sample commissioning plan
DESCRIPTION
This is sample Commissioning Plan for Sewerage Treatment PlantTRANSCRIPT
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TABLE OF CONTENTS
1. INTRODUCTION
1.1 Introduction
1.2 Document Management
1.3 Permitting
1.4 Project Description
1.5 Related Documents
2. DEFINITIONS
2.1 Terms Used in Document
2.2 Acceptance Criteria
3. SAFETY & RISK APPRAISAL
3.1 Restricted Area Plan
3.2 Safety & Risk Management
3.2.1 During Equipment & Mechanical Testing
3.2.2 During Process Commissioning
3.2.3 During Plant Operation
3.3 Commissioning Risk Appraisal
3.4 Emergency & Contingency Plan
4. CONTACTS AND ROLES
4.1 Commissioning Organization
4.2 Names and Contact Details
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5. PROGRAMME & ACTIVITY PLAN
5.1 Programme Narrative
5.2 Pre-commissioning and Commissioning Programme
6. E&M COMMISSIONING AND COMPLETION
6.1 Constraints on Commissioning
6.2 Interfaces
6.3 Checksheets for ITP Pre-Commissioning and Commissioning
6.3.1 Pre-commissioning Checklists
6.3.1.1 Pumps 6.3.1.2 Grit Classifiers 6.3.1.3 Screens 6.3.1.4 Air Blowers 6.3.1.5 Air Diffusers 6.3.1.6 Scum Skimmers 6.3.1.7 Metal pipe works 6.3.1.8 Plastic pipe works 6.3.1.9 Penstocks 6.3.1.10 Transformer 6.3.1.11 Generator Set 6.3.1.12 Switchgear 6.3.1.13 MCC 6.3.1.14 Panel Board 6.3.1.15 Sodium hypochlorite pumps and tanks 6.3.1.16 Polymer Preparation System 6.3.1.17 Mixers and thickeners 6.3.1.18 Filter Press 6.3.1.19 Air Compressor and Air Receivers 6.3.1.20 Lifting Appliances 6.3.1.21 Potable water pumps & tanks 6.3.1.22 Reuse water pumps and tanks 6.3.1.23 Odor Control Unit
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6.3.2 E&M System Commissioning & Acceptance Test (SCAT)
6.3.2.1 Phase 1 – Power Supply 6.3.2.1.1 Grounding System 6.3.2.1.2 34.5 kV Utility 6.3.2.1.3 Transformer 6.3.2.1.4 LV Switchgear 6.3.2.1.5 Motor Control Centre (MCC)
6.3.2.2 Phase 2 - Inlet Works 6.3.2.3 Phase 3 - SBR System 6.3.2.4 Phase 4 - Effluent and Chlorination Disinfection
System 6.3.2.5 Phase 5 - Thickening System 6.3.2.6 Phase 6 - Dewatering System 6.3.2.7 Phase 7 - Reuse Water System 6.3.2.8 Phase 8 - Potable Water System 6.3.2.9 Phase 9 - Deodorizing System 6.3.2.10 Phase 10 – Generator 6.3.2.11 Phase 11 – Building Services 6.3.2.12 Phase 12 - Lighting Protection 6.3.2.13 Phase 13 - SCADA Alarms
6.4 Commissioning Sequence and Start Up Methodology
6.4.1 Phase 1 – Power Supply 6.4.1.1 Grounding System 6.4.1.2 34.5 kV Utility 6.4.1.3 Transformer 6.4.1.4 LV Switchgear 6.4.1.5 Motor Control Centre (MCC)
6.4.2 Phase 2 - Inlet Works 6.4.3 Phase 3 – SBR System 6.4.4 Phase 4 – Effluent and Chlorination Disinfection System 6.4.5 Phase 5 – Thickening System 6.4.6 Phase 6 – Dewatering System 6.4.7 Phase 7 – Reuse Water System 6.4.8 Phase 8 – Potable Water System 6.4.9 Phase 9 - Deodorizing System 6.4.10 Phase 10 – Generator 6.4.11 Phase 11 – Building Services 6.4.12 Phase 12 – Lighting Protection 6.4.13 Phase 13 – SCADA Alarms 6.4.14 Phase 14 – Full plant operation at 75 MLD
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7. PROCESS COMMISSIONING
7.1 Maintenance for off-line system (assuming all installed)
7.2 How to bring additional process tanks/ systems on-line
8. TRAINING PLAN
8.1 Process
8.2 E&M
APPENDICES
Appendix 1 IFC/As-built Drawings Appendix 2 Permits Appendix 3 Inspection & Testing Plan Appendix 4 Restricted Area Plan Appendix 5 JV’s Commissioning Organization Appendix 6 Pre-commissioning & Commissioning Programme Appendix 7 Testing and Commissioning Forms Appendix 8 Process Commissioning Plan Appendix 9 TNSTP Training Plan
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1. INTRODUCTION
1.1 Introduction
This document is the commissioning plan for the STP, a sewage treatment plant
providing sewage treatment to dedicated sewage collected from Taguig and Makati.
The purpose and objective of the Commissioning plan is to set out the procedures
by which the plant shall be tested and commissioned for all equipment, systems, and
the process.
This plan introduces the plant and equipment, defines terms, presents a safety and
risk appraisal, introduces the team and their roles, gives a program and activity plan,
sets out the commissioning procedures and documentation for each equipment and
system, and the process, and gives a training plan for training of Client’s personnel
in the equipment and process operation.
1.2 Management of the document
The Commissioning Plan is a live document and the master copy shall be
maintained and updated on site with a back-up copy retained in the partner
contractor’s office or another alternative location. It is produced concurrently with the
production of the O&M Manual, as many of the documents and activities are
common.
A copy of all permits related to the commissioning, shall be provided in the Appendix
2 of this document. Where permits are not available prior to commissioning, they
shall be provided and inserted as soon as they become available.
The plan sets out required documentation for the testing of each equipment and
system, and the process proving. Sample forms for each type of documentation are
included in this Commissioning Plan and provided in Appendix 7. Completed test
and log documents shall form auxiliary volumes.
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Drawings to be referred to during commissioning shall be listed in the plan and
provided in Appendix 1 and the designer should confirm that the drawings listed are
the most updated versions (either IFC or As-built) and are the correct versions for
reference.
1.3 Permitting
The following permits are required prior to or relating to the commissioning:
a.) Fire Protection
b.) Mechanical
1.) Permit to Operate Generator Sets (PTO)
c.) Electrical
1.) Meralco Permit Application
2.) Certificate of Electrical Inspection
3.) Energization Permit
d.) Environmental Permit
1.) Discharge Permit
The Discharge Permit is a permit applied for from Laguna Lake Development
Authority (LLDA) and permits the plant to discharge effluent to the receiving
water body. The Permit is applied for when the STP is ready to commence
operation, with the target date for testing of effluent compliance with
discharge standards. Following completion of the process commissioning,
inspectors from LLDA will take sample from the effluent of the STP to test for
compliance. Following testing for compliance, the discharge permit will be
issued. Quarterly reporting to LLDA on the plant performance, following
format specified by LLDA will be implemented following receipt of discharge
permit.
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2.) Sanitary Permit
3.) Hazwaste Disposal
4.) Emission(for Genset) from DENR
1.4 Project Description
The Sewage Treatment Plant (LKK-TNSTP) is an underground Sequencing Batch
Reactor type Sewage Treatment Facility designed to treat up to MLD of sewage
coming from the North Catchments.
Details of the process design are provided in the approved Process Design
Document with reference no.
The STP comprises of influent pumping, screening and grit and grease removal,
SBR basins for biological activated sludge treatment, chlorination disinfection, and
sludge handling and filter press sludge dewatering. Odor control facilities are
provided.
Process Flow Schematic (please also refer to Appendix 3).
A detailed process description is provided in Section 8 Process Commissioning, with
simple description as follows:
INFLUENT RECEIPT
Raw sewage enters the STP from two sources: a pressure main, which receives
up to 70 MLD average dry weather flow per day, and a gravity flow to an on-site
sump, which will receive up to 5 MLD average dry weather flow per day and the
site returns.
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PRELIMINARY TREATMENT
Removes debris and grit prior to entering the biological process. Comprises of
coarse and fine screening, with three sets of parallel screens (2 duty and 1
standby at design flow) and grit removal in three grit and grease chambers, again
with 2 duty and 1 standby unit at design flow.
SECONDARY TREATMENT
Uses activated sludge Sequencing Batch Reactor to removes degradable
organics and nutrients. Organics are converted to biomass, carbon dioxide and
water. Biomass is settled and treated effluent is discharged.
DISINFECTION
Uses sodium hypochlorite (NaOcl) disinfection to reduce colliforms in the treated
effluent.
SLUDGE TREATMENT
Sludge is thickened and dewatered using sludge thickeners and filter press.
Polymer is dosed during both thickening and dewatering to enhance the
thickening and dewatering processes.
The treated effluent is discharged into the adjacent creek.
1.5 Related Documents
The commissioning plan makes reference to the following drawings and
documents.
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Single Line Diagram for MCC-2 E-WW-MP-TG-10-003a-4000-E005-2 E
Single Line Diagram for MCC-2 E-WW-MP-TG-10-003a-4000-E005-3 E
Single Line Diagram for Socket E-WW-MP-TG-10-003a-4000-E004-2 B Outlet Maintenance Panel Single Line Diagram E-WW-MP-TG-10-003a-4000-E002-1 E MV Switchgear
Document Schedule:
Document
Inlet Works
Drawing Nos.
E-WW-MP-TG-10-003a-4000-P003-2
Rev.
F
SBR System E-WW-MP-TG-10-003a-4000-P003-3 F
Effluent & Chlorination
Disinfection System E-WW-MP-TG-10-003a-4000-P003-4 F
Thickening System E-WW-MP-TG-10-003a-4000-P003-5 F
Dewatering System E-WW-MP-TG-10-003a-4000-P003-6 F
Reuse Water System E-WW-MP-TG-10-003a-4000-P003-7 F
Single Line Diagram for LV
Switchgear Room E-WW-MP-TG-10-003a-4000-E004-1 E
Single Line Diagram for
MCC-1 E-WW-MP-TG-10-003a-4000-E005-1 E
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2. DEFINITIONS
2.1 Terms Used in Document
Pre-commissioning Carry out all tests checks, and inspections on
individual plant systems and equipment prior to plant
operation.
Commissioning Design, planning and application of activities required
to bring an item of plant or process into full operation
and provide adequate support and training to the end
user to safely run it.
FAT Factory Acceptance Test
P&ID Process and Instrumentation Diagram
Handover The transfer of ownership and responsibility for the
operation and maintenance from the Contractor to the
end user.
SCADA System Control and Data Acquisition
MCC Motor Control Centers
Functional Tests Test used to measure all individual components of the
plant are ready for operation in accordance to the
product specification and Contract requirements.
Trial Operation Test used to demonstrate the quality of the functions
of the system and satisfactory operation of the Plant.
It shall be run for a continuous period of 28 days.
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2.2 Acceptance Criteria
The JV shall monitor plant performance and ensure that it meet the the quality
standards defined in the Contract Performance Specification. Such shall be
documented and included in the Contractor’s report. If the plant fails to meet any
of the Performance requirement for plant reliability, functionality and hydraulic
performance, the JV shall undertake necessary measures for improvement.
See attached Appendix 3. “Inspection & Test Plan”
3. SAFETY AND RISK APPRAISAL
3.1 Restricted Area Plan
See attached Appendix 4. “Restricted Area Plan”
3.2 Safety and Risk Management
This section applies for the management of HSE at Sewage Treatment Plant
throughout the Testing and Commissioning process and eventually the process
proving. The Safety Officer is responsible for the proper implementation of HSE
throughout the commissioning process. The preparation and improvement of the
safety plan, identification of hazards and its controls.
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All personnel involved on the Testing and Commissioning works shall undergo
Safety Training / Induction
Safety Trainings
Safety Training / Induction shall include the following topics, but not limited to:
– Brief description of the Sewage Treatment Plant
– Safety features of the plant
• Gas detectors and alarms
• Fire fighting equipment
• Emergency exits, assembly area and routes
• Emergency back-up system
– Chemicals used in the plant and chemical safety
– Frequency of trainings
– Required Personal Protective Equipment per area
– Area Zoning and Restricted Access
– Signage and Warning Signs
– Plant Facilities
– Safety Rules and Regulations and Permit to Work System
– Key Personnel and Organizational Chart
All personnel involved in the Testing and Commissioning Works shall undergo the Safety Training / Induction before commencing work on site
Client and visiting personnel shall undertake a Safety Briefing and be escorted at all times while visting the plant
All personnel, client representatives and visitors shall have their attendance at the Project Induction Program recorded in the Safety Training Attendance and shall be kept by the Safety Officer for safekeeping
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Permit to Work System
Permit to work has been established to maintain control of hazardous work being
carried out on the worksite and to ensure that all necessary safety precautions
are carried out. It should be noted that a work permit does not guarantee safety;
an accident can occur at any time and safety rules must be always followed.
It identifies conditions and limits potentially harmful effects on the person carrying
out the work by specifying safety precautions to be followed during work activity.
It gives a comprehensive and detailed record of all ongoing work, control of the
work situation and avoids conflicting or incompatible work being carried out
simultaneously.
Safe Work Permits shall be issued for the following activities:
- Hot Works
- Cold Works
- Lifting Operation
- Confined Space Entry
- Excavation Works
- Electrical Works
- Energizing / Isolation / Lock Out Tag Out
STARRT card shall also be utilized in conjunction with the above mentioned Safe
Work Permits
Personal Protective Equipment
PPE means all equipment and clothing which is intended to be worn or held by a
person at work and which affords protection against one or more risks to health
or safety. This includes clothing designed to protect against adverse weather
conditions.
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Protective clothing includes - for example - gloves, safety shoes, safety helmets
and high visibility jackets. Protective equipment includes eye protectors, safety
harness, and respirators.
As a minimum, all Testing and Commissioning operatives must wear safety
helmet and safety shoes.
As per area requirements or as per Risk Assessment other items may be
required (refer to PPE requirement table)
The Risk Assessment will take account of:
The PPE - is appropriate for the risk(s) involved and the conditions at the place
where exposure may arise;
Takes ergonomic considerations into account, be capable of being fitted to (and
used by) that employee where applicable;
So far as is practicable, prevent or adequately control the risk of exposure
without increasing the overall risk;
Is designed and manufactured to an approved standard.
Where more than one sort of PPE has to be used simultaneously, each must be
compatible with the other and full effectiveness must be maintained.
PPE must be maintained by the user - e.g. cleaned, repaired or replaced - in an
efficient state.
Suitable storage arrangements should be made to prevent damage to the PPE,
including that which has already been issued.
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PPE INSPECTION
It is the responsibility of the PPE user to carry out a visual inspection and
functional check (if applicable) prior to every use. General inspection shall be
done every three (3) months to be conducted by Safety Officer. If any PPE is
defective or damaged, it must be immediately reported to Safety Officer to
assess and for replacement as necessary.
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Waste Management
Joint Venture are committed to implement the project environmental plan so that it is
effective, accurate and economical and ensure that the procedures put into place are
working and are maintained. This is to ensure that all waste materials are:
• Reduced, reused and recycled as far as possible;
• Properly categorized for correct collection, storage, handling, treatment and
disposal;
• Traceable from production source through to final disposal.
Restricted Areas
Sewage Treatment Plant Facilities shall have restricted access particularly in areas
where hazard criteria based from risk assessment would fall from medium to high.
Special training including PPE is required prior to entry to such areas with restrictions.
Primarily, the entire Sewage Treatment Plant shall be an all restricted area.
Visitors shall only be allowed on two (2) locations, one is the visitors parking area and
the other one is the admin area. Visitors can only access restricted area given the
following conditions:
- They have an appointment with the plant management with at least two (2)
working days advance notice
- They have undergone the required safety briefing conducted by authorized
personnel
- They are equipped with the appropriate PPE
- They are accompanied by a duly authorized plant representative
Visitors shall only be allowed on certain restricted areas even with the presence of all
the above mentioned requirements since special trainings shall be required for further
access on highly restricted areas
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Emergency Response Procedure
Required Emergency Response Procedures shall be defined and developed by
the Testing and Commissioning and Design team.
Emergency Escape Routes and Emergency Devices
Emergency escape routes together with emergency contact numbers and contact
persons shall be verified and made available during the commissioning works.
For the initial layout of emergency devices, refer to appendix **
DEFINITIONS AND PROVISIONS
HAZARDOUS LOCATION
The National Electrical Code (NEC) defines hazardous locations as those areas
"where fire or explosion hazards may exist due to flammable gases or vapors,
flammable liquids, combustible dust, or ignitable fibers or flyings."
HAZARDOUS WORKPLACES
OCCUPATIONAL SAFETY AND HEALTH STANDARDS
(As Amended, 2006)
Department of Labor & Employment Philippines
RULE 1010
OTHER SAFETY RULES
1013: Hazardous Workplaces:
For purposes of this Standards, the following are considered "hazardous
workplaces:"
a. Where the nature of work exposes the workers to dangerous environmental
elements, contaminants or work conditions including ionizing radiation,
chemicals, fire, flammable substances, noxious components and the like;
b. Where the workers are engaged in construction work, logging, fire fighting,
mining, quarrying, blasting, stevedoring, dock work, deep-sea fishing and
mechanized farming;
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c. Where the workers are engaged in the manufacture or handling of explosives
and other pyrotechnic
products;
d. Where the workers use or are exposed to power driven or explosive powder
actuated tools;
e. Where the workers are exposed to biologic agents such as bacteria, fungi,
viruses, protozoas, nematodes, and other parasites.
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3.3 Commissioning Risk Appraisal
The principal risks associated with Commissioning of the STP have been assessed
and included into HAZCOM study assessment. The outcome of these risks during
commissioning should be recorded and included in O&M Manuals. Information
should be provided on risk to health and safety, preventative measures and
emergency procedures associated in Commissioning.
The principal risk associated with the Testing and Commissioning of the STP have been assessed to be
the following:
CAUSE EFFECT RISK LEVEL & MITIGATION
Handling and Spillage of
Chemicals
� Environmental Hazard (soil,
water and air pollution)
� Chemical reaction and
contamination
� Skin contact / irritation
� Respiratory irritation
� Ingestion
Medium
- Provide PPE for handling of
chemicals
• Safety eye goggles
• Chemical Gloves
• Chemical Respirators &
Breathing Apparatus
• Apron
• Safety Shoes / Boots
- Provide chemical spill cleanup
kit and cleanup procedure
training
- All liquid chemical containers
and tanks should be contained
within a bunded area
- Check proper storage of
chemicals to avoid cross
contamination and reaction
- Check storage area for
sufficient ventilation
- Provide MSDS of all chemicals
present
- Provide training for chemical
handling and storage
- Provide safety eye wash and
shower station
- Provide first aid kit
Electrical � Electrocution resulting to Medium
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- Extension leads
- Faulty wiring / grounding
- Arcing
personnel injury or death
� Equipment damage
- All electrical and control
equipments including but not
limited to wires and cables
should be checked and punch
listed prior to testing
- Check all grounding / earthing
systems
- Check all connections,
isolations and fail safe devices
prior to testing
- PTWS and LOTO
- Area restriction to authorized
personnel only
Equipment damage due to:
- Misuse
- Factory defect / Malfunction
� Equipment damage
� Personnel injury
Medium
- All equipments should be
checked and punch listed prior
to initial testing
- Only trained personnel should
be involved in the
commissioning, testing and
operation of equipments
- Testing and commissioning
procedure should be in
accordance with the O&M
manuals and all submitted
documentation
Falls from elevated level /
reservoir due to:
- Slips
- Trips
- Unprotected / barricaded
levels and floor openings
� Personnel injury / Death
� Drowning
Low
- All walkways, aisles, stairways
and catwalks should be clear
from debris, water, oil and
grease
- Ramps or catwalk with non-slip
surface should be installed on
walkways with pipes crossing
- Permanent railings complete
with top rails, mid rails and toe
boards should be installed
prior testing and commissioning
works. In any cases where work
should be done outside such
barriers, fall protection system
should be used
- Life vest should be used in
addition with fall protection
system when working outside
the safety barrier particularly
on the SBR and holding tanks
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- Indicate emergency shutdown
button / call point
- Area restriction to authorized
personnel only
Excessive Noise � Hearing Damage Low
- Provide suitable hearing
protection (ear plugs / ear
muffs)
- Provide demarcation for sound
level around genset room
Moving vehicles / Traffic � Vehicular collision resulting to
property damage
� Pedestrian struck by moving
vehicles resulting to injury
Low
- Provide traffic man if necessary
- Indicate traffic route inside
plant area
- Provide pedestrian lines and
safety bollards
- Specify parking, waiting/stand
by and loading area
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4. CONTACTS AND ROLES
4.1 Commissioning Organization
See attached Appendix 5. “JV’s Commissioning Organization”
4.2 Names and Contact Details
NAME COMPANY POSITION PHONE NUMBER
Commissioning Director 0917-55806xx
Project Manager 0917-59278xx
Head, Testing & Commissioning
Electro-Mechanical
0917-59585xx
Instrumentation & Control
Engineer
0908-59412xx
Head, Testing & Commissioning
Building Services Manager
0949-95949xx
Head, Process Commissioning 0917-79113xx
Commissioning Co-ordination
Manager
0917-80806xx
Head, Commissioning Safety 0932-84804xx
Process Engineer 0917-81071xx
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NAME
COMPANY
POSITION
PHONE NUMBER
Control & Instrumentation
Supervisor
0917-53953xx
Head of Mechanical (Testing &
Commissioning)
0915-13347xx
Mechanical Commissioning
Supervisor, Auxillary
0915-68977xx
Mechanical Engineer, SBR &
Auxilliary
0915-61830xx
Mechanical Commissioning
Supervisor, SBR
0919-22084xx
Scheduler/Planner 0932-84819xx
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Commissioning Team Terms of Reference
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Commissioning Director
- Overall-in-charge of the testing and commissioning.
- Develop overall project planning, master program on testing and commissioning.
- Single point of contact to JV member, consultant, client, suppliers and
subcontractors.
- Act as JV Representative in project meetings with consultants and clients.
- To chair all the internal project team meetings.
- Ensure development of the quality culture on site by delivering training to internal
staff.
Project Manager
- Monitor the performance of the Quality Management Systems to comply with the
JEC Quality Procedures.
- Responsible for the deployment of suitable project team member and facilities.
- Develop and maintain the project organization chart for commissioning phases.
- Delegation of work to each project team member (including JV member).
- To maintain the integrity of the project team (including JV member).
- To seek resources to solve technical, commercial and contractual issues.
- Manage and control resources, cost and time.
- To arrange all necessary reports to clients.
- To arrange all commissioning reports and analysis to Commissioning Director.
- To report project risk and propose mitigation measures to Commissioning
Director.
- Oversee project administration, procurement, sub-letting and document control.
Commissioning Coordination Manager
- Liaison between installation and commissioning stages.
- Liaison between construction and safety / environmental.
- Attending all testing and commissioning co-ordination meetings.
- Assisting in the preparation of the 2 week lookahead programmes. - Advising on any proposed actions which require input from design and
construction activities. - Assisting the Project Manager in co-ordination of site activities. - Preparation and input into Progress Reporting on Commissioning. - Informing the project manager on all relevant aspects of construction works in
terms of planning, progress, quality, safety and subcontractor performance
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Head of Testing & Commissioning (Electro-mechanical)
- Liaise with external suppliers and client to ensure that the Quality Management
System is compliant with contract requirements.
- Assist in the conduct of Supplier Evaluation activities, including auditing and
document vetting.
- Design, implement & maintain the quality assurance program audit for ISO
compliance.
- Ensure corrective Reports are submitted after each audit and followed up for
implementation and compliance.
- Ensuring project execution in accordance with the project quality control plan and
quality requirements in the contract.
- Execution of testing and commissioning activities.
- Ensure the optimization and operation of subcontractors bespoke process plant
and all associated proprietary equipment such as control systems, instruments,
valves and pumps etc at various sites.
- The ability and willingness to undertake ‘hands on’ work whenever necessary.
- Compilation of detailed formal site reports and other documentation to support JV
activities including office administration forms such as timesheets, expenses, risk
assessments etc.
- When necessary and practical provide support to clients by e-mail or telephone.
- Multi skilled installation, commissioning and troubleshooting of all associated
proprietary equipment such as control systems, instruments, valves and pumps.
Head of Testing & Commissioning (Building Services)
- Resolving structural/civil matters concerning project execution, planning and site
queries in cooperation with the project team.
- The ability to supervise and manage other personnel with regards to building
services.
- Person-in-charge with the fire fighting and building services.
- When necessary and practical provide support to colleagues in relation to
general project work etc.
- Operate at all times within the guidelines of the company’s and clients
procedures regarding quality, health, safety and environmental issues.
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- Undertake office based activities as necessary, including but not limited to
preparation of O&M manuals, commercial proposals and technical advice to
clients and colleagues.
- Be aware and take account of commercial and contractual issues in relation to
project timescales and budgets etc. concerning building services.
Head of Testing & Commissioning (Process)
- Liaise with client to develop solutions to requirements of process commissioning.
- Person-in-charge in the preparation and updating of process commissioning
plan.
- Be a technical point of contact both internally and externally when it comes to
process commissioning.
- Liaising with other departments within the JV Commissioning team.
- Undertake both formal ‘classroom’ and ‘hands on’ training of client’s personnel
and prepare appropriate training documentation whenever required.
Process Engineer
- Concept and development of the process design and commissioning.
- Working within a team to ensure co-ordination of the testing and commissioning.
- Liaise with construction team, and other JV Design team members to ensure
feasibility of the design.
- The multi skilled installation, commissioning and troubleshooting of the JV
process plant.
Electrical Commissioning Supervisor
- Concept and development of the testing and commissioning of electrical
components.
- Liaising with other trades within the JV Commissioning Organization.
- Liaise with construction team to ensure feasibility of the electrical design.
- Be a technical point of contact both internally and externally in regards with
electrical commissioning.
Mechanical Commissioning Supervisor
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- Concept and development of the testing and commissioning of mechanical
components.
- Liaising with other trades within the JV Commissioning Organization.
- Liaise with construction team to ensure feasibility of the mechanical design.
- Be a technical point of contact both internally and externally in regards with
mechanical commissioning.
Scheduler/Planner
- Determining critical / key logic when producing commissioning programme.
- Producing and sending out testing and commissioning progress up-dates weekly.
- Determining site loading to suit programme demands and staff/resource levels to
suit programme requirements.
- Prepare all programmes as required by the commissioning team.
- Attending progress meeting with the client.
- Providing current position reports for board level presentations by the
Commissioning Director.
Commissioning Safety Head
- Responsible of overall project safety.
- Prepare and up-date commissioning safety plan.
- Prepare risk assessments for all site activities and review sub-contractor method
statement and risk assessments.
- Carry out weekly project safety audits.
- Provide safety training for site staff and operatives prior to testing and
commissioning.
- Provide briefings for operative toolbox talks.
- Prepare weekly, monthly safety reports
- Monitor and control testing and commissioning safety.
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5. PROGRAMME AND ACTIVITY PLAN
5.1 Programme Narrative
The interrelationship between and sequence of events for testing and
commissioning activities are schematically set out in Figure 1, and are defined in
Section 2.
Figure 1: Testing and Commissioning Activities
Commissioning has two distinct phases, separated by the introduction of
sewage. Prior to the introduction of sewage all testing shall be of individual
systems and shall be dry or wet testing with clean water.
Following the completion of individual systems testing, the system shall be
seeded with sludge (biomass) and sewage shall be introduced to the plant. The
commissioning activities shall be focused on systems integration testing and
process biological start-up and stabilization. Following process establishment,
the 28 day trial operation shall commence to demonstrate the process
performance. Successful completion of Trial Operation shall be followed by the
process proving period.
Phase Pre-
Commissioning
Trial operation Process proving
period
Installation checks Dry tests West tests Functional tests Process establishment 28 day test 2 year period
Visual inspections Rotation/electrical
checks
Pumps run on clean
water
Interaction of plant Seed sludge introduced No modifications to
operation of plant
Detailed monitoring
periods within this time
Check interlinks of
equipment work
Software checking Feed with sewage,adjust,
calibrate, generally settle
plant and build biology to
correct operating
position.
Inputs only as the
allowable levels in the
operation and
maintenance manual
Calibration - of
whatever can be
calibrated
Monitor and adjust until
effluent parameters
achieved
Influent Sewage
Characterisation Study
Operating
Commissioning
All relevant permits need to
be in place - effluent
discharge commences
Ha
nd
ov
er
Ind
ica
tive
act
ivit
ies
Intr
od
uce
wa
ter
Intr
od
uce
se
wa
ge
Live flow present to be managed
CONTROLLED DOCUMENT
The testing and commissioning activities shown in the pre-commissioning and
commissioning program prior to the introduction of sewage are categorized by
systems, i.e. inlet work, each SBR, air blower for SBR, effluent disinfection &
reuse water system, sludge thickening & dewatering system, deodorization
system, power system, process start up, trial operation and the other services.
For each system in the program, the appropriate activities, such as the pipework
hydraulic test, air pipework pneumatic test, electrical cable insulation test,
instrumentation and control cable insulation test, equipment functional test, pump
functional test, switchgear test, etc., will be indicated.
The schedules of the testing activities are staggered for reasonable manpower
arrangement of testing and inspection.
Pre-commissioning will be conducted before the commissioning for each system.
However, there may be both pre-commissioning and commissioning activities
ongoing for different systems at the same time. Each activity shown in the
program includes pre-commissioning and commissioning.
Before the permanent power on, i.e. end January 2013, those tests not requiring
permanent power such as the pipework hydraulic test, air pipework pneumatic
test, electrical, instrumentation and control cable insulation test will be
conducted. Testing will commence from mid Dec 2012.
After the completion of testing of transformer, MV switchgear and LV switchgear,
the permanent power supply will be switched on. i.e. end Feb 2013, by Meracle.
Following the permanent power supply being on, the clean water functional test
of equipment and pumps, SCADA and the other services, as appropriate, will be
conducted. For the MLR pumps, WAS pumps, effluent pumps and the other
pumps, clean water will be filled in for functional tests. The dates of clean water
filling in shall be referred to the program.
Once the tests of pipework, cables and equipment of inlet work, SBR no. 2, 3, 4,
6, 7 and 8, blowers, effluent system and deodorization system are finished, the
process start up will commence, i.e. mid Feb 2013, with the seeding of the target
operational SBR basins with biomass (activated sludge from other STP), and the
acceptance of influent sewage.
CONTROLLED DOCUMENT
For the influent flow of 51 MLD only 6 SBRs are required for process start up.
These basins will be seeded and the process startup, as detailed in Section 7
(Process Commissioning) shall be followed.
The process start-up is estimated to take 15 days, and the initial tests and
systems integration will be completed during this time, which shall be early March
2013. A four (4) day influent sewage characterization shall also be performance
once a consistent inflow of sewage to the STP has been established.
Following process startup and when the process is stable and producing
consistent effluent quality meeting the required discharge standards, the 28 days
trial operation will commence.
51MLD incoming sewage is assumed to be received for the process start up and
trial operation.
The disinfection system, reuse water system and deodorization systems will be
tested during the process start-up, i.e. early March 2013.
The sludge thickening & dewatering system will be process commissioned when
there is sufficient sludge available from the process. This may be during the 28
day trial operation, or later, depending on the loading to the STP.
For the building services and the lifting appliances, the tests will be completed
before construction completion milestone date, i.e. 3 April 2013.
CONTROLLED DOCUMENT
6. E&M COMMISSIONING AND COMPLETION
6.1 Constraints on Commissioning
The main constraints on commissioning shall be identified by JV at a later part of
Installation works.
6.2 Interfaces
The interfaces with each discipline (Electrical, Mechanical, Process,
Instrumentation and Control) will be required. The Commissioning Co-ordinator
shall be responsible for the co-ordination of the works to be carried out during
testing and commissioning.
As the Commissioning stage progresses, the operating parameters may require
adjustment and where modifications are required, the JV shall liaise closely with
all parties involved to secure an agreed course of action.
CONTROLLED DOCUMENT
7. CHECKSHEETS FOR ITP PRE-COMMISSIONING AND
COMMISSIONING
These check lists showing the check points be submitted for information as a
complete package. The individual check lists items will be inspected and signed
off by the JV and where appropriate, and requested by a Work Inspection Report,
the Engineer as the pre-commissioning and commissioning is carried out. The
master file of the completed and partially completed check lists will be maintained
and controlled by the JV. Once any given checklist is fully complete, it will be
submitted to the Engineer for final signature and the option is available for the
signature of the Client also as an indication of a review of the check list form. The
signed form shall be returned to the Contractor. On completion of the Trial
Operation and Reliability Tests a copy of all the completed check lists will be
submitted as part of the Commissioning Report along with the test data and
operational conditions during the Take-Over.
7.1 Pre-Commissioning Checklists
In this section, JV shall provide all records and tests carried out in preparation for
the pre-commissioning works.
The following should be included:
1. CABLE TEST SCHEDULE – this needs to demonstrate that all cables have
been tested and checked to confirm that cables are correctly connected to the
correct terminals and / or drives.
2. PLANT TEST AND DETAILS – this needs to demonstrate that plant is
correctly set up and is safe to commission.
CONTROLLED DOCUMENT
3. CIVIL WORK TESTS – this needs to demonstrate that the structure have
been properly constructed and tested, all connections in place and is safe to
commission. All results to be recorded in this section of the commissioning
plan.
Tests should include:
• Pipeline pressure tests
• Water retaining structure tests
• Certificates of tests for tank cover materials
4. Test Certificates for permanently installed monitoring equipment such as Gas
Detection Systems – to be placed in O&M manual.
5. Test to be carried out on lifting equipment, davit posts and pressure vessels,
tests to be recorded and certificates placed in O&M manual.
6. PRESSURE TESTING – details of sources of water for commissioning to be
recorded in plan and confirmation of agreements with both parties for use of
water for testing and method of disposal after testing.
See attached Appendix 7 “Testing and Commissioning Forms”.
7.2 E&M System Commissioning & Acceptance Test (SCAT)
In this section, JV shall provide all records and tests carried out during the
commissioning works.
CONTROLLED DOCUMENT
7.3 Electrical & Mechanical Commissioning Sequence and
Start Up Methodology
Each system will be dry and wet tested as part of the functional tests prior to
overall process commissioning. All structures should be demonstrated to be free
of leakage or excessive cracking or any other indications of potential structural or
service failure during commissioning. Checklists for the pre-commissioning and
commissioning of elements and systems are to be enumerated.
Once the dry functional tests are complete and the tank systems (SBR, Inlet,
chemical dosing) have been tested with water to ensure their correct
functionality, process commissioning prior to the Trial Operation and Reliability
Tests will commence. The overall sequence and procedures can be referred to
section the procedures outlined.
8. PROCESS COMMISSIONING
See attached Appendix 8 for the approved “Process Commissioning Plan”.
9. Training Plan
Training requirements shall be established as specified in the Contract. As a
minimum, management, supervisory, process, operations and maintenance
personnel shall be trained. JV shall provide a syllabus of the training to be
provided. A comprehensive training plan shall also be developed by the JV in
conjunction with the Operation and Maintenance manual.
See Appendix 9 “TNSTP Training Plan”.
CONTROLLED DOCUMENT
It would be helpful if Client could confirm the names and positions of the individuals who will form part of the Operations and Maintenance Team at LKK. As well as formal classroom training required for certain elements it is intended that the majority of the training will be of a “hands-on” type working alongside the JV’s commissioning team. The relevant Client staff will need to be full time available at the plant from the start of commissioning. Furthermore it is recommended that operational staff are made available for pre-commissioning testing which will be witnessed by the Engineer in order to maximize their understanding of how the systems work.