Commissioning

[components total commissioning/ quality assurance program] Purpose of start-up activities

- activities that are performed after the equipment or system has been fully installed, and before the formal commissioning is performed.

[components total commissioning/ quality assurance program] Purpose of construction quality assurance activities

- specified by project specifications and key activities should be summarized within the commissioning plan. -The construction team should use their procedures for these activities if they have them. If they do not have their own, the project specifications should be used. If no project specifications are identified, CAI has a "tool box" (extranet) or procedures to cover many of the activities that can be applied to the project.

Describe typical pre-start-up activities (activities that prepare a system for start-up, not construction quality activities).

-Control device loop checks, from field device through control software screen. -Can include simulation of alarms and interlocks. -Equipment and ductwork closeout inspections -Final drawing verification and final equipment installation verification using formalchecklists - Initial valve and damper line‐ups -Initial loop tuning -Determination of setpoints and setpoint ranges to be qualified -Initial run‐in of equipment, setting special parameters, etc. as per vendor manuals

Describe typical construction quality assurance or quality control activities. Discuss problems associated with trade contractor's performance and documentation of these activities.

-Welding inspections, qualified personnel Duct Leak testing, Air and water balancing, Hydrostatic, pneumatic, or vacuum testing, Meggar checks -Rotation checks, Alignment and initial lubrication, Instrument and equipment installation inspections, Control device loop continuity checks, Vibration testing, In‐progress construction quality assurance walk‐throughs -Trade contractors not have recently been trained on GMP documentation styles, or be familiar with what is acceptable as for recording information and document numbering etc.

[components total commissioning/ quality assurance program] Purpose of receiving activities

-activities done via the receipt verification program, which is split in to two primary elements: material receipt and material control. -Material is received at the project site and inspected to verify conformance to specifications. Once the material has successfully passed verification, it must be controlled to ensure the correct material is used in the construction of the plant. -As part of the receiving process, the contractor will usually perform a bench calibration or operational check after verifying the instrument meets specifications.

[components total commissioning/ quality assurance program] Purpose of commissioning activities

-activities that inspect and test everything, both those aspects that impact the product as well as those that have "merely" a business impact. -the commissioning testing should be viewed as the process by which control system flaws or bugs are discovered and eliminated.

[components total commissioning/ quality assurance program] Purpose of vendor activities

-activities that the vendor performs during fabrication of the item. -important that these key activities be performed in a controlled, documented manner

Describe how to handle discrepancies or deviations encountered during commissioning.

-document the non-conformance (through paper of electronic form) -captured on a punch list

Discuss "Mechanical Completion". Include the process and potential problems associated transitioning from construction into startup.

-is a construction milestone when systems/equipment are installed but not commissioned (started-up) -Start‐ups should be controlled with a predefined procedure which should include any needs for lockout/tagout for special testing with safety concerns. -Training of teams and dry‐runs should also be considered for sophisticated evolutions. -problems can occur such as leaks, wrong rotation, system/equipment simply doesn't work, automation troubles, etc.

Describe how to control the initial startup of a system. List typical items that may be adjusted during start-up and setting to work, and what should be documented.

-should be controlled with a procedure. -Consider training of teams and dry‐ runs of sophisticated evolutions. Safety concerns, such as lockout/tagout, should also be covered. Typical items include: -Loop tuning / parameters, Final alarm set points, Speed, Pressure and other operating set points

Define Commissioning. Discuss typical commissioning activities (see write-up).

-well‐planned, documented, and managed engineering approach to the start‐ up and turnover of facilities, systems, and equipment to the end‐user that results in a safe and functional environment that meets established design requirements and stakeholder expectations.

Describe the typical contents of a turnover package (see write-up). Describe an efficient process for assembling the turnover package.

A collection of pertinent design, construction, vendor, and operational documentation. This collection of documentation is used for the qualification and process validation activity, as well as reference and single source information for the life of any particular system, process, or piece of equipment.

Describe an efficient document control and management process.

An efficient document control process has assigned doc numbers, controlled revisions, archived older versions, new revisions state what document they supersede, documents should be checked in and out or dated each time they are edited to avoid confusion.

Define "Good Engineering Practice" (GEP). Discuss how GEP applies to the construction and commissioning process (see diagram).

GEP are proven and accepted, cost‐effective, engineering methods and practices that ensure the effective satisfaction of stakeholder requirements -ensures that an engineering project meets the requirements of the user while being cost effective, compliant with regulations and well documented. -GEP program may be categorized into three subsections: Project Engineering, Common Practices, and Operation and Maintenance.

Discuss the purpose and typical contents (see write-up) of a Commissioning Plan .

The purpose is to define the facilities, systems, and equipment that will be commissioned (based on the system boundaries). It also defines how they will be commissioned and what the responsibilities for the associated staff personnel are.