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 6.3.1.2 6.3.1.3 6.3.1.4 6.3.1.5 6.3.1.6 6.3.1.7 6.3.1.8 6.3.1.9 6.3.1.10 6.3.1.11 6.3.1.12 6.3.1.13 6.3.1.14 6.3.1.15 6.3.1.16 6.3.1.17 6.3.1.18 6.3.1.19 6.3.1.20 6.3.1.21 6.3.1.22 6.3.1.23
Pumps Grit Classifiers Screens Air Blowers Air Diffusers Scum Skimmers Metal pipe works Plastic pipe works Penstocks Transformer Generator Set Switchgear MCC Panel Board Sodium hypochlorite pumps and tanks Polymer Preparation System Mixers and thickeners Filter Press Air Compressor and Air Receivers Lifting Appliances Potable water pumps & tanks Reuse water pumps and tanks 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 CONTROLLED DOCUMENT
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 Appendix 2 Appendix 3 Appendix 4 Appendix 5 Appendix 6 Appendix 7 Appendix 8 Appendix 9
IFC/As-built Drawings Permits Inspection & Testing Plan Restricted Area Plan JV’s Commissioning Organization Pre-commissioning & Commissioning Programme Testing and Commissioning Forms Process Commissioning Plan 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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Document Schedule:
Drawing Nos.
Rev.
E-WW-MP-TG-10-003a-4000-P003-2
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
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 Outlet Maintenance Panel
B
Single Line Diagram MV Switchgear
E
Document Inlet Works
E-WW-MP-TG-10-003a-4000-E002-1
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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 Environmental Hazard (soil, Medium Chemicals water and air pollution) - Provide PPE for handling of Chemical reaction and chemicals contamination • Safety eye goggles Skin contact / irritation • Chemical Gloves Respiratory irritation • Chemical Respirators & Ingestion 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 CONTROLLED DOCUMENT
- Extension leads - Faulty wiring / grounding - Arcing
Equipment damage due to: - Misuse - Factory defect / Malfunction
personnel injury or death Equipment damage
Equipment damage Personnel injury
Falls from elevated level / Personnel injury / Death reservoir due to: Drowning - Slips - Trips - Unprotected / barricaded levels and floor openings
- 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 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 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 CONTROLLED DOCUMENT
Excessive Noise
Hearing Damage
Moving vehicles / Traffic
Vehicular collision resulting to property damage Pedestrian struck by moving vehicles resulting to injury
- Indicate emergency shutdown button / call point - Area restriction to authorized personnel only Low - Provide suitable hearing protection (ear plugs / ear muffs) - Provide demarcation for sound level around genset room 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
0949-95949xx
Building Services Manager 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 CONTROLLED DOCUMENT
-
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
Trial operation
Dry tests
West tests
Functional tests
Process establishment
Visual inspections
Rotation/electrical checks
Pumps run on clean water Check interlinks of equipment work
Interaction of plant
Seed sludge introduced
Calibration - of whatever can be calibrated
Software checking
Introduce sewage
Installation checks
All relevant permits need to be in place - effluent discharge commences
Process proving period
28 day test
2 year period
No modifications to operation of plant Feed with sewage,adjust, Inputs only as the calibrate, generally settle allowable levels in the plant and build biology to operation and correct operating maintenance manual position.
Monitor and adjust until effluent parameters achieved Influent Sewage Characterisation Study Live flow present to be managed
Detailed monitoring periods within this time
Handover
PreCommissioning
Introduce water
Indicative activities
Phase
Operating
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.
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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.
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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.
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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.
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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.
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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.
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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”.
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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.
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