The Mechanical Integrity of equipment and systems begins with the design and specification in the engineering phase and is heavily impacted by proper follow through during the construction phase.
The construction aspect of a project will normally include provisions for IPS equipment installation, loop check, commissioning and validation. All of the careful and detailed work accomplished during the design and engineering project phase can be destroyed, through introduction of systematic failures, if the appropriate attention to detail is not applied to the construction phase of a project.
As with the design and engineering phase, SIS-TECH has the industry experience to develop the necessary construction related procedures and supervision which will ensure a smooth start-up upon turn over to operations. SIS-TECH can work with the facility owner and construction contractor to ensure the construction personnel understand the importance of following and not deviating from the specified IPS installation detailed specification.
Call SIS-TECH for assistance with any of the following:
Pre-Start-Up Safety Review
With the experience, procedures and supervision provided by SIS-TECH in the previous construction steps the PSSR becomes a formality of a completed checklist with a smooth transition to operations.
Site Acceptance Test (SAT)
Following the Factory Acceptance Test and subsequent shipment of the safety logic solver to the field it is beneficial to perform a Site Acceptance Test in conjunction with the overall Validation.
Effective SAT procedures demonstrate the functionality of the SIS hardware and logic. SIS-TECH generates step-by-step procedures incorporating sign-off spaces for critical steps. These procedures have sufficient detail to address testing of the critical hardware and logic functionality. SIS-TECH procedures contain the following information:
* SIS logic description
* Trip values
* Instrument ranges
* Testing tolerances
* Communications to occur between the SIS and the BPCS
* Bypass initiation, if required
SIS-TECH provides SAT support and conducts the SAT in accordance with the procedure.
Validation Documents and Supervision
Validation is a culmination of the proper follow through on all of the aforementioned processes. Validation is the process of documenting the performance of the entire installed Instrumented Protective System on a loop by loop or safety function basis (sensor-logic solver-final element) to ensure it delivers the performance as defined in the Safety Requirements Specification. SIS-TECH’s developed procedures and supervision will document the specified operation for a smooth hand-off to facility operations and maintenance.
The successful completion of validation starts the clock on some important maintenance lifecycle responsibilities including the inspection and proof test intervals of the individual components of the IPS during normal operation. The experience of SIS-TECH will ensure all aspects of moving forward to a reliable operations phase are addressed. Some of these include verifying all component proof tests have been developed and are available to operations and maintenance, and verifying all required documentation/data has been transferred from the engineering database to the maintenance management database, thus enabling reliability data capture, analysis and trending.
Commissioning Documents and Supervision
Following equipment installation, the process of proving the components perform as specified begins. This process can include calibration or calibration checks of the sensor and final elements, the loop check or “ring-out” of the wiring/terminations between system components and the initial “proof test” of the individual system components. There are different complexities to each system component and these must be appropriately planned for in the construction time line. Considerations for sensor/instrument protection or “roll-out” during piping and equipment hydrostatic testing must be addressed. A number of “systematic” failures will be discovered during commissioning and these need to be addressed in a timely manner. Experienced SIS-TECH personnel will ensure follow-up occurs in the most effective manner, along with proper documentation follow-up, as to not impact turn over to operations and to achieve reliable performance during normal operations.
Installation Documents and Supervision
All IPS components must maintain the seven key attributes of independence, functionality, integrity, reliability, auditability, access security and MOC across the lifecycle. Several of these attributes can be negatively impacted by the initial installation. The experience of SIS-TECH serves as the “independent” set of eyes to verify that the installation details are properly designed during the engineering phase and properly installed during the construction phase. Examples of issues which need to be considered are ambient/environmental effects: steam spray, salt spray, lightning and human factor effects: vehicular traffic, periodic maintenance of surrounding equipment.
Installation, Commissioning and Validation (ICV) Plan
The most effective and efficient means to achieve the successful installation, commissioning and validation of an IPS should begin with the planning and verification actions at various steps in the design phase of a project. Having the experience of SIS-TECH involved, throughout all phases of the project, will ensure that the planning and follow through for these important and necessary actions are completed in the most efficient and cost effective manner possible, thereby delivering reliable performance across the entire lifecycle. Some of the planning and coordination issues which need to be included in the plan are: delivery schedule of all system components, grounding/power checks, instrument protection during piping and equipment hydrostatic testing, full loop (system) performance (validation) check and documentation updates.
Lifecycle Documentation Management--“As-Built” Incorporation
As mentioned in the design engineering section, one of the most important components of lifecycle Mechanical Integrity and most often ignored or forgotten is lifecycle documentation management.
This is especially important during the construction phase. Construction contract installers must understand that the IPS equipment must be installed per the installation specification provided with no deviation. Sometime, due to unforeseen circumstances, it is necessary to make field changes during construction. These field changes must be reviewed and approved by the designated level of expertise and authority following the same level of rigor as Management of Change during normal plant operations. Those approved changes must be incorporated into the designated master documentation.
The Safety Lifecycle documentation management software, coupled with experienced SIS-TECH supervision, will ensure as-built changes are properly reviewed, approved and incorporated in the master documentation.