plant-commissioning

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ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
PLANT COMMISSIONING
AUTHOR:
Wilton Centre Engineering Quality Manager
APPROVED BY:
Wilton Centre Engineering Manager
ISSUING AUTHORITY:
Wilton Centre Research Manager
REVISION STATUS:
Fifth Issue of 1 June 1996
REVISION
DATE
BY
APPROVED
4
1.12.95
1.6.96
ATT
ATT
JSK
5
Page 1 of 8
ASG/WCE/2043
ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
1
PURPOSE
This instruction gives the steps to be taken in the period leading up to the completion
of construction of a plant where this involves Wilton Centre Engineering.
2
SCOPE
This instruction covers all plants installed in the Wilton Centre Semi-Technical area,
and also Engineered Lab Rigs in the main building laboratories.
3
REFERENCES
3.1
PRJ05: Project Engineering Control.
3.2
ASG/GEN/6001: Work Control Permit System
3.3
ASG/WCE/2007: Modifications.
3.4
RT/ERM/3002: SHE assurance for research plants
4
DEFINITIONS
4.1
Plant: a plant, unit, or engineered laboratory rig, irrespective of size, the construction
of which involved Wilton Centre Engineering.
4.2
Commissioning Manager: the representative of the plant owner who takes
responsibility for commissioning activities on the plant. (This will normally be the
future plant manager.)
4.3
Project Engineer: the engineer responsible for design and construction of the plant.
(Normally a member of Wilton Centre Engineering, and leading a multi-discipline
team.)
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ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
5
INSTRUCTION
5.1
INTRODUCTION
Commissioning is normally a joint activity between the project team responsible for
the design & construction of the plant, and the plant operating team. Separate
commissioning teams are not usually employed. At the project launch meeting,
outline agreement will normally be reached on which teams are to be involved in
commissioning, and the names of those who are to fill the key roles (see ref 3.1).
Commissioning and handover of responsibility from the project team to the operating
team takes place in stages, which are defined below. It is important that these stages
and the responsibilities for each stage are defined & understood by all those involved.
5.2
COMMISSIONING
The four stages of commissioning are:
(1)
Construction and engineering checks
(2)
Precommissioning
(3)
Process commissioning
(4)
Completion of commissioning and start of production.
Normal production, which in R&T usually involves experimentation, follows
completion of stage 4. A summary of the four stages and the associated
responsibilities is shown in Appendix 1. The detailed responsibilities are as follows.
5.2.1
Stage 1: Construction & Engineering Checks.
The project engineer is responsible for the plant, for all the activities on the plant and
chairs the plant project meetings. The construction work control permit, ref 3.2,
remains in force and the plant remains isolated from electric power and process
services throughout this stage.
As the phases of construction are completed, the engineering checks, detailed in
Appendix 1, are intended to confirm that the plant has been constructed according to
the design. Any errors found during the engineering checks shall either be corrected
at the time or listed on the Project Reservations List for subsequent correction. The
project engineer is responsible for dealing with all items on the Project Reservations
List.
The control of work permit issued for construction of the plant is withdrawn at the
end of this stage. This shall be done before any piped or wired services are supplied
to the plant.
All necessary registration documents (eg INS2) and their associated inspections shall
be completed by this point.
Page 3 of 8
ASG/WCE/2043
ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
5.2.2
Stage 2: Precommissioning
At the start of this stage the commissioning manager takes responsibility from the
project engineer for the safety of the plant and for the planning and prioritising of all
activities on it, although the project engineer remains responsible for completion of
engineering work on the plant. Electric power and process services are now supplied
to the plant.
The stage involves leak testing (the commissioning manager's responsibility) and
further engineering checks (the project engineer's responsibility), which are defined
in Appendix 2.
Individual work control permits are issued for engineering work by the new plant's
normal permit issuer, ref 3.2. Note that the blanket work control permit used for
construction was only permissible because the plant was effectively isolated from all
sources of danger such as power and services. Once these services have been
supplied to the plant a blanket permit is no longer acceptable and a separate permit is
required each time the plant is handed over for engineering work.
During this stage the project meetings should continue but it may be appropriate for
them to be chaired by the commissioning manager. Daily commissioning meetings
led by the commissioning manager may also be appropriate.
Engineering errors found during this stage shall either be corrected at the time or
recorded on the Project Reservations List. Any changes to the design of the plant
shall be controlled by the "change of requirements" procedure in ref 3.1.
5.2.3
Stage 3: Process Commissioning
Process materials are introduced into the plant for the first time. The responsibilities
are the same as for stage 2, with the addition of the requirement for the
commissioning manager to write procedures covering the chemical substances and
their reactions.
Note that it is important that the instrument checks in stage 1 are all completed
satisfactorily for the entire plant before materials capable of creating a potentially
explosive atmosphere are introduced into any portion of the plant.
5.2.4
Stage 4: Completion of commissioning and start of production
The change from stage 3 to stage 4 occurs once the plant has started to fulfil (at least
part of) the purpose for which it was designed although there may be outstanding
tasks on the Plant Reservations List.
The other key change associated with this stage is that changes to the plant are now
subject to the modifications procedure, ref 3.3, which replaces the change-ofrequirements procedure of ref 3.1.
The commissioning manager is responsible for the carrying out of modifications
(their physical execution will usually involve a plant engineer). Apart from this the
responsibilities and procedures are the same as in stages 2 and 3. The project
engineer remains responsible for completing tasks on the Plant Reservations List.
The plant project meetings should continue.
Page 4 of 8
ASG/WCE/2043
ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
The end of this stage is defined by the completion of the outstanding items on the
Plant Reservation List and of the Plant Dossier, ref 3.4. The end of project review
form, QC 201, shall then be completed by the project engineer (see ref 3.1).
After completion of stage 4, the project engineer will have no further formal
involvement with the plant unless a new project is commissioned.
5.2.5
The commissioning manager is responsible for completion of Hazard Study 6, which
takes place about 6 months after the completion of commissioning (see ref 3.4).
6
DOCUMENTATION
6.1
Project completion form QC201.
7
APPENDIX 1: STAGE 1 - ENGINEERING CHECKS
7.1
INSTALLATION CHECK
7.1.1
As far as possible, any correction of installation errors shall be made during the
installation period.
7.1.2
Towards the completion of installation, all lines, vessels, service connections and
instruments shall be examined and detailed checks made. These shall include the
presence & correct positioning of equipment, accessibility of valves and sample
points, run of lines, security of joints, fastenings and fixings, and correct labelling of
all plant items and instruments. Pipework shall be checked to ensure that the
installation conforms to the drawings. Checks shall be made to ensure that all valves
and other operating controls are safely accessible; that all necessary material
identities have been recorded; that RVs, BDs & vents are tagged; and that RVs have
been check-lifted.
7.1.3
If the nature of the project makes it appropriate, the Project Engineer shall designate
a specific print of the current revision of the line diagram, and all items checked and
found to be satisfactory shall be marked up on it. Any errors shall either be corrected
at this time or listed on the Project Reservation List for rectification.
7.1.4
Any work found necessary to commission the plant during the installation check shall
be agreed between the Project Engineer and the Customer and listed on the
Reservation List. If the "designated line diagram" method is in use, then as such
work is complete and checked the diagram shall be marked up accordingly.
7.2
PRE-TRANSFER SAFETY CHECKS
In conjunction with the above, the Project Engineer shall make the following safety
checks, which cover the requirements of Hazard Studies 4 and 5.
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ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
(a)
Check that the Hazop (alias Hazard Study 3) review has been carried out, the actions
attended to, and the report signed and issued.
(b)
Check that, if Area Classification is appropriate, then it has been carried out and any
drawing issued.
(c)
Check that all bursting discs have been fitted and tagged by an ICI technician.
(d)
Check that all relief valves have been check lifted, tagged and refitted correctly by an
ICI technician.
(e)
Check that all relief streams have been inspected and signed off on form Ins 4.
(f)
Check that all lifting beams have been proof tested and that all lifting equipment has
been registered.
(g)
Check that all pressure vessels and relief streams installed have been registered
correctly.
(h)
Check that any gearboxes have had the correct oil added.
(i)
Check that Hazardous Area Initial Inspections have been completed and documented.
(j)
Check by walking round the plant that there are no safety hazards (eg valve handles
blocking stairs, sharp edges at head height) and that the plant generally fulfils the
design requirements.
7.3
PRE-TRANSFER INSTRUMENT & ELECTRICAL CHECKS
7.3.1
Before power is supplied to the plant, an electrical test certificate shall be
completed by the electrical contractor and returned to the Project Electrical Engineer,
and a check shall be made to ensure that all electrical installation work has been
signed off.
7.3.2
A visual check shall be made of all junction boxes, cables, glands and terminals.
7.3.3
If there is any instrument & electrical equipment in potentially explosive
atmospheres, the appropriate Initial Inspections shall be carried out. This may
include point-to-point wiring checks.
7.3.4
Any malfunctions shall be recorded on the Project Reservation list.
8
APPENDIX 2: STAGE 2 - PRECOMMISSIONING
8.1
INSTRUMENT AND ELECTRICAL CHECKS & TESTS
8.1.1
The basic philosophy is that testing shall start with all fuses removed, and shall
proceed one loop at a time.
8.1.2
The loop sheets shall be used as the check list and each loop shall be given a
functional test. If appropriate it shall be calibrated.
8.1.3
Page 6 of 8
Each trip shall be given a functional test and calibration.
ASG/WCE/2043
ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
8.1.4
Control circuit and rotation tests of all drives shall be carried out by agreement with
the mechanical and operating teams. A check shall be made to ensure that the correct
direction of rotation of all motors have been verified.
8.1.5
Any malfunctions shall be recorded on the Project Reservation list.
8.2
LEAK TESTING
8.2.1
Leak testing shall be carried out by the operating team using a procedure agreed with
the Project Engineer and (except in main building labs) the Semitech Area
Operations Team.
8.2.2
If electrical power and instruments are required for the leak test, the pre-transfer
Instrument & Electrical checks shown above shall also have been completed.
8.2.3
Individual sections of line or equipment shall be tested using a suitable fluid at
working pressure, and commencing at the point of supply and proceeding in discrete
sections until the whole plant has been tested. As each section is systematically
tested and made leak-tight, the agreed copy of the line diagram shall be marked up to
indicate a successful test.
8.2.4
Care shall be taken to ensure that no section under test is isolated from its relief route,
and that relief is installed adequate for the tests being carried out.
Page 7 of 8
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ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
9
APPENDIX 3: PLANT COMMISSIONING AND HANDOVER
OF RESPONSIBILITY
Stage:
1
Engineering checks
2
Precommissioning
3
Process commissioning
4
Completion of commissioning and start of production
Page 8 of 8
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ENGINEERING & OPERATIONS GROUP
INSTRUCTIONS
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ASG/WCE/2043
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