Tarlton Commissioning Plan - Welcome to …€¦ · · 2015-10-26Document Title: TPL25 –...

TRANSNET PIPELINES

TPL 25

Tarlton Commissioning Plan

Issue Date: 03/07/2015 Revision No.: A Project No.: 11992

Date: 03/07/2015

Document Title: TPL25 – Tarlton Commissioning Plan

Author: Edward Standen

Revision Number: A

Checked by: Trevor Albertyn

Approved by: Didier Regnaud

For: SiVEST Project Management Division

Signature:

Approved by: Charl Bothma (TPL Project Manager)

For: Transnet Pipelines

Signature:

TRANSNET PIPELINES prepared by: SiVEST TPL25 – Commissioning Plan

Revision No. A

03 July 2015 Page 1 of 9

TRANSNET PIPELINES 11992 - TPL 25

Commissioning Plan Contents Page 1. Introduction: ...................................................................................................................... 2

2. Extent of Work: ................................................................................................................. 2

3. Organisation: ..................................................................................................................... 2

3.1. Stages to Construction and Commissioning. ........................................................... 2

3.1.1. C1 - Pre-Commissioning ...................................................................................... 3

3.1.2. C2 - “Cold” Commissioning .................................................................................. 4

3.1.3. C3 - “Hot” Commissioning ................................................................................... 4

3.2. Roles and responsibilities ........................................................................................ 5

3.3. Division of Works into sub-systems for Commissioning .......................................... 6

3.4. Commissioning activity sequencing ......................................................................... 7

4. Schedule: .......................................................................................................................... 7

5. Individual Equipment Testing Procedures: ....................................................................... 9

6. Facility Testing Procedures:.............................................................................................. 9

7. Safety: ............................................................................................................................... 9

8. Check / Data Forms: ......................................................................................................... 9

9. Hand-over Procedures: ..................................................................................................... 9

Annexure A ................................................................................................................................ 1

Annexure B ................................................................................................................................ 2

Annexure C ................................................................................................................................ 3

Annexure D ................................................................................................................................ 4

Annexure E ................................................................................................................................ 5

Annexure F ................................................................................................................................ 6


Revision No. A


1. Introduction:

This document is a commissioning plan developed for the Tarlton Fire Protection

upgrade and is to be used to inform the Contractor of the commissioning requirements

for inclusion in the offer as well as to guide the construction and commissioning process

during implementation.

This document will require revision and updating by the Project Manager and Contractor

during implementation. Areas requiring updated are indicated and updates may be in

the form of revisions to the document or addition of Annexures and addendums.

The intention of this document is to indicate the parties involved in commissioning and

define the roles and responsibilities as well as reporting and approval requirements.

2. Extent of Work:

The commissioning shall consider the full extent of the Works and shall encompass

monitoring and approval of civil, structural and building works in addition to monitoring,

approval, installation verification and performance testing of the piping, electrical, control

and mechanical equipment installations.

Commissioning shall be an ongoing process and shall commence during construction

both in order to reduce the overall timeline as well as due to necessity as some

commissioning activities need to be completed before other construction activities can

commence; an example of this is the bottom layer of piping in trenches must be

hydrostatically tested before the pipe can be backfilled and the piping layer above that

layer can be installed.

3. Organisation:

The organisation of the works will facilitate the efficient management and completion of

the commissioning by defining responsibilities, defining the division of works into

manageable and separate sub-systems and indicating a preliminary sequencing of the

commissioning activities.

These factors will inform the scheduling of commissioning activities as well as the

interfaces between the Employer, Project Manager and Contractor.

3.1. Stages to Construction and Commissioning.

The development from existing site to completed installation will develop through a

number of stages broadly comprising construction and commissioning.

There are a number of interfaces and at multiple points during construction and

commissioning the Contractor shall be required to gain permission from the Project

Manager to progress to the following stage.


Revision No. A


The construction will primarily be controlled by the utilisation of Work Permits. Work

Permits shall be completed for each area of work for each day and shall indicate any

work to be completed which will require further permissions. Approval of a work permit

will not constitute approval of that work requiring further permission and the relevant

forms shall be completed for all such works.

Works which require additional permission include:

Excavation

Work within bunds

Work on Tanks

Backfilling over pipelines

Pouring Concrete

The Contractor shall develop standard forms for management of all works requiring

additional approval. These shall indicate the following as a minimum:

Date

Area of works (indicating extents)

Node (i.e. pipe number)

Permission Required

Contractors Name, Position and Signature

Once an area of works is complete the Construction team shall complete pre-

commissioning.

Once pre-commissioning has been completed and signed off, the commissioning team

can complete cold-commissioning then hot-commissioning.

These activities are defined as follows:

3.1.1. C1 - Pre-Commissioning - Contractor and/or Suppliers & Construction

Team

Pre-commissioning consists of Punch Listing of discrete parts of equipment or

systems by Contractors and/or Suppliers before handing over to the Commissioning

Team.

The Construction Engineer will sign off this stage of commissioning when the

following have been achieved:

Punch Listing by the Contractor and Project Construction Team

Rectification of Cat 1 & 2 Punch List Items by the Contractor

Cleaning of the area intended for hand-over

Completion of test sheets such as for Megger, alignment and pressure tests

The equipment or module shall have all hardwired interlocks and protective

systems checked and tested by the Contractor or Supplier

The Construction Engineers shall complete the Certificate once they have

satisfied themselves that all the remaining items on the Punch List can be carried

forward to run testing without endangering life or the safety of the works. They

shall clear any uncertainties with the Construction Manager


Revision No. A


The Construction Team, Commissioning Team and Client Commissioning Team

shall sign the C1 Acceptance Certificate

C1 – “Pre” Commissioning shall be considered complete when all the above items

have been addressed and all documentation submitted to the Document Controller.

C1 - Document Package consists of:

C1 - Acceptance Certificate

QC Data Packs for all disciplines, which include:

- All pre-commissioning checklists and test certificates.

- Punch or Defect Lists

The C1 – Pre-Commissioning Acceptance Certificate must be signed off before

proceeding to the next stage of commissioning.

3.1.2. C2 - “Cold” Commissioning - Contractors and/or Suppliers,

Construction Team and Commissioning Team

This involves running the equipment or module dry to test or perform relevant checks

on the equipment or system. After all safety checks have been completed, all

equipment such as conveyors, motors etc. are run for short periods under the

supervision of the Contractors and/or Suppliers, Construction Engineer and

Commissioning Engineers in accordance with the running tests and procedures

provided by the Design Engineer, Contractor and/or Suppliers.

The following shall be done during these tests:

Equipment or module PLC sequence interlocks shall be checked

Checking, calibration and rectification of all instrumentation such as level, flow,

pressure, density, power meters etc.to ensure correct functionality

Leaks, splashing and any other adverse operating feature shall be eliminated

Unacceptable structural vibrations shall be identified and eliminated

Warranty repairs shall be identified and the installation Contractor and/or

Supplier will provide a programme for rectification

All equipment that forms a zone or stream shall be run simultaneously where

possible, to allow balancing and to check all interlocks and process control



Additions to QC Data Packs:

- Dry run test certificates

- Cold Commissioning Checklists

- Master Punch or Defect Lists

The C2 - “Cold” Commissioning Acceptance Certificate must be signed off before

proceeding to the next stage of commissioning.

3.1.3. C3 - “Hot” Commissioning” - Client Commissioning Team

This involves operating systems to test or perform relevant checks in order to balance

the operation and prove the performance of the system. After all “cold”

commissioning has been completed, whole systems are operated under the

supervision of the Contractors and/or Suppliers, Construction Engineer and


Revision No. A


Commissioning Engineers in accordance with the running tests and procedures

provided by the Design Engineer, Contractor and/or Suppliers.

The following shall be done during these tests:

Discharge flow rates are verified or balanced

Pipelines, valves and systems are tested with full product flow.

Pump flow tests are conducted to prove performance

Foam dosing performance is tested to prove range of operation and correct foam

premix generation

Leaks, splashing and any other adverse operating feature shall be eliminated

Unacceptable structural vibrations shall be identified and eliminated

Warranty repairs shall be identified and the installation Contractor and/or

Supplier will provide a programme for rectification



Additions to QC Data Packs:

- Run test certificates

- Hot Commissioning Checklists

- Final / Master Punch or Defect Lists

- Final Hand Over Certificates

The C3 - “Hot” Commissioning Acceptance Certificate must be signed off in order to

certify completion.

Defect Classification:

Cat 1 These deviations, defects or outstanding items may affect health

and/or safety of personnel and operability and must therefore be

rectified immediately.

Cat 2 These deviations, defects or outstanding items may affect

operability and must therefore be rectified before commencement

of “cold” commissioning.

Cat 3 These deviations, defects or outstanding items do not affect

operability and therefore may rectified during operation but will be

subject to access permits.

3.2. Roles and responsibilities

There are three primary parties involved in the commissioning; these are the Employer,

Project Manager and Contractor.

The primary responsibility for the planning and completion of the commissioning

including the development of all test procedures for equipment and facilities shall rest

with the Contractor. The Contractor may develop these procedures or commission

equipment or system suppliers to develop and complete these procedures however the

responsibility shall at all times remain with the Contractor and the Employer or Project


Revision No. A


Manager may at any time interact directly with the Contractor should problems arise in

interaction with the Contractors appointed sub-consultants.

The Contractor shall complete the following in addition to all commissioning tests:

Develop Commissioning Schedule (may form part of master construction

schedule)

Develop Commissioning Control Document

o This document shall indicate all commissioning activities and interfaces

and shall be a live document, updated and signed off as activities are

completed in order to indicate what following activities can occur.

Develop a Safety Lock out Procedure

Develop Individual Equipment Commissioning Procedures.

Develop Facility Commissioning Procedures.

Arrange for the attendance of the Employer and / or Project Manager at all

activities they are required to witness (this includes planning of activities and

liaison regarding the availability of necessary persons but does not included

provision for travel, accommodation or other similar requirements for persons

other than the Contractor or their suppliers or representatives)

Maintain the records of all commissioning completed and all approved

documents.

The Employer and Project Manager shall be required to witness and approve all final

facility testing. The Employer Project Manager shall also be required to approve the

Commissioning Plan, the Contractors Commissioning Schedule and the Contractors

Commissioning Control Document

The Project Manager shall also be required to approve the Safety Lock-out Procedure

and all Individual Equipment and Facility Commissioning Procedures and shall witness

and approve all tests conducted during cold and hot commissioning.

Particular activities which the Project Manager must approve are:

All back filling must be approved prior to commencement.

Connection to any power supply must be approved

Filling or pressurising of any systems

Starting of any drives (other than valve actuators)

Particular tests which may not form part of cold or hot commissioning but that the Project

Manager must witness and approve are:

Alignment of the fire pump unit

Piping connection to fixed / separately supported equipment

3.3. Division of Works into sub-systems for Commissioning

The commissioning activities of each phase consider different scales of systems.

Pre-commissioning activities consider individual pieces of equipment, lines or sections of

lines and other small installations which form part of a larger system. The division of

systems into separate elements for the pre-commissioning phase means that there are

numerous interfaces which could be neglected and thus the pre-commissioning phase


Revision No. A


must include consideration of interfaces; for instance the connection of pipework to a

pump must be considered and this could form part of the pump or pipework pre-

commissioning or a separate element. For the purpose of this project, all equipment will

be pre-commissioned prior to the installation of pipework connections and the connection

of pipework will form part of the pre-commissioning check for the pipework. This

includes tanks, pumps and any separately supported valves.

Further commissioning including cold and hot commissioning tests are performed on

systems not elements and as such the scope for division is limited. Broadly there are

storage, pumping, foam dosing, distribution, detection and control systems. Each of

these can be cold-commissioned separately with further division possible. There are

elements which will require sequencing such that one two aspects are commissioned

together or for instance the piping can only be commissioned once the storage and

pumping have been commissioned.

Hot-commissioning requires that all systems related to the hot-commissioning activity

have been cold-commissioned. Hot-commissioning will involve the operation of multiple

systems concurrently to both ensure their operational functionality as well as to allow

performance testing of the systems.

3.4. Commissioning activity sequencing

The sequencing of the stages of commissioning is most critical at the interface with

construction and particularly with regards to the installation of piping in trenches and to

operational facilities.

For the installation of piping in trenches, each level of piping needs to be backfilled

before the level above it may be installed; in order to prevent significant rework, all

pipework must be pre-commissioned before it may be backfilled as this verifies the

pipework is free from leaks and suitable for service.

For the installation of piping to tanks, gantries and other working areas, pre-

commissioning shall be completed immediately after completion of the works in an area

in order to prevent the need to grant further access for remedial work after the area has

been returned to operation.

Further to these sequencing considerations, as noted previously, piping may only be

installed to equipment after the equipment has been installed and pre-commissioned.

The Contractor therefore needs to consider this in the scheduling and management of

the construction.

4. Schedule:

The Contractor is to include the commissioning activities in the construction schedule.

Commissioning activities are to take place from an early stage of construction and the

necessary provision for time and resources shall be evident on the programme.

The following is a draft breakdown of the activities during the various project stages:


Revision No. A


Stage Activities

Pre

-

con

stru

ctio

n

Ensure the commissioning costs are considered in the estimate

Make sure that the requirements of the commissioning process are clearly defined

in the tender documentation that is issued to the specialist trade contractors C

on

stru

ctio

n

Prepare the commissioning specification

Produce a detailed commissioning programme

Produce first draft O&M manuals, commissioning method statements and an off-

site commissioning strategy before the start of installation work

Co-ordinate third party involvement in the commissioning process

Conduct pre-commissioning works, involving verification of installation works and

static tests.

Verify and document that the required performance outcomes have been achieved

Collate the pre-commissioning checklists and test sheets in the format agreed

Monitor progress of commissioning activities and construction works

Ensure that continual progress is made with the development of the O&M manuals

Co

mm

issi

on

ing

Perform the setting to work of systems.

Verify and document that the required performance outcomes have been achieved

Carry out regulation of systems. Verify and document that the required

performance outcomes have been achieved.

Undertake performance testing of the works.

Verify and document that the required performance outcomes have been achieved.

Involve facilities management personnel in the commissioning works

Collate the commissioning checklists and test sheets in the format agreed by the

commissioning team

Finish the production of the O&M manuals and integrate the required

commissioning information.

Monitor progress of commissioning process activities and construction works

Pre

-han

do

ver

Verify the quality of the documentary evidence from commissioning process works

Ensure that all required statutory documentation has been produced

Conduct training of users and operators

Update the commissioning plan. Changes made and knowledge gained during site-

based works should be reflected in post-handover works


Revision No. A


5. Individual Equipment Testing Procedures:

The Contractor shall be responsible for the development of commissioning procedures

and test forms for each piece of equipment and element of the works and each stage of

commissioning.

These shall correlate with the Commissioning Control Document.

6. Facility Testing Procedures:

The Contractor shall be responsible for the development of the cold and hot-

commissioning procedures and test forms for each system.

These shall correlate with the Commissioning Control Document.

7. Safety:

Safety is of the utmost importance during construction and no work shall be conducted in

the vicinity of pressurised or running equipment. Commissioning work shall require the

completion of work permits.

8. Check / Data Forms:

In addition to the test forms and procedures for the various phases of commissioning,

there shall be final approval forms. Draft forms have been included in the appendices.

The forms required include:

Pre-commissioning Acceptance Certificate

Cold-commissioning Acceptance Certificate

Hot-commissioning Acceptance Certificate

Design Acceptance

Change Control Notice

Commissioning Dossier Checklist

9. Hand-over Procedures:

The Contractor shall be responsible for the completion of all commissioning including

hot-commissioning.

Hand-over shall be achieved once all commissioning work has been completed with all

tests, verifications and settings approved by the Engineer and the Employer. Hand-over

shall also require that all documentation including all Manuals, Quality Control Files, as-

built and red-lined drawings and operating spares have been supplied by the Contractor.


Revision No. A


Annexure A C1 – PRE-COMMISSIONING ACCEPTANCE CERTIFICATE

AREA / SUB - AREA :

MECHANICAL EQUIPMENT LIST ATTACHED

ELECTRICAL EQUIPMENT LIST ATTACHED

C & I EQUIPMENT LIST ATTACHED

This is to certify that the Equipment / System (as per attached lists) has been tested

and punch listed and “cold” commissioning may commence.

It is the responsibility of the Contractor/Supplier to address the Punch Lists as per a

program agreed with the Construction Manager.

RESPONSIBLE PERSONS:

DISCIPLINE NAME SIGNATURE DATE

MECHANICAL:

AREA ENGINEER

COMMISSIONING ENGINEER

ELECTRICAL:

AREA ENGINEER


C & I:

AREA ENGINEER / COW

DESIGN / COMM. ENGINEER

OTHER:

CONSTRUCTION MANAGER

AREA TEAM LEADER

CLIENT ELEC. ENGINEER

CLIENT C & I ENGINEER

CLIENT COMM. ENGINEER


Revision No. A


Annexure B

C2 – “COLD” COMMISSIONING ACCEPTANCE CERTIFICATE

AREA / SUB - AREA :





and “hot” commissioning may commence.

It is the responsibility of the Contractor/Supplier to address the Final / Master Punch

Lists as per a program agreed with the Construction Manager.

Final Hand Over / Release Certificates have been issued to the Contractor.

Client has taken over the responsibility for the care, custody and control of the

system/plant.



MECHANICAL:


DESIGN ENGINEER

ELECTRICAL:


DESIGN ENGINEER

C & I:

COMM / DESIGN ENGINEER

AREA TEAM LEADER




CLIENT PROJECT MANAGER


Revision No. A


Annexure C

C3 – “HOT” COMMISSIONING ACCEPTANCE CERTIFICATE

AREA / SUB - AREA :





and “hot” commissioned.

It is the responsibility of the Contractor/Supplier to address the Final / Master Punch

Lists as per a program agreed with the Construction Manager.

Client has taken over the responsibility for the care, custody and control of the

system/plant.



MECHANICAL:


DESIGN ENGINEER

ELECTRICAL:


DESIGN ENGINEER

C & I:

COMM / DESIGN ENGINEER

AREA TEAM LEADER




CLIENT PROJECT MANAGER


Revision No. A


Annexure D

DESIGN ACCEPTANCE

AREA / SUB - AREA :


ELECTRICAL EQUIPMENT LIST / CABLE SCHEDULE ATTACHED

C & I EQUIPMENT LIST / CABLE SCHEDULE ATTACHED

DESIGNERS / SUPPLIERS;

COMPANY DOCUMENT RECEIVED

COMMENT

The above mentioned installation / system has been constructed according to

approved design and thus is “fit for purpose”.

Alterations / Amendments / Additions / Exclusions / Restrictions

Name_____________________ Signature_________________ Date______________ Design Engineer


Revision No. A


Annexure E

CHANGE CONTROL NOTICE

Contractor /Vendor:: Area:

Attached : SI Nº CVCO Nº CN Nº:

Originator : Date : Sign : Revision :

Description :

Name Signature Date

Requested by:

Schedule checked

Hazop completed

Disciplines Design Cost Equip. cost Estimated by Total

Mechanical

Elect/Instr/Contr

Civil/Structural

Other

Cost :

TICK IN APPROPRIATE BLOCK

PROCEED WITH WORK

PROCEED WITH CHANGE WHILE COST & SCHEDULE IMPACT IS BEING

EVALUATED (EVALUATION TO BE COMPLETED WITHIN 2 WEEKS)

HOLD UNTIL DETAILED EVALUATION OF COST & SCHEDULE IMPACT IS APPROVED

SIGNING AUTHORITY

FOR EMPLOYER

Name :…………………....

Title ………………………

Signed …….………………

Date ……..…………..……..


Revision No. A


Annexure F

COMMISSIONING DOSSIER CHECKLIST

AREA / SUB - AREA :


ELECTRICAL EQUIPMENT LIST / CABLE SCHEDULE ATTACHED

C & I EQUIPMENT LIST / CABLE SCHEDULE ATTACHED

Checklist:

Yes No Comment

1. Mechanical QC Packs

As - Built Drawings

O & M Manuals (Spare Parts List)

2. C & I (Install) QC Packs

Loop Drawings

As - Built Cable Schedules

3. C & I (Supply) Certificates Of Compliance

Calibration Certificates

Delivery Acceptance

Data Sheets

4. Electrical QC Packs

As Built Drawings

5. Equipment: Data Sheets

Certificates Of Compliance

6. Pre- Commission Acceptance Certificate

7. Cold commissioning Acceptance Certificate

8. Final Hand Over Certificates to Contractors

9. P & ID’s (Redlined or As Built)

10. Other Drawings

11. Design Acceptance

12. READY FOR TRANSMITTAL TO CLIENT

SiVEST Project Management Division 4 Pencarrow Crescent, La Lucia Ridge Office Estate, Umhlanga Rocks. 4320 PO Box 1899, Umhlanga Rocks. 4320 South Africa Tel + 27 31 581 1500 Fax +27 31 566 2375 Email [email protected] www.sivest.co.za Contact Person: Didier Regnaud Cell No.: 082 818 4965 Email: [email protected]

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