and accidents. Set up a system to control documentation and data. Evaluate how the system is working.

Slide 10: 

Essential elements in Cleanliness Q Assurance Plan Cleanliness Flaw list Cleanliness KPI ‘Built It Clean Policy’ Cleanliness Matrix Preservation Matrix Embed mitigation actions in ITPs, Procedures ,Method statements Q Tour Score card /Check sheet PEFs marking after cleaning Cleanliness Dossier

Essential Elements in Tightness : 

Essential Elements in Tightness Q Assurance Plan Flaw list Tightness KPI ‘Built It Tight’ Policy Flange Management System One Time Installation of CVs/ESD Valves. Valve Testing at site Procedures & Monitoring Sheet Embed mitigation actions in ITPs, Procedures ,Method statements Q tour Score Card / Check Sheet

Essential Elements in Testing : 

Essential Elements in Testing Q Assurance Plan Flaw list Testing KPI ‘ Test It to Run ’ Policy Testing Plan Individual machine/ Instruments Integrated plan of systems/ sub system machines WEFS Dry Functional Test Dynamic Functional Test Vendor Documents/Vendor Support Multi Discipline Interface

Essential Elements in O &M : 

Essential Elements in O &M Q Assurance Plan Flaw List 3 D Model Review Q tours for accessibility ,operability & maintainability Valves accessibility & Operation monitoring sheet ( Sub System wise) Instruments accessibility /maintainability monitoring sheet ( Sub System wise) Structure , Grating , Railing & Ladders Check sheets Lighting arrangement check sheet Signage & Labelling Checking Sheet Load lifting arrangement sheet Operating Manuals, Standard Operating Procedures & Maintenance Procedures Filters , NRVs,Vent& Drain, Safety Valves , Utility Points location check sheet

Essential Element in Integrity : 

Essential Element in Integrity QA Plan Flaw list Selection and specification of Equipment s & Its Vendor. Contractual obligation of Vendor for Service and Support Functional Testing of equipments Preservation of equipments

Essential Element In Prototype : 

Essential Element In Prototype QA Plan Flaw list Identification of Prototype items Testing Training and Vendor Support

Phase wise - Essential Element : 

Phase wise - Essential Element Engineering Concept Selection Clear definition of Contractors work scope in Project Contract Embedding FSI requirements in Project Specifications Confirmation of incorporations of FSI mitigation actions in Detail Engineering 3 D Model review – O&M Selection of Process , Equipments and Machines – Integrity ,Complexity and Prototype FSI Training & Workshop FSI Health check

Phase wise - Essential Element : 

Phase wise - Essential Element Procurement Address FSI requirements in all Purchase Order and make Contractual obligation for FSI compliance for All Vendors/ Sub Vendors. Effective supervision on Vendor/ Sub Vendors for FSI compliance Effective control over Third Party Inspection Company for FSI compliance at Vendor shop – Inspection & Testing FSI requirement in Packaging, Preservation and Transportation Address Vendor support & services and spare items/ special items FSI Training & Workshop FSI Health check

Phase wise - Essential Element : 

Phase wise - Essential Element Construction Cleanliness & Preservation Tightness O &M Inspection Training Q tour Health check CSU Testing Tightness Training Vendor Support

FSI Success Factors : 

FSI Success Factors Contractual requirement to EPC Contractors. High Level Commitment for FSI implementation Budget for FSI training , motivation and campaigning Serious initiative for FSI implementation at early stage of project Comprehensive Flaw list with established root causes and well defined mitigation actions with identified authority for embedding it in the controlling documents/ Inspection. Hard evidence to ensure that mitigation actions are embedded in the system . FSI action statistics as a talk of every meeting / part of monthly reports. Robust FSI training programme till bottom of work force Impressive Hearts & Mind programme to ensure work force active participation across the project Compulsory Periodic Health check to assess status of FSI implementation in every phase of the project with Dynamic & empowered FSI organisation to drive FSI implementation

Slide 20: 

Discussion

Slide 21: 

Thanks