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: For: Charl Bothma (TPL Project Manager) Transnet Pipelines Signature:
Contents 11992 - TPL 25 Commissioning Plan 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 03 July 2015 Page 1 of 9
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. 03 July 2015 Page 2 of 9
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 precommissioning. 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 03 July 2015 Page 3 of 9
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 C2 - Document Package consists of: C2 - Acceptance Certificate 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 03 July 2015 Page 4 of 9
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 C3 - Document Package consists of: C3 - Acceptance Certificate 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 Cat 2 Cat 3 These deviations, defects or outstanding items may affect health and/or safety of personnel and operability and must therefore be rectified immediately. These deviations, defects or outstanding items may affect operability and must therefore be rectified before commencement of cold commissioning. 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 03 July 2015 Page 5 of 9
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 03 July 2015 Page 6 of 9
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 precommissioning 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, precommissioning 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: 03 July 2015 Page 7 of 9
Stage Activities Preconstruction 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 Prepare the commissioning specification Produce a detailed commissioning programme Produce first draft O&M manuals, commissioning method statements and an offsite commissioning strategy before the start of installation work Construction 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 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. Commissioning 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 Verify the quality of the documentary evidence from commissioning process works Pre-handover 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 sitebased works should be reflected in post-handover works 03 July 2015 Page 8 of 9
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 hotcommissioning 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, asbuilt and red-lined drawings and operating spares have been supplied by the Contractor. 03 July 2015 Page 9 of 9
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: MECHANICAL: DISCIPLINE NAME SIGNATURE DATE AREA ENGINEER COMMISSIONING ENGINEER ELECTRICAL: AREA ENGINEER COMMISSIONING 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 03 July 2015 Page 1 of 6
Annexure B C2 COLD 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 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. RESPONSIBLE PERSONS: MECHANICAL: DISCIPLINE NAME SIGNATURE DATE COMMISSIONING ENGINEER DESIGN ENGINEER ELECTRICAL: COMMISSIONING ENGINEER C & I: DESIGN ENGINEER COMM / DESIGN ENGINEER AREA TEAM LEADER CLIENT ELEC. ENGINEER CLIENT C & I ENGINEER CLIENT COMM. ENGINEER CLIENT PROJECT MANAGER 03 July 2015 Page 2 of 6
Annexure C C3 HOT 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 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. RESPONSIBLE PERSONS: MECHANICAL: DISCIPLINE NAME SIGNATURE DATE COMMISSIONING ENGINEER DESIGN ENGINEER ELECTRICAL: COMMISSIONING ENGINEER C & I: DESIGN ENGINEER COMM / DESIGN ENGINEER AREA TEAM LEADER CLIENT ELEC. ENGINEER CLIENT C & I ENGINEER CLIENT COMM. ENGINEER CLIENT PROJECT MANAGER 03 July 2015 Page 3 of 6
AREA / SUB - AREA : Annexure D DESIGN ACCEPTANCE MECHANICAL EQUIPMENT LIST ATTACHED 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 03 July 2015 Page 4 of 6
Annexure E CHANGE CONTROL NOTICE Contractor /Vendor:: Area: Attached : SI Nº CVCO Nº CN Nº: Originator : Date : Sign : Revision : Description : Requested by: Schedule checked Hazop completed Name Signature Date Disciplines Design Cost Equip. cost Estimated by Total Mechanical Elect/Instr/Contr Civil/Structural Other TICK IN APPROPRIATE BLOCK PROCEED WITH WORK Cost : 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...... 03 July 2015 Page 5 of 6
AREA / SUB - AREA : Annexure F COMMISSIONING DOSSIER CHECKLIST MECHANICAL EQUIPMENT LIST ATTACHED ELECTRICAL EQUIPMENT LIST / CABLE SCHEDULE ATTACHED C & I EQUIPMENT LIST / CABLE SCHEDULE ATTACHED Checklist: 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 Yes No Comment 03 July 2015 Page 6 of 6
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 info@sivest.co.za www.sivest.co.za Contact Person: Didier Regnaud Cell No.: 082 818 4965 Email: didier@sivest.co.za