It is a sad fact of life that one regularly hears about contractors having left a site before a project has been completed. This is often the result of either not having a proper specification or not working to the specification.
With more than 100 years of combined engineering experience in the fields of plant automation, simulation, optimisation and information systems in mineral processing and related industries, systems engineering and integration company Iritron has achieved a sound track record of project successes.
The company attributes these successes to its disciplined approach to project management. This procedure describes how it has formalised the steps of project acceptance testing, commissioning and handover.
Objectives
The goals of a formal project acceptance testing, commissioning and handover procedure are:
* To define areas of responsibility and acceptance.
* To clarify and define different phases of acceptance and handover.
* To record items outstanding for phase or project completion on a punch list.
* To minimise outstanding work at the various phases or project start up.
* To optimise plant start up.
* To determine whether design characteristics and parameters are met.
* To ensure technical acceptability of plant and equipment.
Procedural overview
During testing and commissioning the project manager, with the assistance of the commissioning team, monitors the equipment and plant installation, operation and performance, along with safety and project schedule. Monitoring takes place on both informal and formal bases, with the latter consisting of official check lists and punch lists.
There are two distinct phases of the punch listing procedure viz. acceptance testing (first punch) and process commissioning (second punch). The first punch list is compiled by the acceptance testing manager and the second punch list by the commissioning manager with critical items clearly indicated. The completion of both punch lists is the responsibility of the project manager. However, the acceptance of the completion of the second punch list is the direct responsibility of the commissioning manager following the criteria set in the relevant contract documents and procedures.
Acceptance testing check lists
Check lists are used by the acceptance testing team and the commissioning team to assist in the monitoring of the equipment installation. The checklists are issued to both the contractor and the commissioning team. The project manager’s acceptance testing team ensures that all equipment is installed correctly and ready for acceptance testing. On completion of the installation, both the contractor and the project manager sign off the checklists. The signing of the checklists does not constitute acceptance by the owner or the project manager of any portion of the works.
The works and the equipment remain the responsibility of the contractor until the Acceptance of Works Certificate is issued. It is the contractor’s duty to ensure that all precautions are taken to protect the equipment and plant against loss or accidental damages until this certificate is issued.
First test: Installation
The mechanical, electrical and instrumentation (MEI) acceptance testing teams check for the correct installation of equipment by the contractor during construction.
The teams check that all equipment is installed as designed. If any modifications are required, these must be noted and channelled through the acceptance testing manager to the construction manager. All installation errors or potential errors should be identified as early as possible to prevent rework by the contractor. Checklists are used to control the monitoring and acceptance of the correct installation of the equipment prior to power being switched on.
This project phase is complete once the installation checklist has been completed and signed off by the contractor and commissioning manager’s representative for all items of equipment.
Second test: Functional
The acceptance testing teams test each individual device or piece of equipment to ensure that all components of the plant function correctly from the scada to PLC to I/O racks, to all field equipment for outputs or the reverse for inputs.
During this testing phase fine adjustments are made to field equipment to ensure correct operation.
The contractor’s technicians check the operation of all equipment to ensure correct operation of the drives and motors.
The MEI and operations acceptance testing teams check for correct operation of the equipment once the contractor has completed the installation and the first test checklist has been signed off. Power is connected to the equipment, direction testing is checked and equipment is run as individual units.
All critical items that will prevent a system from running are noted on a list forming part of the first punch list for rectification by the contractor.
This testing phase is completed for an item of equipment once all critical items on the first punch list have been corrected and the checklist has been signed off by the contractor and the commissioning manager’s representative. At this point the unit is ready to be run as part of a system.
Third test: System
On completion of the second test, the MEI and operations acceptance testing team run each system to check interlocking and ensure that the plant is ready to accept feed.
Wet and dry calibrations are carried out as part of this testing phase where this is practical.
The commissioning teams punch list the systems with items listed as critical and non-critical.
This test phase is considered complete for a system when the critical items on the punch list have been rectified and the contractor and the commissioning manager’s representative have signed off the checklist.
The plant is now handed over to operations personnel for process commissioning.
Fourth test: Process commissioning
From this point, routine maintenance is the responsibility of the owner. Abnormal maintenance and properly authorised scope changes are attended to by the contractor and supervised by the project manager’s construction teams.
In this test phase, feed is introduced into the plant for the first time and the systems are brought up to nominal operating throughput.
The second punch list is produced by the process commissioning team and all critical items are rectified prior to the commencement of the performance test.
The performance test is carried out to ensure that the entire plant is capable of operating continuously at nominal throughput for a period of not less than 24 hours.
The Final Acceptance Certificate is issued to the contractor on completion of all the items on the second punch list.
Project close-out
Project close-out is considered complete with the notification to the owner’s management and project department of the completion of the project with respect to:
* As-built drawings.
* Operation manuals.
* Maintenance manuals.
* Spares requirements.
* Cost reconciliation
* Contractual documentation.
* Contract special conditions.
* Performance data.
* Standard operating procedures.
* Design calculations.
* Warranties.
* Project assessment and justification with respect to original justification.
For more information contact Alwyn Rautenbach, Iritron, +27 (0)12 349 2919, [email protected], www.iritron.co.za
| Tel: | +27 12 349 2919 |
| Fax: | +27 12 349 1609 |
| Email: | [email protected] |
| www: | www.iritron.co.za |
| Articles: | More information and articles about Iritron |
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