Академический Документы
Профессиональный Документы
Культура Документы
Commissioning manual: -
● What procedures are available covering all commissioning activities?
● Is there a commissioning procedure index?
● Is there a commissioning procedure completion plan with clear
responsibilities identified?
● How is progress on the procedure completion plan reported?
● Is there a project approved revision control system in place?
● Is the procedure layout including space for sign off upon completion and/or
for regulatory witness sign off?
● Do they include Piping and Instrumentation Diagrams (P & IDs)
commissioning boundary limit markups?
● Who has reviewed the procedures and how is it controlled?
● Do the procedures include a prerequisite list?
● Do the procedures include a safety section?
● How was the various discipline input covered by responsible engineer?
● Where is the master controlled copy kept?
E. Planning philosophy/procedure.
F. Punch List procedure.
G. Progress reporting structure.
H. Commissioning (Design) query system.
I. Permit to work system.
J. Electrical isolation.
K. Mechanical isolation
L. Commissioning jumper/bypass log system.
M. Blinding list log.
N. Operation and Maintenance (O & M) manual.
Contents: -
1. Why is this important?
2. When should this be done?
3. Who should do this?
4. What should be done?
6. Preparation of operating manual general index and instructions: -
7. Basic considerations in preparing operating manuals.
8. The content of the Operations and Maintenance (O & M)Manual providing the
overview of the complete installation and covering individual systems,
equipment and material installed by Contractor shall include but not limited to: -
8.1 INTRODUCTION.
• Phase I) Basic Design Stage (Containing 7 Standards).
• Phase II) Detailed Design, Engineering and Procurement Stages (Containing 2
Standards).
• Phase III) Start - Up Sequence and General Commissioning Procedures
(Containing 2 Standards).
8.2 SCOPE.
8.3 REFERENCES.
8.4 DEFINITIONS AND TERMINOLOGY.
8.5 SYMBOLS AND ABBREVIATIONS.
8.6 UNITS.
8.7 FORMAT: -
1 original and 4 copies of each O & M manual shall be provided.
• General In principle.
• Covers and Size: -
•• Language.
• Titles.
• Dividers.
8.8 NOTEWORTHY POINTS: -
• General
8.9 CONTENTS OF OPERATING MANUAL: -
• Chapter Design Basis.
• Chapter Process Description: -
•• Nature of Process.
•• Process of flow.
• Chapter Operating Variables and Controls.
• Chapter Auxiliary Systems.
• Chapter Utility System operating manual.
• Chapter Equipment operation.
• Chapter Instrumentation and Control.
• Chapters Start - Up and Shut – Down.
• Chapter Normal shutdown procedures & Emergency Shut - Down Procedure):-
•• Normal shutdown procedures.
•• Emergency Shutdown Procedure:
• Chapter Miscellaneous Procedures.
• Chapter Health, Safety & Environment System operating manual: -
•• Health.
•• Safety.
•• Environment.
•• Safety manual/Quality manual.
• Chapter Analytical Tests.
• Chapter Catalysts, Chemicals, Packing, lubricant oil, filters and …
• Chapter Drawings.
• Validation: -
9 APPENDICES.
Operations and Maintenance (O & M) manuals are central to training the Owner's
operating personnel in advance of the commencement of Commissioning and Start-
up activities. Operation Manuals describe each system's made of operations, and the
Overall Plant Operating and Maintenance philosophy. In addition to Operations and
Maintenance (O & M) manuals, owners sometimes procure generic and/or custom
built Operator Training Simulator(s) to ensure that process Operators are well trained
ahead of Start - up.
This will be produced by the Contractor as construction/installation proceeds and
reviewed by the Designer. It will be 90% complete prior to start - up inspections.
During the commissioning stage, all missing data will be added, so that it will be
100% complete prior to issuance of the Interim Certificate. During the Warranty
Period, it will be refined as required. This manual will be organized so that keeping it
up - to - date will require minimum time and resources
1. Why is this important?
▪ A manual that describes key components and systems within the building(s) and
explains how they should be operated and maintained will help ensure that the
project fulfills its promise to its occupants and to its community.
▪ The team that designs and develops the building, especially if the team includes
the property manager, is in the best position to describe its efficient operation and
maintenance, and to create the manual over the course of the entire development
process.
2. When should this be done?
▪ After construction is complete but before the project is occupied.
▪ Prior to commencement of the Tests on Completion, the Contractor shall supply
to the Engineer provisional operation and maintenance manuals in sufficient detail
for the Employer to operate, maintain, dismantle, reassemble, adjust and repair the
Plant.
▪ The Works shall not be considered to be completed for the purposes of taking -
over under Sub - Clause Taking Over of the Works and Sections until the
Engineer has received final operation and maintenance manuals in such detail, and
any other manuals specified in the Employer's Requirements for these purposes.
3. Who should do this?
The owner/developer, the design team, the Contractor and the property manager.
8.2 SCOPE.
This Engineering Standard covers the minimum requirements of format, in preparing
process and/or utility units operating manuals, including essential instructions and
points of noteworthy.
The purpose of this Manual is to standardize the content and format of operating
manuals which shall be prepared by the Contractor. Although operating manuals
differ to some extent from process to process, the basic philosophy and general
aspects shall conform to the concepts of this Standard.
8.3 REFERENCES.
Throughout this Standard the following dated and undated standards/codes are
referred to. These referenced documents shall, to the extent specified herein, form a
part of this standard. For dated references, the edition cited applies. The applicability
of changes in dated references that occur after the cited date shall be mutually agreed
upon by the Company and the Vendor. For undated references, the latest edition of the
referenced documents (including any supplements and amendments) applies: -
• Basic Design Package & Recommended Practice for Feasibility Study.
• Process Flow Diagram.
• Detailed Design, Engineering and Procurement.
• Process Design of Plant Waste Water Sewer Systems.
8.4 DEFINITIONS AND TERMINOLOGY.
• Company or Employer/Owner: Refers to one of the related affiliated companies
of the petroleum industries
• Contractor: Refers to the persons, firm or company whose tender has been
accepted by the Employer, and includes the contractor’s personnel representative,
successors and permitted assigns.
• Project: Refers to the equipment, machinery and materials to be procured by the
Contractor and the works and/or all activities to be performed and rendered by
the Contractor in accordance with the terms and conditions of the contract
documents.
• Units: Refer to one or all process, offsite and/or utility units and facilities as
applicable to form a complete operable refinery/and or plant.
8.5 SYMBOLS AND ABBREVIATIONS.
8.6 UNITS.
This standard is based on international system of units (SI), as per Company except
where otherwise specified.
8.7 FORMAT: -
1 original and 4 copies of each O & M manual shall be provided.
• General In principle, a separate operating manual shall be prepared for each
process and/or utility unit. However, in the case of short volumes, operating
manuals for two or maximum three units can be integrated into one book upon
approval of the Company. The compiled operating manuals should consist of
related units, where possible.
• Covers and Size: -
•• Language.
The ruling language shall be in Local and/or English language. However from
time to time the Company may instruct that certain correspondence…etc. The
format of operating manuals shall essentially conform to company requirements.
Note: The quality of operating manual (binding, cover, paper…etc.) shall be
approved by the company. For covers, type and size and color of titles and any
other characters, shall be approved by company.
• Titles: -
•• The manual shall be named as Operating Manual.
•• The titles on the front cover shall include: -
••• Company name and logo.
••• Project name.
••• Printing of Operating Manual.
••• Plant or unit name.
••• Lant or unit number.
••• Contractor(s) name and Logo.
••• Contract number.
••• Document number.
••• Date, it shall be referred to the month and year of the plant commissioning
date.
•• A typical arrangement of the front cover titles is illustrated in typical front
cover title
•• The titles on the bottom cover shall include all requirements as outlined in The
titles on the front cover above presents a typical arrangements of the bottom
cover titles.
• Dividers should be: -
•• Provided to separate each chapter with appropriate designations of the
concerned subject.
•• Provided to separate each chapter with appropriate designations of the
concerned subject.
• Chapter Utility System operating manual: This section describes in detail the
operation philosophy and data for utility facility. The items should be description
of utility of process for easy understanding and operation guidelines. Utility
systems which supplement the main process should be described as a separate
subsection. Wherever possible, process description should be supplemented by
simple sketches showing the major equipment and process control for a particular
unit /utility operation. This enhances the understanding of the utility requirement
data and consumption. The following section shall be included with full
description of operating guidelines for utility in process plant where application.
The Utility Flow Diagram (UFD) consumption list shall be prepared during detail
of engineering phases and attached to the manual. In some cases licensor shall be
submitted utility data and consumption. Some of utility systems as below: -
•• Steam Boiler System.
•• Power Generation System.
•• Fuel Gas System.
•• Cooling Water System.
•• Instrument/utility Air and Nitrogen Package.
•• Flare and blow down system.
•• Firefighting system.
•• Diesel Generator package.
•• Etc.
• Chapter Equipment operation: The detailed start - up, operation and inspection
prior to operation for all main equipment and relevant accessories as well as
packaged units to be outlined in this section. Reference to the operating and
maintenance instructions prepared by the equipment manufacturer for each item
shall be given. Main operating points and all useful operation guidelines shall
also be pointed out. Machinery equipment auxiliary systems such as anti - surge
system, lube oil, sealing system, tempered water…etc. and fired heater burners,
forced draft and induced draft fans operations should be explained in detail and
all possible troubles and their relevant troubleshooting guide of such systems to
be described: -
•• Machineries.
•• Heat exchangers.
•• Fired heaters.
•• Towers, vessels and reactors.
•• Package units.
•• Tank and storage facilities.
- Heating up of plant.
- Establish operation.
- Start chemical injection.
\
- Line out.
•• Normal start - up procedure: -
- General.
- Re - start - up after short shutdown duration (hot start).
- Re - start - up after long shutdown duration (cold start) (to be continued).
•• Normal operation procedures.
- Operating procedures should clearly lay down instructions for operation of
process plant that take into consideration Control Of Substances
Hazardous to Health (COSHH), Manual Handling, Permit To Work,
Personal Protective Equipment (PPE) Regulations, quality, Hazard
Operability (HAZOP), Risk Assessment and Health, Safety and
Environmental (HSE) requirements.
- The procedure should represent a definition of good or best practice that
should be adhered to at all times. Process operatives should be provided
with guidance concerning the required operating philosophy to ensure that
they comply with procedural requirements.
- Operating procedures should be controlled documents, generally covered
under the owner’s quality system.
- Any changes should be fully controlled and documented and should be
subject to company change procedures.
- Normal operating instructions at both system and major equipment level
including details of all associated safety precautions: -
-- General.
-- Normal operating conditions.
-- Check points and adjustments.
-- Reduced operation.
-- Safe operating limits and associated indications, alarms and interlocks,
the consequences of exceeding these limits, the action by operations
personnel to correct the deviation or the actions taken by interlock
system.
- Operating instructions should be close to the user and kept up to date. The
following issues should be considered in assessing operating procedure
documentation: -
-- There should be no easier, more dangerous alternatives than following
the procedure.
-- There should be a suitable Quality Assurance (QA) system in place to
ensure that the procedures can be kept up to date and that any errors are
quickly detected and hence corrected.
-- The procedures should not be needlessly prescriptive.
-- The best way of Ensuring that procedures do not become overly
prescriptive is through involving the operator during the design stage.
-- Procedures should contain information on the requirements for the
wearing of personal Protective equipment during the task.
-- Any risks to the operator should be documented at the start of the
procedure, based on a risk assessment of the task.
-- An appropriate method of coding each procedure should be used.
-- Each time a procedure is produced it should be dated and also marked,
where appropriate, with a shelf life, i.e. ‘This procedure is only valid
for 6 months after the date hereon’.
-- There should be no ambiguity between which procedures apply to which
situations.
-- Procedures do not always have to be paper based.
-- At the start of the procedure an overview of the task should be
provided.
-- Prerequisites should present clearly at the start of the procedure to
ensure that the operator can check that it is safe to proceed.
-- The most important information on the page should be identified and
this should be designed to be the most prominent information.
-- Separate headings should be used to differentiate clearly between sub
tasks.
-- Any warnings, cautions or notes should be placed immediately prior to
the instruction step to which they refer.
-- The nomenclature should be consistent with that on controls or panels.
-- Symbols, colors, and shapes used for graphics should conform to
industry standards.
-- Safety information: -
--- Fire water network - overview.
--- Deluge system - overview.
--- Inert gas system - overview.
--- Fire equipment - overview.
--- Arterial safety data sheets.
--- Firefighting and protective equipment.
--- Personal protection.
--- Fire and safety point shelters.
--- Fire & Gas detection.
--- Fire proofing.
--- Data sheets for Pressure Safety Valves (PSVs).
--- Data sheets for car sealed valves.
--- Cause & Effect diagram.
--- Emergency Shut Down (ESD) system description.
--- Safety Instrumented system description {includes Safety Integrity
Levels (SILs)}.
--- Recommended Safety Instrumented System (SIS) testing schedule.
--- Instrument alarms.
--- Alarm management protocol.
--- Selected element of the process safety management system.
--- Maintenance of safety equipment and housekeeping.
--- Control of Work (COW) procedures, e.g. isolation, purging, venting
of process systems in preparation for safe work…etc.
--- Testing schedules for hydrocarbon content in effluent streams and
levels of air particulates.
--- Testing schedules for noise (Decibels) at plant battery limit.
-- Safety concepts: -
--- General.
--- Codes and standards.
--- Climatic condition.
-- Hazardous area: -
--- Typical sources of hazard to be considered for area classification.
--- Machines, equipment, or their parts for production and processing
of dangerous substances which can be released into
atmosphere in normal and abnormal operating conditions have to
be generally considered as a source of hazard.
--- The items listed here below will be particularly taken into account: -
---- Pump glands and shaft glands on rotating and reciprocating
shafts of rotary filters, contactors, mixers and other machines.
(In centrifugal, reciprocating and rotary compressors the
glands are the main hazard, but other sources of hazard should
be regarded as the compressor casing and in some cases, parts
of the gland sealing system).
---- The drain rims around the pump pad.
---- Cooling water effluent systems from hydrocarbon service.
---- Vents of safety valves and rupture disk when non convoyed to
flare gas meter.
---- Drain connection used in process operation and permitting
release of flammable vapor to atmosphere.
---- Sample points.
---- Vents to atmosphere.
---- Motorized valves.
---- Some types of stream analyzers.
---- Drum and container filling plant.
---- Fixed roof storage tanks, including water draw - off
arrangement.
---- Floating roof storage tanks including water draw - off
arrangement.
-- Hazardous area classification: -
--- Gas group.
Gases and vapors are classified into groups as follow: -
---- Group A: Acetylene.
---- Group B: Hydrogen.
---- Group C: Ethylene.
---- Group D: All hydrocarbons.