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+ BEFORE task can be done, what other work (inspections, measurements, records, isolations, tests, etc);
. . need to be completed (related to this task or other tasks)?
^ ApxA2f06 √Design+Improve.docx - Appendix A Safe & Improved Design & Site Work
- what are the Risk and HSE issues? (∆ Apx03 s111+2 www.liztid.com/mylizt/267)
- do we need a written Work Plan? Who needs to review the plan?
- AFTER; what work is to follow and how will it be handed over? Will they be ready for taking over?
- When is handover? How does this affect transport, customs, insurance, unloading/ installation, testing, ownership?
- what QA is required? Consents? (www.liztid.com/mylizt/267; Apx03 s170.01 ITP)
- what reviews are reqd? Design, HAZOP, HACCP, Legal, Constructability, Commissioning, HSE, etc
- UNO 1 week is required to review shop drawings, Work Plans, ITP, data for reviews, etc
- what skills, equip, materials and information is required? Who is contact person(s)?
- is admin complete; PO/ contract, consents, insurance certs, bonds, inductions, training, current drgs & spec, Client approval?
- Please ensure that work is to Good Manufacturing Practice, so we can be proud of our work and no one is hurt.
- Dumb questions are easier to handle than dumb mistakes
===== also
∆ "Apx0 Legends, Contents, etc; www.liztid.com/mylizt/271
∆ Apx01 Proj Admin Notes.
∆ Apx02 Design & Purchasing Notes.
∆ Apx03 Site Work NOTES
∆ Apx04 Commissioning
∆ Apx05 Operations
∆ Apx06 Maintenance
∆ Apx08 Reference Info
∆ Apx10 Computer Notes
∆ Project/ Site specific MyLizt
===== also refer
www.liztid.com/mylizt/106 Apx Eng; PROFESSIONALS
www.liztid.com/mylizt/229 Apx Eng; SERVICES
www.liztid.com/mylizt/225 Apx Eng; SUPPLIERS
===== Legend
∆ xxx; reference Web page xxx
^ xxx; reference document xxx
++ improvements/ ways of doing things better
* this list is frequently modified, so print/ pdf the section for your reference
r1908
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1.6.20 Turnover – After flushing, dynamic checkout and water runs the process system will be turned over to operations for their use. Project personnel are instructed not to perform work on systems after turnover unless the proper Client Operations approval has been obtained.
1.6.21 Start-up – That point in time of commissioning when raw material is introduced with the intent of making a product to specifications.
ref WBM Checkout Procedures Manual.doc
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"That point in time of commissioning when raw material is introduced with the intent of making a product to specifications."
What needs to be complete before commissioning?
Is it safe to introduce product before ALL the work is complete?
Equipment list
Punchlist
===== Resources
People
Raw materials
Disposal of product produced
Test equipment (calibration)
Commissioning (and operational) spares
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HSNO requires labelling in accordance with AS 1345
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
Plant:
Equip#:
Description:
Maufacturer:
Model:
Blade Pitch
1. Have the manufacturer’s instructions been reviewed?
2. Has the seal water line be disconnected, flushed and reconnected? Turned on?
3. Has the seal water flow been adjusted properly?
4. Has the packing gland been adjusted properly?
5. Has the mechanical drive checkout been completed with the proper documentation?
6. Has the electrical checkout been completed with the proper documentation?
7. Establish liquid level in tank or chest. Then run agitator. Check and record amps reading.
8. Was blade pitch rechecked after running?
ref; DYNAMIC CHEKLIST - Mechanical Equipment - Agitator.doc
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
Structure
Equip#
Description
Manufacturer;
Model
1. Have the manufacturer’s instructions been reviewed?
2. Has the electrical checkout been completed with the proper documentation?
3. Check and record “no load’ amps.
4. Have emergency stops and interlocks been checked?
5. Operate conveyor; observe belt travel, all idlers, belt slack, drives and take-up. Adjust as required to train.
ref WBM DYNAMIC CHECKLIST - Mechanical Equipment - Conveyor.doc
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
===== Require:
Design Philosophy, PFD, PID,
_ FD
_ Simulation completed
===== Precommissioning on water
===== Commissioning on product
===== Site Acceptance Tests
### record of all software changes/ overrides (approval method, for safety to people, plant, operations)
record that these have been restored
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vJ Replacement for Hart communicator (220915+BdR)
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
**/ Legend; www.liztid.com/mylizt/271#lttheading15321
- AS 4343
VHL= Very Harmful Liquid, VHG= Very Harmful Gas, HL= Harmful Liquid, HG= Harmful Gas
NHL= Non Harmful Liquid, NHG= Non Harmful Gas, NC= Not Classified (water 0 < T < 65 C?)
# NHG can be dangerous inside buildings, as they displace oxygen
=====
VHG, VHL, HG, HLG (Chemicals);
_ Isolation VALVE for tie in, hydrotest against, & break line or valve for drain/ flush/ blow (to or from)
NHG, NHL, NC (W_, IA, CA);
_ Isolation valve for tie in, press test & repair, then flush/ blow
# NHG can be dangerous inside buildings
===== Require:
PFD, PID
. . also GA and/ or Isos, Equipment list, MTO, equipment specs, equipment manuals
_ Installation check list with cols for:
. . installed (bolted tight, will it be removed for hydro or flushing?)
. . CV stroked or BV stroked (ZSO+ZSC checked), instruments reading, motors bumped, pumps clear
* spare gaskets for hydro, flush and reinstatement
_ Remove equipment for hydro (if not rated for HTP)
_ Remove equipment for flush (filters, strainers, etc)
_ Temporary strainers for flush
_ Hydro completed- inspection procedure
_ Service pressure test; W_, IA, CA, NHG?, (Isolation valve for tie in, press test/ repair & flush/ blow)
_ Flush; xxx vol, m/s
_ Air blow; xxx s
_ Made tight
_ All bolts tight
_ Piping QA package
* Acceptance for above
===== SITE Drg markups
Yellow highlight= installation complete, mech, instr or elect (highlight each tag#)
Blue highlight= flushed and pressure tested (mechanically complete), ie turns green
Red Highlight= Wired and belled/ stroked, bumped (operational), ie turns orange
Red pen= changes
Black or blue pen= useful notes
Initials and dates are helpful, if later changes
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| 140N Spares; Commissioning |
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
===== Require:
_ Equipment list, Commissioning spare parts, Operational spare parts
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
===== FAT
_ Construction QA
_ Performance test
===== Site
=== Precommissioning
__ pump labelled
__ pump checked that empty, before closing up
__ grouted
__ lubricated, motor, bearings, gearbox
__ belt drive tension
__ alignment
__ Power wiring (from now on=> isolation/ hold cards needed)
__ Instruments wired (thermistors)
__ Bump test
__ VSD check
===== SAT (with piping check completed)
__ Pump curve (at agreed speed)
__ Pressure + flow at 3 points min (check against pump curve)
_____ Optg motor current . . _____ Full Load current . . _____ Overload setting
__ test pump cutout settings
===== Require:
PID
. . also GA, Equipment list, equipment specs, equipment manuals
_ Installation check list with cols for (same list as piping list):
. . installed, CV stroked, BV stroked (ZSO+ZSC checked), instruments reading, motors bumped, pumps clear
. . seal water, drain
* spare gaskets for hydro, flush and reinstatement
_ Remove equipment for hydro (if not rated for HTP)
_ Hydro completed- inspection procedure- acceptance
_ Flush; xxx vol, m/s
_ Air blow; xxx s
_ Made tight
_ All bolts tight
_ Tank QA package
* Acceptance for above
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
**/ Apx 3 Site Work NOTES s170, www.liztid.com/mylizt/267#lttheading13426
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
===== FAT
_ Construction QA
_ Hydro/ Leak test
===== SAT
_ Hydro/ Leak test
====== Require:
PID
. . also GA, Equipment list, equipment specs, equipment manuals
__ Installation check list with cols for (same list as piping list):
. . installed, CV stroked, BV stroked (ZSO+ZSC checked), instruments reading, motors bumped, pumps clear
. . blanketing, vents
* spare gaskets for hydro, flush and reinstatement
__ Remove equipment for hydro (if not rated for HTP)
. . (what HTP at top, HTP at btm?)
__ Remove equipment for flush (filters, strainers, etc)
__ Hydro completed- inspection procedure
__ Flush; xxx vol, m/s
__ Air blow; xxx s
__ Made tight
__ All bolts tight
__ Tank QA package
* Acceptance for above
* Shop or Site?
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
Tag #:
System #:
Location:
1. Does the nameplate conform to the design specification?
2. Did the main breaker operate properly?
3. Did all contractors, relays, meters and switches properly?
4. Were all the moving parts free to operate?
5. Were all the control cards inspected for damage?
6. Were the control cards properly inserted?
7. Were all bolts and terminations tightened properly?
8. Did all push buttons, interlocks, alarms and other associated equipment operate properly?
9. Was the insulation resistance of the control circuits checked?
10. Are the wires correctly labelled or tagged?
11. Was the equipment properly grounded?
12. Were the supplier procedures reviewed and completed?
13. Is supplier check sheet attached will all preliminary settings?
14. Has the drive been programmed?
15. If not, why not?
ref WBM; DYNAMIC CHECKLIST - ELECTRICAL - AC VARIABLE FREQUENCY DRIVE.doc
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* review s1 Preparation and s170 QA
Supplier's manual(s)
QC procedure/ checklist
__ PS1, __ PS2, __ PS3, __ PS4
Record of above
===== Check valves
__ tagged and correct type
__ correct flow direction
__ innards are in place
__ fully assembled, gaskets, bolts tight etc
===== Manual valves
__ tagged and correct type
__ fully assembled, gaskets, bolts tight etc
__ manually stroke (check valve operates ok)
__ position set for next operation (eg hydro, flush, etc)
===== Powered BLOCK valves
__ tagged and correct type
__ fully assembled, gaskets, bolts tight etc
__ compressed air connected and control wired
* Stroke
__ signal open=> opens and LSO reads
__ signal close=> opens and LSC reads
===== Powered CONTROL valves
__ tagged and correct type
__ fully assembled, gaskets, bolts tight etc
__ compressed air connected and control wired
* Stroke
4mA=> ___ % open . . 12 mA=> ___ % open . . 20 mA=> ___ % open
20 mA=> ___ % open . . 12 mA=> ___ % open . . 4mA=> ___ % open
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| 990 Index, Abbreviations & Definitions |
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**/ Apx 9 CONTENTS, Legend, etc, www.liztid.com/mylizt/271
Producer Statements
PS1= by the Designer, who says it was designed to; code standard, other
PS2= by the person who checked that it was designed correctly
PS3= by the Manufacturer, who says it was built in accordance with design, drawings, specification, etc
. . incl calibration certs (by manufacturer or approved)
PS4= by the person who checks that it was built in accordance with design,
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